Multiquip dca-60ssai User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

DCA-60SSAI WHISPERWATTTM

GENERATOR

(Standard)

© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST NO. 7451201B

FINAL COPY

MULTIQUIP INC.

PARTS DEPARTMENT:

18910 WILMINGTON AVE.

800-427-1244

CARSON, CALIFORNIA 90746

FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244

800-835-2551

FAX:310-537-3927

FAX:310-638-8046

E-mail:mq@multiquip.com www:multiquip.com

PAGE 2 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700 FAX: 310/537-3927

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ...........................................

3

Table Of Contents ....................................................

4

Parts Ordering Procedures ......................................

5

Rules for Safe Operation .........................................

6-9

Towing and Transportation .......................................

10

Trailer Safety Guidelines ..........................................

11-17

TrailerWiring Diagram ..............................................

18

Electric Brake Troubleshooting ................................

19

Hydraulic Brake Troubleshooting ..............................

20

Operation Decals .....................................................

21-22

DCA -60SSI2 Specifications ...................................

23

General Information .................................................

24

Major Components ..................................................

55

Dimensions..............................................................

26

Control Panel Descriptions ......................................

28-29

Engine Operating Panel Descriptions ......................

30-31

Output Terminal Panel Descriptions .........................

32-33

Output Amperage Setup ..........................................

34-35

Output Voltage Setup...............................................

36-39

Installation ...............................................................

40-41

Pre Set-up ...............................................................

42-45

Load Application ......................................................

46

Generator Start-up Procedure .................................

47-49

Generator Shut-down Procedure ..............................

50

Maintenance ............................................................

52-55

Generator Wiring Diagram ........................................

56

Engine Wiring Diagram ............................................

57

Engine Troubleshooting ............................................

58-59

Generator/EngineTroubleshooting ...........................

60

Explanation of Codes in Remarks Column ..............

62

Suggested Spare Parts ...........................................

63

MQ POWER DCA-60SSAI

 

AC GENERATOR

 

Generator Assembly ................................................

64-65

Control Box Assembly .............................................

66-67

Engine & Radiator Assembly...................................

68-71

Engine Operating Panel Assembly ..........................

72-75

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

ISUZU 6BD1 ENGINE

Cylinder Head Cover Assembly ............................

90-91

Cylinder Head Assembly ......................................

92-93

Cylinder Block Assembly .....................................

94-97

Oil Pan and Level Gauge Assembly .....................

98-99

Camshaft and Valve Assembly.............................

100-101

Crankshaft Piston and Flywheel Assembly ..........

102-103

Timing Gear and Flywheel Housing Assembly .....

104-105

Inlet Manifold Assembly .......................................

106-107

Exhaust Manifold Assembly .................................

108-109

Ventilation Assembly ............................................

110-111

Water Pump and Corrosion Resistor Assembly ....

112-113

Thermostat and Housing Assembly .....................

114-115

Engine Water Piping Assembly.............................

116-117

Fan and Fan Belt Assembly .................................

118-119

Fuel Injection Assembly .......................................

120-121

Fuel Filter and Bracket Assembly ........................

122-123

Fuel Pump and Pipe Assembly ............................

124-125

Oil Cooler and Oil Filter Assembly .......................

126-127

Oil Pump and Oil Strainer Assembly ....................

128-129

Oil and Vacuum Piping Assembly ........................

130-131

Electrical Control Assembly .................................

132-133

Starter Components Assembly ............................

134-135

Alternator Components Assembly ........................

136-137

Injection Pump Components Assembly ...............

138-141

Governor Components Assembly .........................

142-145

Feed Pump Assembly ..........................................

146-147

Misc. Injection Pump Assembly ...........................

148-149

Coupling Assembly...............................................

150-151

Water Sedimenter Assembly ................................

152-153

Switch and Relay Assembly .................................

154-155

Terms and Condition of Sale — Parts ..................

156

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

PARTS ORDERING PROCEDURES

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.

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%

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.

**Common nuts, bolts and 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

Extra

Fax

Discount

USA

 

for

Domestic

 

 

Only

 

 

 

 

Dealers

 

UPS

 

Special

 

ed orders

only

For

fax

 

 

 

Now! Direct TOLL-FREE access to our Parts Department!

Toll-free nationwide:

800-421-1244 Toll-free FAX:

800/6-PARTS-7 • 800-672-7877

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 5

CAUTION:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only!This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-60SSAI portable generator:

GENERAL SAFETY

DONOToperateorservicethisequipmentbefore 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, steeltoed boots and other protective devices required by the job.

NEVERoperate 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.

RULES FOR SAFE OPERATION

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns.

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.

CAUTION:

Always refuel in a well-ventilated area, away from sparks and open flames.

Always use extreme caution when 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 result from fuel vapors, or if fuel is spilled on a hot engine.

NEVER operate the generator in an 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.

PAGE 6 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

RULES FOR SAFE OPERATION

CAUTION:

NEVER touch output terminals during operation. This is extremely dangerous. Always stop the machine when contact with the output terminals is required.

CAUTION:

Backfeed to a utility system can cause electrocution and.or property damage. Do not connect to any building's electrical system except through an approved device or after building main switch is opened.

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 terminal connections may cause damage to the generator and electrical shock.

CAUTION:

DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

Radiator

1.Radiator Cap - Removing the radiator cap while the engine is hot will result in high 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.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 7

RULES FOR SAFE OPERATION

Battery

CAUTION:

Never over fill the battery with water above the upper limit.

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.Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

5.Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible 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 plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

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 precaution s and operations techniques before using generator.

Always store equipment properly when not in use.

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.

Refer to the Isuzu 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 properly secured to the hook of guard frame on generator.

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 generator during transport.

PAGE 8 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

RULES FOR SAFE OPERATION

Transporting

Always shutdown engine before transporting.

Tighten fuel tank cap securely.

Drain fuel when transporting generator over long distances 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

Always know the location of the nearest fire extinguisher and first aid kit. Know the location of the nearest telephone.

Also know the phone numbers of the nearest ambulance, doctor and fire department.

Maintenance Safety

NEVER lubricate components or attempt service on a running machine.

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.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 9

DCA-60SSAI —TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION :

Check with your county or state safety towing regulations department before towing your generator.

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.

The following list of suggestions should be used when towing your generator:

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).

ALWAYS inspect the hitch and coupling for wear. 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 make sure the trailer is equipped with a "Safety Chain".

ALWAYS attach trailer’s safety chain to bumper of 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 unless posted otherwise. 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, then insert locking pin to lock wheel stand in place, while parked.

Avoid sudden stops and starts. This can cause skidding, 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

PAGE 10 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —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.

Explanation of Chart:

This section is to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer 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 maintenance components of the trailer. The following trailer components will be discussed in this section:

Brakes

Tires

Lug Nut Torquing

Suspension

Electrical

Brake Troubleshooting Tables

Use the following definitions with reading Table 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, hydraulic, hydraulic-surge and air.

3.GVWR- Gross Vehicle Weight Rating (GVWR), is the maximum number of pounds the trailer can carry, including 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.

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 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. See Table 4 and Figure 5 or lug nut tightening and sequence.

13.Axle - Indicates the maximum weight the axle can support 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 shocks 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.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 11

DCA-60SSAI —TRAILER-SPECIFICATIONS

Table 1. Specifications

MODEL

APPLICATION

FUEL

BRAKE

GVWR

FRAME

FRAME

JACK

 

 

CELL

SYSTEM

 

LENGTH

WIDTH

STAND

 

 

 

 

 

 

 

 

TRLR-10W

SDW225,

NO

NO

1900LBS

96"

50"

800LB.

 

SGW250,TLW300

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-10

DCA10, TLG12,

NO

NO

1900LBS

96"

50"

800LB.

 

DCA-15

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-10XF

DCA10, TLG-12,

52 GAL

NO

1900LBS

96"

50"

800LB.

 

DCA15, TLW-300

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-225W

WELDERS,

NO

NO

2200LBS

85"

42"

800LB.

 

DA7000SS

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-BLW400

BLW-400

NO

ELECTRIC

2700LBS

W/MAST 154"

55"

800LB.

 

 

 

 

 

W/O 124"

(78" TALL)

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-50X

DCA-25

NO

NO

2700LBS

124"

55"

800LB.

 

 

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-50XF

DCA-25

41 GAL

NO

2700LBS

124"

55"

800LB.

 

 

 

 

 

 

 

FULL TILT WHEEL

 

 

 

 

 

 

 

 

TRLR-70W

DCA-45, -60, 70

NO

SURGE

7000LBS

186"

77"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-70X

DCA-45, -60, 70

OPT

SURGE

7000LBS

138"

66"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-70XF

DCA-45, -60, 70

53 GAL

SURGE

7000LBS

138"

66"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-100XF

DCA-100, 125

150 GAL

HYDRAULIC SURGE

7000LBS

190"

76"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-85/125

DCA-85, 100,

145 GAL

HYDRAULIC

10000LBS

186"

77"

2000LB.

 

125

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-150XF

DCA-150, 180

200 GAL

HYDRAULIC SURGE

11160LBS

204"

84"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-220XF

DCA-220

250 GAL

HYDRAULIC SURGE

14000LBS

222"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-300XF

DCA-300

250 GAL

HYDRAULIC SURGE

18000LBS

238"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-400XF

DCA-400

350 GAL

ELECTRIC

18000LBS

238"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-600XF

DCA-600, 800

550 GAL

AIR

30000LBS

384"

96"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

TRLR-800SX

DCA-600, 800

550 GAL

AIR

30000LBS

384"

96"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

 

 

 

 

 

 

 

 

PAGE 12 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —TRAILER-SPECIFICATIONS

Table 1. Specifications (Con't)

MODEL

COUPLER

TIRES

WHEELS

AXLE

HUBS

SUSPENSION

ELECTRICAL

 

 

 

 

 

 

 

 

TRLR-10W

2" BALL CLASS

175-13C

13"X4.50"

2200# 2X2

5 LUG

3 LEAF

4 WIRE LOOM W/

 

2 ADJUSTABLE

 

 

 

 

 

4 POLE FLAT

 

 

 

 

 

 

 

 

TRLR-10

2"BALL CLASS

175-13C

13"X4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-10XF

2"BALL CLASS

175-13C

13"X4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-225W

2"BALL CLASS

175-13B

13X4.5"

2200#2X2

5 LUG

Q FLEX

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-BLW

2"BALL CLASS

175-13C

13 X 4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

400

2 ADJUSTABLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-50X

2" BALL CLASS

B78-13LRC

13"X4.50"

3500lbs.

5 LUG

4 LEAF

4 POLE RUBBER

 

 

 

 

2-3/8"

 

 

FLAT

 

 

 

 

 

 

 

 

TRLR-50XF

2" BALL CLASS

B78-13LRC

13"X4.50"

3500lbs.

5 LUG

4 LEAF

4 POLE RUBBER

 

 

 

 

2-3/8"

 

 

FLAT

 

 

 

 

 

 

 

 

TRLR-70W

2" BALL CLASS

205-14C

14"X5"

3500lbs.

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

 

 

 

 

 

 

 

 

TRLR-70X

2" BALL CLASS

205-14C

14"X5"

3500lbs

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

 

 

 

 

 

 

 

 

TRLR-70XF

2" BALL CLASS

205-14C

14"X5"

3500lbs.

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

 

 

 

 

 

 

 

 

TRLR-100XF

ADJUSTABLE 2-5/6

205-15C

14"X5.5"

3500lbs

5 LUG

5 LEAF

4 WIRE LOOM

 

OPT 3" EYE

BIAS (4)

 

3"

 

 

 

 

 

 

 

 

 

 

 

TRLR-85/125

ADJUSTABLE 2-5/6

ST225/75R15D

14"x6"

(2)-6000lbs

6 LUG

7 LEAF

4 WIRE LOOM

 

OPT 3" EYE

RADIAL (4)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-150XF

3" BALL EYE

750-16 E

16"X7"

(2)-6000lbs

8 LUG

7 LEAF

4 WIRE LOOM

 

 

BIAS (4)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-220XF

3" EYE

ST235/85R16E

16"X7"

(2)-7000lbs

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(4)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-300XF

3" EYE

ST235/85R16E

16"X7"

(2)-6000lbs

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(6)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-400XF

3" EYE

ST235/85R16E

16"X7"

(3)-7000lbs.

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(6)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-600XF

5TH WHEEL

ST215/75R17.5H

16"X7"

(3)-10000lbs

8 LUG

7 LEAF

6 WIRE LOOM

 

 

RADIAL (8)

 

 

 

 

 

 

 

 

 

 

 

 

 

TRLR-800AR

5TH WHEEL

ST215/75R17.5H

16"X7"

(3)-10000lbs

8 LUG

AIR-RIDE

6 WIRE LOOM

 

 

RADIAL (8)

 

 

 

 

 

 

 

 

 

 

 

 

 

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 13

DCA-60SSAI —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 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:

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 the vehicle’s brakes are actuated and the trailer’s brakes are actuated

Brake system can provide an independent emergency brake system

Remember in order to properly synchronize the tow vehicle’s braking to the trailer’s braking, 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.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 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 will require inspection and maintenance. Please inspect these components as required.

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.

PAGE 14 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

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.

Figure 3 below displays the major hydraulic/air/surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 15

DCA-60SSAI —TRAILER SAFETY GUIDELINES

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. 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 and tread wear.

Table 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

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. Torqued suspension components as detailed in Table 3.

CAUTION:

 

NOTE

 

 

 

 

 

 

ALWAYS wear safety glasses when removing

 

Figure 4. Major Suspension Components

 

or installing force fitted parts. Failure to comply

 

 

 

may result in serious injury.

 

 

 

 

 

 

 

 

 

 

PAGE 16 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —TRAILER SAFETY GUIDELINES

Table 3. Suspension Torque Requirements

Item

Torque (Ft.-Lbs.)

 

 

3/8" U-BOLT

MIN-30 MAX-35

 

 

7/16" U-BOLT

MIN-45 MAX-60

 

 

1/2" U-BOLT

MIN-45 MAX-60

 

 

SHACKLE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.

SPRING EYE BOLT

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

 

RETAIN NUT-BOLT ASSEMBLY.

 

 

SHOULDER TYPE

MIN-30 MAX-50

SHACKLE BOLT

 

 

 

Lug Nut Torque 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 by Table 4.

3.After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

Table 4. Tire Torque Requirements

Wheel Size

First Pass

Second Pass

Third Pass

 

FT-LBS

FT-LBS

FT-LBS

 

 

 

 

12"

20-25

35-40

50-65

 

 

 

 

13"

20-25

35-40

50-65

 

 

 

 

14"

20-25

50-60

90-120

 

 

 

 

15"

20-25

50-60

90-120

 

 

 

 

16"

20-25

50-60

90-120

 

 

 

 

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 17

DCA-60SSAI —TRAILER-WIRING DIAGRAM

PAGE 18 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI —TRAILER-BRAKETROUBLESHOOTING

Table 5. Electric Brake Troubleshooting

Symptom

Possible Cause

Solution

 

 

 

No Brakes or Intermittent Brakes

Any open circuits or broken wires?

Find and correct.

 

 

 

 

Any short circuits?

Find and correct.

 

 

 

 

Faulty controller?

Test and correct.

 

 

 

 

Any loose connections?

Find and repair.

 

 

 

 

Ground wire secure?

Find and secure.

 

 

 

Weak Brakes or Brakes Pull to

Grease or oil on magnets or linings?

Clean or replace.

One Side

 

 

Connections corroded?

Clean and correct cause

 

 

 

of corrosion.

 

 

 

 

Brake drums scored or grooved?

Machine or replace.

 

 

 

 

Brakes synchronized?

Correct.

 

 

 

Locking Brakes

Brake components loose, bent or broken?

Replace components.

 

 

 

 

Brake drums out-of-round?

Replace.

 

 

 

Noisy Brakes

System lubricated?

Lubricate.

 

 

 

 

Brake components correct?

Replace and correct.

 

 

 

Dragging Brakes

Bearings of the wheel adjusted?

Adjust.

 

 

 

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 19

DCA-60SSAI —TRAILER-BRAKETROUBLESHOOTING

Table 6. Hydraulic Brake Troubleshooting

Symptom

Possible Cause

Solution

 

 

 

No Brakes

Brake line broken or kinked?

Repair or replace.

 

 

 

Weak Brakes or Brakes Pull to

Brake lining glazed?

Reburnish or replace.

One Side

 

 

Trailer overloaded?

Correct weight.

 

 

 

 

 

Brake drums scored or grooved?

Machine or replace.

 

 

 

 

Tire pressure correct?

Inflate all tires equally.

 

 

 

 

Tires unmatched on the same axle?

Match tires.

 

 

 

Locking Brakes

Brake components loose, bent or broken?

Replace components.

 

 

 

 

Brake drums out-of-round?

Replace.

 

 

 

Noisy Brakes

System lubricated?

Lubricate.

 

 

 

 

Brake components correct?

Replace and correct.

 

 

 

Dragging Brakes

Brake lining thickness correct or in right

Install new shoes and

 

wrong position?

linings.

 

 

 

 

Enough brake fluid or correct fluid?

Replace rubber parts

 

 

fill with dot4 fluid.

 

 

 

PAGE 20 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — GENERATOR DECALS

The DCA -100SSJU generator is wquipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 21

Multiquip dca-60ssai User Manual

DCA-60SSAI — GENERATOR DECALS

PAGE 22 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

 

 

DCA-60SSAI — SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

Table 7. Specifications

 

 

 

 

 

 

 

 

Generator Specifications

 

 

 

 

 

 

 

Model

DCA-60SSI2

 

 

 

 

 

 

 

Type

Revolving field, self ventilated, open protected type synchronous generator

 

 

 

 

 

 

 

 

Armature Connection

Star with Neutral

 

Zig Zag

 

 

 

 

 

 

 

 

Phase

3

 

Single

 

 

 

 

 

 

 

 

Standby Output

72 KVA (57.6 KW)

 

41.5KW

 

 

 

 

 

 

 

 

Prime Output

60 KVA (48 KW)

 

34.6KW

 

 

 

 

 

 

 

 

Voltage

240V or 480V

 

240/120V

 

 

 

 

 

 

 

 

Frequency

 

 

60 Hz

 

 

 

 

 

 

 

 

Speed

 

1800 rpm

 

 

 

 

 

 

 

 

Power Factor

0.8

 

1

 

 

 

 

 

 

 

Aux. AC Power

Single Phase, 60 Hz

 

 

 

 

 

 

 

 

Voltage

 

 

120 V

 

 

 

 

 

 

 

Output

4.8 KW (2.4 KW x 2)

 

 

 

 

 

 

 

 

Engine Specifications

 

 

 

 

 

 

 

Model

ISUZU A-6BG1

 

 

 

 

 

 

 

Type

4 Cycle, water-cooled, direct injection

 

 

 

 

 

 

 

 

No. of Cylinders

 

6 cylinders

 

 

 

 

 

 

 

Bore x Stroke

4.1 in. x 4.9 in. (105 mm x 125 mm)

 

 

 

 

 

 

 

Rated Output

77HP/1800 rpm

 

 

 

 

 

 

 

Displacement

396 cu. in. (6494 cc)

 

 

 

 

 

 

 

 

Starting

 

Electric

 

 

 

 

 

 

 

Coolant Capacity

7.8 gal. (29.5 liters)

 

 

 

 

 

 

 

Lube Oil Capacity

5.1 gal. (19.3 liters)

 

 

 

 

 

 

 

 

Fuel Consumption

3.9 gal. (14.9L)/hr at full load

 

3.0 gal. (11.4L)/hr at 3/4 load

 

 

 

 

 

 

 

2.4 gal. (9.1L)/hr at 1/2 load

 

1.9 gal. (7.2L)/hr at 1/4 load

 

 

 

 

 

 

 

 

 

 

 

Battery

12V100AH x 2

 

 

 

 

 

 

 

Fuel

#2 Diesel Fuel

 

 

 

 

 

 

 

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 23

DCA-60SSAI — GENERAL INFORMATION

DCA-60SSAI FAMILIARIZATION

Generator

The MQ Power Model DCA-60SSAI is a 48 kW generator that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

zTachometer

zWater Temperature Gauge

zOil Pressure Gauge

zCharging Ammeter Gauge

zEngine Throttle Lever

zPanel Light

zPanel Light Switch

zOil Pressure and WaterTemp. Indicator lights

Generator Control Panel

The “Generator Control Panel” is provided with the following:

zOutput Voltage Adjustment Knob

zFrequency Meter (Hz)

zAC Ammeter (Amps)

zAC Voltmeter (Volts)

zAmmeter Change-Over Switch

zVoltmeter Change-Over Switch

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

zThree 120/240V output receptacles, 50 amp

zTwo 120V input receptacles, 20 amp

z3 Load Circuit Breakers 240V @50 amps

z2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

zMain Circuit Breaker 150 amps

zOver-Current Relay

Open Delta Excitation System

The DCA-60SSAI generator is equipped with the state of the art "Open-Delta" excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the power to the Automatic Voltage Regulator (AVR) is supplied from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a "fixed ceiling" and responds according the demands of the required load.

Engine

The DCA-60SSAI is powered by a 4 cycle, water cooled,

Isuzu A-6BG1diesel engine. This engine is designed to meet every performance requirement for the generator.

Reference Table 1, page13 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-60SSAI generator are addressed on the following pages.

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±1.5%. The electronic governor option increases frequency variation to ±.25%.

PAGE 24 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — MAJOR COMPONENTS

Figure 6. Major Components

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 25

DCA-60SSAI — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 7. Dimensions

PAGE 26 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

NOTE PAGE

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 27

DCA-60SSAI — CONTROL PANEL

Figure 8. Control Panel

PAGE 28 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

DCA-60SSAI — CONTROL PANEL

The definitions below describe the controls and functions of the DCA-60SSAI " Control Panel " (Figure 8).

1.Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

2.AC Ammeter – Indicates the amount of current the load is drawing from the generator.

3.ACVoltmeter – Indicates the single phase output voltage present at the UNV terminals.

4.Pilot Lamp - This lamp indicates the load is not properly set. Readjust the load, or use the voltmeter changeover switch to adjust phase position.

5.Main Circuit Breaker – This three-pole, 150 amp main breaker is provided to protect the UNV voltage output terminals from overload.

6.Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

7.Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off.

8.Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage.

DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01) — PAGE 29

DCA-60SSAI — ENGINE OPERATING PANEL

Figure 9. Engine Operating Panel

PAGE 30 — DCA-60SSAI — PARTS AND OPERATION MANUAL— FINAL COPY (09/15/01)

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