MULTIQUIP Power WHISPERWATT DCA-220SSK Guide

© COPYRIGHT 2001, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
Revision #3 (06/05/01)
MULTIQUIP INC.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
DCA-220SSK
WHISPERWATTTM
GENERATOR
(Standard)
PARTS AND OPERATION MANUAL
Up to S/N3696500
S/N3699150 to S/N3699619
S/N3699637 to S/N3703349
S/N3703364 to S/N3703853
S/N3703869~
(For serial numbers not listed, please refer to Sunbelt or GEER manuals)

PAGE 2 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — 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-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
TABLE OF CONTENTS
NOTE
Specification and part
number are subject to
change without notice.
Here's HowTo Get Help........................................3
Table Of Contents.................................................4
PartsOrdering Procedures ...................................5
Rules for Safe Operation ......................................6-9
Towing Safety Precaution .....................................10
Trailer Safety Guidelines.......................................11-17
TrailerWiring Diagram ...........................................18
Electrical BrakeTroubleshooting...........................19
Hydraulic BrakeTroubleshooting...........................20
Operation and Safety Decals................................21-22
DCA 220 Specifications .......................................23
GeneralInformation ..............................................24-26
MajorComponents ...............................................27
Dimensions...........................................................28-29
ControlPanel Descriptions ...................................30-31
Engine Operating Panel Descriptions ...................32-33
OutputTerminal Overview.....................................34-41
Installation ............................................................42-43
Pre Setup .............................................................44-47
Load Application ...................................................48
Generator Start-up Procedure (Manual)................49-52
GeneratorStart-up Procedure (Auto) ....................53
GeneratorShut-Down Procedure ..........................54
Maintenance .........................................................56-59
GeneratorWiringDiagram.....................................60
EngineWiringDiagrams .......................................62-63
EngineTroubleshooting .........................................64-65
Generator/EngineTroubleshooting ........................66
MPECTroubleshooting .........................................67
Explanation of Code in Remarks Column .............68
Serial Numbers Pertaining to Unit ........................68
Suggested Spare Parts ........................................69
DCA-220SSKGENERATOR
Generator Assembly-Up to S/N1337562...............70-73
GeneratorAssembly-S/N1337563~ ......................74-77
Control Box and Panel Assembly-
Upto S/N1337562 ................................................78-81
Control Box and Panel (Optional)-
Upto S/N1337562 ................................................82-85
ControlPanel Assembly-S/N1337563~.................86-87
Control Box Assembly-S/N1337563~ ...................88-91
Engine & Radiator Assembly-Up to S/N1337562..92-95
Engine & Radiator Assembly-
S/N1337563to 3690734 .......................................96-99
Engine & Radiator Assembly-S/N3690735~ .........100-103
Engine Operating and OutputTerminal Assembly-
Upto S/N1337562 ................................................104-109
Engine Operating Panel Assembly (Opt.Parts,
withSlow-Down)-Up to S/N1337562 .....................110-115
Engine Operating Panel Assembly-S/N1337563~ 116-119
OutputTerminal Panel Assembly-
S/N1337563to 3690734 .......................................120-121
OutputTerminal Panel Assembly-S/N3690735~ ...122-123
Actuator-S/N3690735~ .........................................124-125
Battery Assembly.................................................126-127
Muffler Assembly .................................................128-129
FuelTank Assembly-Up to S/N1337562 ...............130-131
FuelTank Assembly-S/N1337563~.......................132-133
Enclosure Assembly-Up to S/N1337562 ..............134-139
Enclosure Assembly-S/N1337563~......................140-145
Rubber Seal Assembly-Up to S/N1337562...........146-147
RubberSealAssembly-S/N1337563~ ..................148-149
Automatic Oil Feeder Assembly (Opt. Parts)-
Upto S/N1337562 ................................................150-151
Control Box Assembly Remote (Opt. Parts)-
Upto S/N1337562 ................................................152-153
Name Plate And Decals .......................................154-157
Terms and Condition of Sale — Parts ..................158

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —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 itemsunder $1.00list 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! Direct TOLL-FREE access
to our Parts Department!
Toll-freenationwide:
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
DomesticUSA Dealers
Only

PAGE 6 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engineor generator.
■ 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
topeople.The generatorenginegivesoffDEADLY carbon
monoxide gas.
■ High Temperatures –Allow the engine to cool before
adding fuel or performing service and maintenance
functions.Contactwith
hot componentscancauseserious
burns.
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
Thisequipment is to be operated by trained
andqualifiedpersonnelonly!Thisequipment
is for industrial use only.
Thefollowing safety guidelinesshouldalways be usedwhen
operating the DCA-220SSK portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment
before reading this entire manual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVER operate this equipment without
proper protective clothing, shatterproof
glasses, steel-toed boots and other
protective devices required by the job.
■ NEVER operate this equipment when not
feeling 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 :
■ Always use extreme CAUTION
when working with flammable liquids.
When refueling, stop the engine and
allow it to cool.DO NOT smokearound
or near the machine. Fire or explosion
could result from fuel vapors, or if fuel
is spilled on a hot engine.
■ NEVERoperatethegeneratorinan
explosive atmosphere or near combustible materials. An
explosion or fire 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.

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —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 except through 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 terminal connections may
causedamagetothegeneratorandelectrical
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
engine is hot due to high pressure, will result in boiling
water to gush out of the radiator, therefore causing
severe scalding to any persons in the general area of
thegenerator.
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-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
RULES FOR SAFE OPERATION
! NEVER Run engine without air filter. Severe engine
damage may occur.
! Alwaysserviceaircleanerfrequentlyto preventcarburetor
malfunction.
! Always disconnect the battery before performing service
onthegenerator.
! Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
! Always store equipment properly when not in use.
Equipmentshouldbe stored in a clean, dry location out of
the reach of children.
! DO NOT leavethegeneratorrunninginthemanualmode
unattended.
! DO NOT allow unauthorized people to operate this
equipment.
! Always read, understand, and follow procedures in
Operator’sManualbeforeattemptingtooperateequipment.
! Refer tothe KomatsuEngine Owner'sManual forengine
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
properlysecuredtothehook ofguard frameongenerator.
! 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. Alwayskeepbatterychargingandboostercablesin good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
toavoidriskofadangerous concentrationofcombustible
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-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 9
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long
distances or bad roads.
■ Alwaystie-down the generatorduring 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
■ Always know the location of the nearest fire
extinguisher
and first aid kit . Know the location of the
nearesttelephone. Also knowthephone numbers ofthe
nearest ambulance , doctor and fire department .
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
RULES FOR SAFE OPERATION

PAGE 10 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
DCA-220SSK —TOWING
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure that the trailer (Figure 1) that supports the
generator and the towing vehicle are in good operating
condition and both units are mechanically sound.
Thefollowinglistofsuggestionsshould beused whentowing
yourgenerator:
CAUTION :
Towing Safety Precautions
■ ALWAYS attach trailer'ssafetychain to bumperof towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ Rememberthemaximumspeed unlessotherwise posted
for highway towing is 45 MPH. Recommended off-road
towing 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, theninsert lockingpinto lockwheelstand inplace,
whileparked.
■ Avoid sudden stops and starts.This can cause skidding,
or jackknifing. 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.
Checkwithyourcountyorstatesafetytowing
regulations department before towing your
generator.
■ Make sure the hitch and coupling of the towing vehicle
areratedequal to,orgreaterthan thetrailer"gross vehicle
weightrating"(GVWR).
■ ALWAYS inspectthe hitchandcoupling forwear.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 makesure thetrailerisequippedwith a "Safety
Chain".
Figure 1. Generator withTrailer

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 11
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and mainte-
nanceguidelinesreferencedinthissectionapplyawiderange
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam-
age 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 reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipmentin use. Fuel cells mustbeempty when trans-
portingequipment.
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).
DCA-220SSK —TRAILER-SAFETY GUIDELINES
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.
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. SeeTable 4 and Figure 5 orlug nuttightening 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). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity 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.
16. Application - Indicates which units can be employed
on a particular trailer.
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.

PAGE 12 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
snoitacificepS.1elbaT
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-220SSK —TRAILER-SPECIFICATIONS

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 13
)t'noC(snoitacificepS.1elbaT
LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE
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
X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053 "8/3-2 GUL5FAEL4REBBURELOP4 TALF
FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053 "8/3-2 GUL5FAEL4REBBURELOP4 TALF
W07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41.sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
X07-RLRT SSALCLLAB"2 ELBATSUJDA"3 C41-502 )4(SAIB "5X"41sbl0053 "3 GUL5FAEL5REBBURELOP4 TALF
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
RA008-RLRT LEEHWHT5H5.71R57/512TS )8(LAIDAR "7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6
DCA-220SSK —TRAILER-SPECIFICATIONS

PAGE 14 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
DCA-220SSK —TRAILER SAFETY GUIDELINES
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
mileinterval, inspect the brakes every 3,000 miles. If driving
over rough terrain, inspect the brakes more frequently.
Electric Brakes
Electricallyactuatedbrakes(Figure 2)are similartohydraulic
brakes. The basic difference is that hydraulic brakes are
actuated by an electromagnet.
Listedbelow aresomeof the advantagesthatelectric brakes
have over hydraulic brakes:
! Brake system can be manually adjusted to provide the
corrected braking capability for varying road and load
conditions
! Brake system can be modulated to provide more or less
braking force, thus easing the brake load on the towing
vehicle
! Brake system has very little lag time between the time
thevehicle’sbrakesareactuatedand the trailer’sbrakes
are actuated
! Brake system can provide an independent emergency
brake system
Inorder to properly synchronizethe towing vehicle’s braking
to the trailer’s braking system, can only be accomplished
by road testing. Brake lockup, grabbiness or harshness is
due to lack of synchronization between the tow vehicle and
the trailer being towed or under-adjusted brakes.
Beforeanybrakesynchronizationsadjustmentscanbemade,
the trailer brakes should be burnished-in by applying the
brakes20-30 times with approximatelya20 m.p.h. decrease
in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
brakes to cool between application. This allows the brake
shoes to slightly be seated into the brake drum surface.
Figure 2 displays the major electric brake components that
willrequireinspectionandmaintenance. Pleaseinspectthese
componentsasrequired.
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
starwheel 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
theground.
8. Repeat steps 1 through 6 on the remaining brakes.

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 15
DCA-220SSK —TRAILER SAFETY GUIDELINES
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such as
shoeandliningreplacement. Thesebrakescanbeadjusted
in the same manner as electric brakes. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Inspectthese components asrequiredusing steps 1through
6 as referenced in the electric brake adjustments section.
Figure 2. Electrical Brake Components
Figure 3. Hydraulic Brake Components

PAGE 16 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
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
properlymatched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in
the inner tube
may cause 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 tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
andtread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
orinstalling force fittedparts. Failureto comply
may result in serious injury.
DCA-220SSK —TRAILER SAFETY GUIDELINES
Figure 4. Major Suspension Components
Suspension
The leaf suspension springs and associated components
(Figure4) 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. Torquedsuspension components
as detailed in Table 3.

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 17
stnemeriuqeReuqroTnoisnepsuS.3elbaT
metI ).sbL-.tF(euqroT
TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG IT ONLY . PARTS MUST ROTATE REELY .
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAI N NUT
- BOLT ASSEMBLY .
SHOULDER TYPE
SHACKLE BOLT
05-XAM03-NIM
stnemeriuqeReuqroTeriT.4elbaT
eziSleehWssaPtsri
SBL-T
ssaPdnoceS
SBL-T
ssaPdrihT
SBL-T
"2152-0204-5356-05
"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
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
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined byTable 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-220SSK —TRAILER SAFETY GUIDELINES
Figure 5.Wheel Lug NutsTightening Sequence

PAGE 18 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
NOTE:
LIGHTS ARE ORIENTED FROMTHE DRIVER’S SEAT
DCA-220SSK —TRAILER-WIRING DIAGRAM

DCA-220SSK —PARTS AND OPERATION MANUAL (STD)—REV. #3 (06/05/01) —PAGE 19
gnitoohselbuorTekarBcirtcelE.5elbaT
motpmyS esuaCelbissoP noituloS
sekarBtnettimretnIrosekarBoN?seriwnekorbrostiucricnepoynA.tcerrocdnadniF
?stiucrictrohsynA.tcerrocdnadniF
?rellortnocytluaF.tcerrocdnatseT
?snoitcennocesoolynA.riaperdnadniF
?eruceseriwdnuorG.erucesdnadniF
otlluPsekarBrosekarBkaeW
ediSen
?sgninilrostengamnolioroesaerG.ecalperronaelC
?dedorrocsnoitcennoCesuactcerrocdnanaelC
.noisorrocfo
?devoorgroderocssmurdekarB.ecalperroenihcaM
?dezinorhcnyssekarB.tcerroC
sekarBgnikcoL?nekorbrotneb,esoolstnenopmocekarB.stnenopmocecalpeR
?dnuor-fo-tuosmurdekarB.ecalpeR
sekarBysioN?detacirbulmetsyS.etacirbuL
?tcerrocstnenopmocekarB.tcerrocdnaecalpeR
sekarBgniggarD?detsujdaleehwehtfosgniraeB.tsujdA
DCA-220SSK —TRAILER-BRAKETROUBLESHOOTING

PAGE 20 —DCA-220SSK —PARTS AND OPERATION MANUAL (STD) —REV. #3 (06/05/01)
gnitoohselbuorTekarBciluardyH.6elbaT
motpmyS esuaCelbissoP noituloS
sekarBoN?deknikronekorbenilekarB.ecalperroriapeR
otlluPsekarBrosekarBkaeW
ediSenO
?dezalggninilekarB.ecalperrohsinrubeR
?dedaolrevoreliarT.thgiewtcerroC
?devoorgroderocssurdekarB.ecalperroenihcaM
?tcerrocerusserperiT.yllauqeseritllaetalfnI
?elxaeasehtnodehctanuseriT.serithctaM
sekarBgnikcoL?nekorbrotneb,esoolstnenopocekarB.stnenopocecalpeR
?dnuor-fo-tuosurdekarB.ecalpeR
sekarBysioN?detacirbuletsyS.etacirbuL
?tcerrocstnenopocekarB.tcerrocdnaecalpeR
sekarBgniggarDthgirnirotcerrocssenkcihtgninilekarB
?noitisopgnorw
dnaseohswenllatsnI
.sgninil
?diulftcerrocrodiulfekarbhguonEstraprebburecalpeR
.diulf4todhtiwllif
DCA-220SSK —TRAILER-BRAKETROUBLESHOOTING