MQ Power WhisperWatt DCA800SSK User manual

© COPYRIGHT 2000, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
Revision #1 (05/14/01)
MULTIQUIPINC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX:[phone]
310-537-3700
SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX:[phone] FAX:[phone]
E-mail:[email protected] •www:multiquip.com
MQ POWER
MODEL DCA-800SSK
PORTABLE GENERATOR
(Standard)
PARTS AND OPERATION MANUAL
PARTS LIST NO. C5872300004

PAGE 2 — DCA-800SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (05/14/01)

DCA-800SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (05/14/01) — PAGE 3
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927

PAGE 4 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
TABLE OF CONTENTS
NOTE
Specification and part number
are subject to change without
notice.
Here's How To Get Help...........................................3
Table Of Contents ....................................................4
Parts Ordering Procedures ......................................5
Rules For Safe Operation .................................... 6-9
Towing ....................................................................10
Trailer Safety Guidelines ........................................11
Trailer Specifications ........................................ 12-13
Trailer Braking System ..................................... 14-15
Trailer Tires & Suspension ............................... 16-17
Trailer Wiring ..........................................................18
Trailer Air Brake Troubleshooting ...........................19
Operation And Safety Decals........................... 20-23
Specifications .........................................................24
General Information......................................... 26-27
Major Components ................................................28
Dimensions ...................................................... 30-31
Control Panel.................................................... 32-33
Engine Operating Panel ................................... 34-35
Output Terminal Panel...................................... 36-41
Installation........................................................ 42-43
Pre-Setup......................................................... 44-47
Load Application ....................................................48
Generator Start-Up Procedure (Manual)......... 49-52
Generator Start-Up Procedure (Auto) ...................53
Generator Shut-Down Procedure ..........................54
Maintenance .................................................... 56-57
Generator Wiring Diagram .....................................58
Engine Wiring Diagram .................................... 60-61
Troubleshooting (Engine)................................. 62-63
Troubleshooting (Engine/Generator) .....................64
Troubleshooting MPEC ..........................................65
Explanation Of Codes In Remarks Column ...........66
Suggested Spare Parts..........................................67
MQ Power DCA-800SSK
ACGenerator
Generator Assembly ..........................................68-71
Control Panel Assembly .....................................72-73
Control Box Assembly........................................74-77
Engine Radiator Assembly.................................78-81
Oil Drain Assembly.............................................82-83
Engine Operating Panel Assembly ....................84-85
Output Terminal Assembly .................................86-87
Battery Assembly ...............................................88-89
Muffler Assembly ...............................................90-91
Fuel Tank Assembly ...........................................92-93
Enclosures Assembly.......................................94-105
Rubber Seals .................................................106-107
Name Plate and Decals .................................108-111
Terms and Conditions Of Sale — Parts ................ 112

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 5
PARTS ORDERING PROCEDURES
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■■
■ UPS Ground Service at no charge for freight
■■
■■
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Commonnuts, bolts and washers (allitems under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
For faxed orders only
UPS
Special
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Now! DirectTOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
■■
■■
■Dealer account number
■■
■■
■Dealer name and address
■■
■■
■Shipping address (if different than billing address)
■■
■■
■Return fax number
■■
■■
■Applicable model number
■■
■■
■Quantity, part number and description of each part
■■
■■
■Specify preferred method of shipment:
•UPS Ground
•UPS Second Day or Third Day*
•UPS Next Day*
•Federal Express Priority One (please provide us with your Federal
Express account number)*
•Airborne Express*
•Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Extra Fax Discount
for Domestic USA
Dealers Only

PAGE 6 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engineorgenerator.
■ The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricted it will cause
serious damage to the
generatororengineandmay
cause injury to people.The
generator engine gives off
DEADLY carbon monoxide
gas.
■ High Temperatures –Allow the engine to cool before
adding fuel or performing service and maintenance
functions.Contact with
hot components cancause serious
burns.
Failure to follow instructions in this manual
may lead to serious injury or even death!
Thisequipmentistobe operated by trained
andqualifiedpersonnelonly!Thisequipment
is for industrial use only.
Thefollowingsafety guidelinesshouldalwaysbe used when
operating the DCA-800SSK portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
readingthisentiremanual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVERoperatethisequipment without proper
protective clothing, shatterproof glasses,
steel-toedbootsandotherprotectivedevices
required by the job.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVERoperatethisequipmentunderthe
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommendedby MQPower for this equipment.Damage
to the equipment and/or injury to user may result.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
CAUTION:
■ Alwaysuseextremecautionwhenworkingwithflammable
liquids.When refueling, stop the engine and allow it to
cool.DO NOT smoke around or near the machine.Fire or
explosion could result from fuel vapors, or if fuel is spilled
on a hot engine.
■ NEVERoperatethegeneratorinan
explosiveatmosphereornearcombustible
materials.An explosionor firecouldresult
causing severe bodily harm or even
death.
■ Topping-off to filler port is
dangerous, as it tends to spill fuel.
■ Alwaysrefuelinawell-ventilatedarea,
away from sparks and open flames.
CAUTION:

DCA-800SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (05/14/01) — PAGE 7
■ Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building'selectrical system exceptthrough an approved
device or after building main switch is opened.
RULES FOR SAFE OPERATION
CAUTION:
■ Never use damaged or worn cables when connecting
power tools or equipment to the generator. Make sure
power connecting cables are securely connected to the
generator’s output terminals, insufficient tightening of the
terminalconnectionsmay causedamagetothe generator
and electrical shock.
CAUTION:
■ DO NOT touch or open any of the below
mentionedcomponentswhile thegenerator
is running. Always allow sufficient time for
the engine and generator to cool before
performingmaintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engineis hotwillresult inhighpressurized, boiling water
to gush out of the radiator, therefore causing severe
scalding to any persons in the general area of the
generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
CAUTION:
CAUTION:
■ NEVER touch output terminals during operation.This is
extremely dangerous.
Always stop the machine when
contact with the output terminals.

PAGE 8 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
■ NEVER Run engine without air filter.Severe engine damage
may occur.
■ Always service air cleaner frequently to prevent carburetor
malfunction.
■ Always disconnect the battery before performing service on
the generator.
■ Always be sure the operator is familiar with proper safety
precautionsandoperationstechniques beforeusinggenerator.
■ Always store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in Operator’s
Manual before attempting to operate equipment.
■ Always be sure the operator is familiar with proper safety
precautionsandoperationstechniques beforeusinggenerator.
■ Refer to the Komatsu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
■ Beforelifting,makesure thegenerator'sliftinghookissecure
andthat thereis noapparent damageto the generatoritself
(loosescrews,nutsandbolts).Ifanypartislooseordamaged,
pleasetake correctiveaction beforelifting.
■ Alwaysdrain fuel priorto lifting.
■ Alwaysmake sure craneor liftingdevice has beenproperly
securedto thehook of guardframeon generator.
■ NEVER lift the machine while the engine is running.
■ Useadequateliftingcable(wireorrope)ofsufficientstrength.
■ Whenlifting thegenerator, alwaysuse thebalanced center-
point suspensionhook and liftstraight upwards.
■ NEVERallowany personor animaltostand underneaththe
machinewhile lifting.
■ When loading the generator on a truck, be sure to use the
frontandbackframebarsasameanstosecurethegenerator
duringtransport.
Battery
Never over fill the battery with water above
theupper limit.
CAUTION:
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Usewellinsulated gloveswhenpickingup thebattery.Use the
following guidelines when handling the battery:
RULES FOR SAFE OPERATION
1. DO NOT drop the battery.There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Alwayskeep batterychargingandboostercables ingood
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
toavoidriskofadangerousconcentrationofcombustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plentyofwater,thencontactthenearestdoctororhospital,
and seek medical attention.

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 9
Transporting
■ Alwaysshutdown enginebefore transporting.
■ Tightenfuel tankcap securely.
■ Drainfuel when transportinggenerator over longdistances
orbad roads.
■ Always tie-down the generator during transportation by
securing thegenerator.
■ Ifgeneratorismountedonatrailer,makesuretrailercomplies
withall localand state safetytransportation laws.See page
10for basictowing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit . Knowthelocationofthe nearesttelephone.
Also know the phone numbers of the nearest
ambulance ,
doctor and fire department .
RULES FOR SAFE OPERATION
Maintenance Safety
■ NEVERlubricatecomponentsorattemptserviceonarunning
machine.
■ Always allow the machine a proper amount of time to cool
beforeservicing.
■ Keepthe machinery inproper running condition.
■ Fixdamageto themachineimmediately andalwaysreplace
brokenparts.
■ Disposeofhazardouswasteproperly.Examplesofpotentially
hazardouswaste areused motor oil,fuel, andfuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source

PAGE 10 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure1) that supports thegeneratorand thetowingvehicle
are in good operating condition and both units are
mechanically sound.
Thefollowing listofsuggestionsshouldbe usedwhentowing
yourgenerator:
CAUTION :
Towing Safety Precautions
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup,brake, andtrailerlights areconnected and working
properly.
■ Rememberthemaximumspeedunless otherwisepostedfor
highwaytowing is 45 MPH.Recommended off-road towing
isnottoexceed10 MPH orlessdependingon typeofterrain.
■ Place chockedblocks underneathwheel toprevent rolling,
whileparked.
■ Place support blocks underneath the trailer's bumper to
prevent
tipping , whileparked.
■ Usethetrailer'shand winchtoadjust theheight ofthetrailer,
then insert locking pin to lock wheel stand in place, while
parked.
■ Avoid sudden stops and starts.This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gasmilage.
■ Avoidsharp turnsto prevent rolling.
■ Removewheel standwhen transporting.
■ DO NOT transportgenerator with fuelin tank.
Check with your county or state safety
towing regulations department before
towingyourgenerator.
■ Make sure the hitch and coupling of the towing vehicle are
ratedequalto,orgreaterthanthetrailer"grossvehicleweight
rating"(GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
towa trailerwith defectivehitches, couplings,chainsetc.
■ Check the tire air pressure on both the towing vehicle and
thetrailer.Alsocheck thetire tread wearonboth vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
DCA-800SSK —TOWING
Figure 1. TypicalTrailer Description

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 11
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and main-
tenance guidelines referenced in this section apply a wide
rangeoftrailers. Rememberperiodicinspectionofthetrailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
! Brakes
! Tires
! LugNutTorquing
! Suspension
! Electrical
! BrakeTroubleshootingTables
Use the following definitions while readingTable 1.
1. Fuel Cell - Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transportingequipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
DCA-800SSK —TRAILER-SAFETY GUIDELINES
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the
trailer’s axle.
11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. SeeTable4 and Figure 5 for lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3 on page 17). Please not that
some trailers have a double axle. This will be shown as
2-6000 lbs., meaning two axles with a total weight ca-
pacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shock
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle. See page 16 for
properwiringconnections.
16. Application - Indicates which units can be employed
on a particular trailer.

PAGE 12 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
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LEDOM NOITACILPPA LEUF LLEC EKARB METSYS RWVG EMARF HTGNEL EMARF HTDIW KCAJ DNATS
51-01-RLRT ,51ACD,21-GLT 003-WLT ONONSBL0091"69"05.BL008 LEEHWTLITLLUF
X01-RLRT ,51ACD,21-GLT 003-WLT ONONSBL0091"69"05.BL008 LEEHWTLITLLUF
FX01-RLRT ,51ACD,21-GLT 003-WLT LAG15ONSBL0091"69"05.BL008 LEEHWTLITLLUF
W522-RLRT 01-ACDONONSBL0022"58"24.BL008 LEEHWTLITLLUF
004-WLB 004-WLBONCIRTCELESBL0072"451TSAM/W "421O/W "55 )LLAT"87( .BL008 LEEHWTLITLLUF
FX51-RLRT 51-ACDLAG14ONSBL0072"421"55.BL008 LEEHWTLITLLUF
X05-RLRT 52-ACDONONSBL0072"421"55.BL008 LEEHWTLITLLUF
FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008 LEEHWTLITLLUF
TBS52-RLRT 52-ACDONONSBL0992"021"66.BL008 LEEHWTLITLLUF
W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002 DAPTALF
X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002 DAPTALF
FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002 DAPTALF
FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002 DAPTALF
521/58-RLRT ,001,58-ACD 521 LAG541CILUARDYHSBL00001"681"77.BL0002 DAPTALF
FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005 DAPTALF
FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005 DAPTALF
FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005 DAPTALF
FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005 DAPTALF
FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005 DAPTALF
XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005 DAPTALF
DCA-800SSK —TRAILER SPECIFICATIONS

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 13
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W51-01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4 TALFELOP4
X01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
FX01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4
W522-RLRT SSALCLLAB"2 ELBATSUJDA2 B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4
004WLB SSALCLLAB"2 ELBATSUJDA2 C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4
FX51-RLRT SSALCLLAB"2CRL31-87B"05.4X"31"2/1-2#0053GUL5FAEL4REBBURELOP4 TALF
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FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053 "8/3-2 GUL5FAEL4REBBURELOP4 TALF
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FX07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41.sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
FX001-RLRT 6/5-2ELBATSUJDA EYE"3TPO C51-502 )4(SAIB "5.5X"41sbl0053 "3 GUL5FAEL5MOOLERIW4
521/58-RLRT 6/5-2ELBATSUJDA EYE"3TPO D51R57/522TS )4(LAIDAR "6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4
FX051-RLRT EYELLAB"3E61-057 )4(SAIB "7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4
FX022-RLRT EYE"3 ELBATSUJDA E61R58/532TS )4(LAIDAR "7X"61sbl0007-)2(GUL8XELFQMOOLERIW4
FX003-RLRT EYE"3 ELBATSUJDA E61R58/532TS )6(LAIDAR "7X"61sbl0006-)2(GUL8XELFQMOOLERIW4
FX004-RLRT EYE"3 ELBATSUJDA E61R58/532TS )6(LAIDAR "7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4
FX006-RLRT LEEHWHT5H5.71R57/512TS )8(LAIDAR "7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6
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DCA-800SSK —TRAILER SPECIFICATIONS

PAGE 14 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:
! An electric brake system can be manually adjusted to
providethecorrectedbrakingcapabilityforvaryingroad
and load conditions.
! An electric brake system can be modulated to provide
more or less braking force, thus easing the brake load
on the towing vehicle.
! An electricbrakesystemhasvery littlelag timebetween
the time the vehicle’s brakes are actuated and the
trailer’s brakes are actuated.
! An electric brake system can provide an independent
emergency brake system.
Road testing is necessary in order to properly synchronize
the towing vehicle’s braking to the trailer’s braking. Brake
lockup, grabbiness, or harshness is due to lack of
synchronization between the tow vehicle and the trailer
beingtowedor under-adjusted brakes.
Before any brake synchronizations adjustments can be
made,the trailerbrakesshould beburnished-inby applying
the brakes 20-30 times with approximately a 20 m.p.h.
decreasein speed,e.g. 40m.p.h.to20m.p.h.. Allowample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.
Figure2displays the major electric brakecomponentsthat
will require inspection and maintenance. Please inspect
thesecomponentsasrequired. RefertoTable 5 forelectric
braketroubleshootingguidelines.
Electric Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
8. Repeat steps 1 through 6 on the remaining brakes.
DCA-800SSK —TRAILER BRAKING SYSTEM

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 15
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake
lines should be periodically checked for cracks, kinks, or
blockage.
Figure3 below displaysthe majorhydraulic/air/surgebrake
components that will require inspection and maintenance.
Inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section. Reference Table 6 for hydraulic brake
troubleshootingguidelines.
Figure 2. Electrical Brake Components
Figure 3. Hydraulic Brake Components
DCA-800SSK —TRAILER BRAKING SYSTEM

PAGE 16 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing
the trailer wheels it is important the wheels, tires, and axle
are properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DONOT install aninnertubeto
correct a leak through the rim. If the
rim is cracked, the air pressure in the
innertubemaycause pieces of the rim
to explode (break off) with great force and cause serious
eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in
preservingtirelife. Pressureshouldbecheckedcoldbefore
operation. DO NOT bleed air from tires when they are hot.
Check inflation pressure weekly to insure the maximum
tire life and to prevent premature tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYSwearsafetyglasseswhenremoving
or installing force fitted parts. Failure to
comply may result in serious injury.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension)immediately. Torquedsuspensioncomponents
as detailed in Table 3.
Figure 4. Suspension Components
DCA-800SSK —TRAILERTIRES & SUSPENSION

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 17
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TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG FIT ONLY
. PARTS MUST ROTATE FREELY .
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT
- BOLT ASSEMBLY .
SHOULDER TYPE
SHACKLE BOLT
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Lug NutTorque Requirements
Itis extremelyimportanttoapplyandmaintainproperwheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO
NOT torquethewheellugnutsallthewaydown. Tighten
each lug nut in 3 separate passes as defined byTable
4.
3. After first road use, retorque all lug nuts in sequence.
Checkall wheel lugnutsperiodically forcontinuedsafe
operation.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
Figure 5. Lug NutTightening Sequence
DCA-800SSK —TRAILERTIRES & SUSPENSION

PAGE 18 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
DCA-800SSK —TRAILERWIRING
Figure 6. Typical Trailer Wire Connector

DCA-800SSK —PARTS AND OPERATION MANUAL (STD)—REV. #1 (05/14/01) —PAGE 19
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DCA-800SSK —TRAILER BRAKETROUBLESHOOTING

PAGE 20 —DCA-800SSK —PARTS AND OPERATION MANUAL (STD) —REV. #1 (05/14/01)
DCA-800SSK —OPERATION AND SAFETY DECALS
The DCA-800SSK generator is equipped with a number of safety decals. These are provided for operator safety and
maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the
machine. If any of the decals on the generator become unreadable, replace them by contacting your representative.