MULTIQUIP Power WHISPERWATT DCA-100SSJU User manual

© COPYRIGHT 2001, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
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
PARTS AND OPERATION MANUAL
MQ POWER
DCA-100SSJU
WHISPERWATTTM
GENERATOR
(Standard)
PARTS LIST NO. M3870300174
S/N UP TO 7400295-100SSJU
S/N FROM 7400296~100SSJU2
Revision #2 (05/03/01)

PAGE 2 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — 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: [phone]

PAGE 4 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
TABLE OF CONTENTS
NOTE
Specification and part number
are subject to change without
notice.
Here's HowTo Get Help............................................... 3
Table Of Contents........................................................ 4
Parts Ordering Procedures .......................................... 5
Rules for Safe Operation .......................................... 6-9
Towing Rules for Safe Operation ............................... 10
Trailer Safety Guidelines............................................ 11
Trailer Specifications ............................................ 12-13
Trailer Braking System ......................................... 14-15
TrailerTires & Suspension .................................... 16-17
TrailerWiringDiagram ................................................ 18
TrailerTroubleshooting (Electric Brakes) .................... 19
TrailerTroubleshooting(HydraulicBrakes) ................. 20
OperationDecals.................................................. 21-22
DCA 100SSJU Specifications ................................... 23
MQ POWER DCA-100SSJU
AC GENERATOR
GeneralInformation ................................................... 24
MajorComponents .................................................... 25
Dimensions................................................................ 26
ControlPanel Descriptions ................................... 28-29
Engine Operating Panel w/key............................. 30-31
Engine Operating Panel w/MPEC ......................... 32-33
OutputTerminal Panel Overview ........................... 34-41
Installation ............................................................ 42-43
Pre Setup ............................................................. 44-47
Load Application ........................................................ 48
GeneratorStart-upProcedure (Manual)................ 49-51
GeneratorStart-up Procedure(Auto)......................... 52
GeneratorShutdownProcedure................................. 53
Maintenance ......................................................... 54-55
EngineTroubleshooting......................................... 56-57
Generator/EngineTroubleshooting ............................. 58
MPECTroubleshooting .............................................. 59
Explanation of Codes in Remarks Column ................ 60
Suggested Spare Parts ............................................. 61
Generator Assembly............................................. 62-63
Control Box Assembly.......................................... 64-67
Engine & Radiator Assembly................................. 68-71
Engine Operating Panel Assembly ........................ 72-73
Output Terminal Assembly..................................... 74-75
Battery Assembly.................................................. 76-77
Muffler Assembly .................................................. 78-79
Fuel Tank Assembly .............................................. 80-81
Enclosure Assembly ............................................. 82-85
Rubber Seal Assembly.......................................... 86-87
Name Plate And Decals ........................................ 88-89
Terms and Condition of Sale — Parts ....................... 90

DCA-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —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,boltsand washers (all items 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-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
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
generator or engine and
may 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.Contactwith
hot componentscancause serious
burns.
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained
andqualifiedpersonnelonly!Thisequipment
is for industrial use only.
Thefollowingsafetyguidelinesshouldalwaysbeusedwhen
operating the DCA-100SSJU portable generator:
GENERAL SAFETY
■ DONOToperateorservicethisequipmentbefore
readingthisentiremanual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVER operate this equipment without proper
protectiveclothing,shatterproofglasses,steel-
toed boots and other protective devices
required by the job.
■ NEVERoperatethisequipmentwhennotfeeling
well due to fatigue, illness or taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommended by MQ Power 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 :
■ Alwaysuse extreme cautionwhen
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
resultfrom fuel vapors,orif fuel isspilled
on a hot engine.
■ NEVERoperatethegeneratorinan
explosiveatmosphereornearcombustible
materials.Anexplosionorfire could result
causing severe bodily harm or even
death.
■ Topping-off to filler port is
dangerous, as it tends to spill fuel.
Always refuel in a well-ventilated area,
away from sparks and open flames.
CAUTION:

DCA-100SSJU — PARTS AND OPERATION MANUAL(STD)— REV. #2 (05/03/01) — PAGE 7
RULES FOR SAFE OPERATION
CAUTION :
■ 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.
■ 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
terminalconnectionsmaycausedamagetothegenerator
and electrical shock.
CAUTION :
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficienttimefortheengineandgenerator
to cool before performing maintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engineishotwillresultinhigh pressurized, boiling water
to gush out of the radiator, 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 is required.

PAGE 8 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
RULES FOR SAFE OPERATION
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ Alwaysserviceaircleaner frequently to preventcarburetor
malfunction.
■ Always disconnect the battery before performing service
onthe generator.
■ Always be sure the operator is familiar with proper safety
precaution s and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipmentshould be stored ina clean,dry locationout of
the reach of children.
■ DO NOT leave the generator runningin the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in
Operator’sManualbeforeattemptingtooperateequipment.
■ Refer to the John Deere Engine Owner's Manual for
engine technical questions or information.
Loading and Unloading (Crane)
■ Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■ Always drain fuel prior to lifting.
■ Always make sure crane or lifting device has been
properlysecuredto thehookofguardframeongenerator.
■ NEVER lift the machine while the engine is running.
■ Use adequate lifting cable (wire or rope) of sufficient
strength.
■ When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
■ NEVER allow any person or animal to stand underneath
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generatorduring transport.
Battery
Neveroverfillthebatterywithwaterabove
the upper limit.
CAUTION :
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
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. Alwayskeepbatterychargingandboostercablesingood
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
toavoidriskofadangerousconcentration ofcombustible
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-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —PAGE 9
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drainfuelwhentransportinggeneratoroverlongdistances
or bad roads.
■ Always tie-down the generator during transportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Alwaysknowthelocationofthenearest fire extinguisher
and firstaid kit .Knowthelocationofthenearesttelephone.
Alsoknowthephonenumbersofthenearest ambulance ,
doctor and fire department .
RULES FOR SAFE OPERATION
Maintenance Safety
■ NEVER lubricate components or attempt service on a
runningmachine.
■ Always allow the machine a proper amount of time to
cool before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always
replace broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.

PAGE 10 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure the trailer (Figure 1) that supports the generator
and the towing vehicle are in good operating condition and
both units are mechanically sound.
Thefollowinglistofsuggestions should beusedwhentowing
yourgenerator:
CAUTION :
Towing Safety Precautions
Check with your county or state safety
towingregulationsdepartmentbeforetowing
yourgenerator.
■ Make sure the hitch and coupling of the towing vehicle
areratedequal to,orgreater thanthetrailer"gross vehicle
weightrating" (GVWR).
■ ALWAYS inspectthehitchandcouplingforwear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS makesurethetrailerisequippedwitha"Safety
Chain".
DCA-100SSJU —TOWING RULES FOR SAFE OPERATION
■ ALWAYS attachtrailer’ssafetychaintobumperof towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ The maximum speed for highway towing is 45 MPH
unlesspostedotherwise. Recommended off-roadtowing
is not to exceed 10 MPH or less depending on type of
terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Use the trailer’s hand winch to adjust the height of the
trailer,theninsertlockingpintolockwheelstandin place,
whileparked.
■ Avoidsudden stops andstarts. Thiscancauseskidding,
or jack-knifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Figure 1. Generator with Trailer

DCA-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —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. Remember periodicinspectionofthetrailer
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
transporting equipment.
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-100SSJU —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 andFigure5forlug nut tighteningand
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
properwiring connections.
16. Application - Indicates which units can be employed
on a particular trailer.

PAGE 12 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
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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
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TBS52-RLRT 52-ACDONONSBL0992"021"66.BL008 LEEHWTLITLLUF
W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002 DAPTALF
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FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002 DAPTALF
FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002 DAPTALF
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FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005 DAPTALF
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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-100SSJU —TRAILER-SPECIFICATIONS

DCA-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —PAGE 13
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W51-01-RLRT SSALCLLAB"2 ELBATSUJDA2 C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4 TALFELOP4
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FX022-RLRT EYE"3 ELBATSUJDA E61R58/532TS )4(LAIDAR "7X"61sbl0007-)2(GUL8XELFQMOOLERIW4
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FX004-RLRT EYE"3 ELBATSUJDA E61R58/532TS )6(LAIDAR "7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4
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DCA-100SSJU —TRAILER-SPECIFICATIONS

PAGE 14 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
DCA-100SSJU —TRAILER BRAKING SYSTEM
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
providethecorrectedbrakingcapabilityforvarying road
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.
! Anelectricbrake system hasverylittlelagtimebetween
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
beingtowed or under-adjustedbrakes.
Before any brake synchronizations adjustments can be
made,thetrailerbrakesshouldbeburnished-inby applying
the brakes 20-30 times with approximately a 20 m.p.h.
decreaseinspeed,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 electricbrakecomponents that
will require inspection and maintenance. Please inspect
thesecomponentsas required. RefertoTable5forelectric
braketroubleshooting guidelines.
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-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —PAGE 15
DCA-100SSJU —TRAILER BRAKING SYSTEM
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 belowdisplaysthe 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

PAGE 16 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
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 aninner tube to
correct a leak through the rim. If the
rim is cracked, the air pressure in the
innertube may cause piecesof 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. Pressure shouldbecheckedcoldbefore
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.
DCA-100SSJU —TRAILERTIRES & SUSPENSION
Figure 4. Suspension Components

DCA-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —PAGE 17
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TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG I T ONLY.PARTS MUST ROTATE REELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY.
SHOULDER TYPE
SHACKLE BOLT
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Lug NutTorque Requirements
Itisextremelyimportanttoapplyandmaintain properwheel
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.
Checkallwheellugnutsperiodicallyforcontinuedsafe
operation.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-100SSJU —TRAILERTIRES & SUSPENSION
Figure 5. Lug NutTightening Sequence

PAGE 18 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
NOTE:
LIGHTS ARE ORIENTED FROMTHE DRIVER’S SEAT
DCA-100SSJU —TRAILERWIRING DIAGRAMS

DCA-100SSJU —PARTS AND OPERATION MANUAL (STD)—REV. #2 (05/03/01) —PAGE 19
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SYMPTOM POSSIBLE CAUSE SOLUTION
NO BRAKES OR INTERMITTENT BRAKES ANY OPEN CIRC ITS OR BROKEN WIRES ? FIND AND CORRECT .
ANY SHORT CIRC ITS ? FIND AND CORRECT .
FA LTY CONTROLLER ? TEST AND CORRECT .
ANY LOOSE CONNECTI ONS ? FIND AND REPAIR .
IS THE GRO ND WIRE SEC RE ? FIND AND SEC RE .
WEAK BRAKES OR BRAKES P LL TO ONE SIDE IS THERE GREASE OR OIL ON MAGNETS OR LININGS ? CLEAN OR REPLACE .
IS THE CONNECTIONS CORRODED ? CLEAN AND CORRECT CA SE OF
CORROSION
.
IS THE BRAKE DR MS SCORED OR GROOVED ? MACHINE OR REPLACE .
IS THE BRAKES SYNCHRONIZED ? CORRECT. ( SEE PG 8 FOR
SYNCHRONIZING
)
LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE , BENT OR BROKEN ? REPLACE COMPONENTS .
IS THE BRAKE DR MS O T - OF - RO ND ? REPLACE .
NOISY BRAKES IS THE SYSTEM L BRICATED ? L BRICATE .
IS THE BRAKE COMPONENTS CORRECT ? REPLACE AND CORRECT .
DRAGGING BRAKES IS THE BEARINGS OF THE WHEEL ADJ STED ? ADJ ST .
DCA-100SSJU —TRAILER-BRAKETROUBLESHOOTING

PAGE 20 —DCA-100SSJU —PARTS AND OPERATION MANUAL (STD) —REV. #2 (05/03/01)
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NO BRAKES IS THE BRAKE LINE BROKEN OR KINKED ? REPAIR OR REPLACE .
WEAK BRAKES OR BRAKES PULL TO ONE SIDE IS THE BRAKE LINING GLAZED ? REBURNISH OR REPLACE
IS THE TRAILER OVERLOADED
? CORRECT WEIGHT .
IS THE BRAKE DRUMS SCORED OR GROOVED ? MACHINE OR REPLACE .
IS THE TIRE PRESSURE CORRECT ? INFLATE ALL TIRES EQUALLY
IS THE TIRES UNMATCHED ON THE SAME AXLE
? MATCH TIRES .
LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE , BENT OR BROKEN ? REPLACE COMPONENTS .
IS THE BRAKE DRUMS OUT - OF - ROUND ? REPLACE .
NOISY BRAKES IS THE SYSTEM LUBRICATED ? LUBRICATE .
IS THE BRAKE COMPONENTS CORRECT ? REPLACE AND CORRECT
DRAGGING BRAKES IS THE BRAKE LINING THICKNESS CORRECT OR IN RIGHT WRONG
POSITION
?
INSTALL NEW SHOES AND LININGS
IS THERE ENOUGH BRAKE FLUID OR CORRECT FLUID
? REPLACE RUBBER PARTS
FILL WITH DOT
4 FLUID
DCA-100SSJU —TRAILER-BRAKETROUBLESHOOTING