Multiquip DCA400SSK2 User Manual

PARTS AND OPERATION MANUAL

MQ POWER

DCA-400SSK

DCA-400SSK2

WHISPERWATT

GENERATOR

(STANDARD)

PARTS LIST NO. C3875300104B

S/N UP TO 3701676-400SSK

S/N3101677~ 400SSK2

Revision #3 (09/17/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046

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

SERVICE DEPARTMENT:

PAGE 2 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

HERE'S HOW TO GET HELP

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

ARAR

TS DEPTS DEP

TS DEP

ARAR

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

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

SERSER

SER

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

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

MAINMAIN

MAIN

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

VICE DEPVICE DEP

VICE DEP

VICE DEPVICE DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

ARAR

TMENTTMENT

TMENT

TMENTTMENT

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help .............................................3

Table Of Contents ......................................................4

Rules For Safe Operation ...................................... 6-9

Towing ......................................................................10

Trailer Safety Guidelines .................................... 11-17

Trailer Wiring Diagram.............................................. 18

Electric Brake Troubleshooting................................. 19

Hydraulic Brake Troubleshooting ............................. 20

Operation And Safety Decals ............................. 21-22

Specifications ...........................................................23

General Information ........................................... 24-25

Major Components ..................................................26

Dimensions (Top, Side And Rear)...................... 28-29

Control Panel...................................................... 30-31

Engine Operating Panel ..................................... 32-33

Output Terminal Panel Overview ........................ 34-39

Installation .......................................................... 40-41

Pre-Setup ........................................................... 42-45

Load Application ...................................................... 46

Generator Start-Up Procedure (Key Switch) ..... 47-50

Generator Start-Up Procedure (Controller) ............. 51

Generator Shut-Down Procedure ............................52

Maintenance ...................................................... 54-57

Generator Wiring Diagram .......................................58

Engine Wiring Diagram ............................................ 60

Troubleshooting (Engine) ................................... 62-63

Troubleshooting (Generator) ...................................64

Troubleshooting (Engine Controller) ........................65

Explanation Of Codes In Remarks Column ............. 66

Suggested Spare Parts ............................................67

MQ Power DCA-400SSK AC Generator

Generator Assembly .......................................... 68-71

Control Box Assembly ........................................ 72-75

Engine Radiator Assembly ................................. 76-79

Engine Operating Panel Assembly .................... 80-81

Output Terminal Assembly ................................. 82-83

Battery Assembly ............................................... 84-85

Actuator Assembly ............................................. 86-87

Muffler Assembly ............................................... 88-89

Fuel Tank Assembly ........................................... 90-91

Enclosure #1 Assembly...................................... 92-95

Enclosure #2 Assembly...................................... 96-99

Enclosure #3 Assembly........................................ 100-

103

Enclosure (Rubber Seals) .............................. 104-105

Oil Piping Assembly ....................................... 106-107

Name Plate and Decals ................................. 108-111

Terms and Conditions Of Sale — Parts ................ 112

NOTE

Specification and part numberSpecification and part number

Specification and part number

Specification and part numberSpecification and part number are subject to change withoutare subject to change without

are subject to change without

are subject to change withoutare subject to change without noticenotice

notice

noticenotice

PAGE 4 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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.

Extra Fax Discount

for Domestic USA

Dealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

■

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-400SSK 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 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 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

hot

components

■

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.

■

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

or even death.

Topping-off to filler port is dangerous, as it tends to spill fuel.

bodily harm

PAGE 6 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

RULES FOR SAFE OPERATION

CAUTION

■

NEVER touch output terminals during operation. This is extremely dangerous. contact with the output terminals.

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.

Always stop the machine when

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain

3. Engine Oil Drain Plug - Removing the engine oil

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.

engine is hot, will result in high pressurized, boiling water to spew out of the radiator, causing severe scalding to any persons in the general area of the generator.

plug while the engine is hot will result in hot coolant to flow out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

drain plug while the engine is hot will result in hot oil to flow out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

CAUTION

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 7

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.

RULES FOR SAFE OPERATION

Battery

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. 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.

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

■

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 precautions 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 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.

■

Make sure the crane or lifting device has been properly secured to the hook of guard frame on generator.

omatsu Engine Owner's Manomatsu Engine Owner's Man

omatsu Engine Owner's Man

omatsu Engine Owner's Manomatsu Engine Owner's Man

ualual

ual

ualual

for

6. In case the battery liquid (dilute sulfuric acid) comes in contact with 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.

clothing or skinclothing or skin

clothing or skin

clothing or skinclothing or skin

PAGE 8 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

, rinse skin or clothing

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or straps) 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.

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances or deteriorated 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

RULES FOR SAFE OPERATION

■

Always know the location of the nearest

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

Also know the phone numbers of the nearest

doctordoctor

doctor

and

doctordoctor

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 0in 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

. Know the location of the nearest telephone.

fire departmentfire department

fire department

fire departmentfire department

fire extinguisherfire extinguisher

fire extinguisher

fire extinguisherfire extinguisher

ambulanceambulance

ambulance

ambulanceambulance

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 9

DCA-400SSK — TOWING

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 unless otherwise posted for highway towing is 55 MPH. It is not recommended for off-road towing. However, if necessary, do not exceed 15 MPH or less depending on type of terrain to prevent damage to the axles.

■

Place

rollingrolling

rolling,

rollingrolling

■

Place prevent

■

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 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.

chocked blocks

while parked.

support blocks

tippingtipping

tipping

tippingtipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

Figure 1. Generator with Trailer

PAGE 10 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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 intended 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. Usually consists of chains and ‘ball’ or ‘eye’.

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 11

DCA-400SSK — TRAILER-SPECIFICATIONS

snoitacificepS.1elbaT

LEDOM NOITACILPPA LLECLEUF METSYSEKARB RWVG EMARF

W01-RLRT

01-RLRT

FX01-RLRT

W522-RLRT

004WLB-RLRT

X05-RLRT

FX05-RLRT

W07-RLRT

X07-RLRT

FX07-RLRT

FX001-RLRT

521/58-RLRT

FX051-RLRT

FX022-RLRT

FX003-RLRT

FX004-RLRT

FX006-RLRT

XS008-RLRT

,522WDS

003WLT,052WGS

-ACD,21GLT,01ACD

,21-GLT,01ACD 003-WLT,51ACD

,SREDLEW

SS0007AD

004-WLBONCIRTCELESBL0072"451TSAM/W

52-ACDONONSBL0072"421"55.BL008

52-ACDLAG14ONSBL0072"421"55.BL008

07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521,001,58-ACDLAG541CILUARDYHSBL00001"681"77.BL0002

081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

008,006-ACDLAG055RIASBL00003"483"69.BL0005

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

EMARF

HTGNEL

"421O/W

HTDIW

"55

)LLAT"87(

KCAJ

DNATS

LEEHWTLITLLUF

.BL008

LEEHWTLITLLUF

DAPTALF

PAGE 12 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TRAILER-SPECIFICATIONS

)t'noC(snoitacificepS.1elbaT

LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W01-RLRT

01-RLRT

FX01-RLRT

W522-RLRT

004WLB-RLRT

X05-RLRT

FX05-RLRT

W07-RLRT

X07-RLRT

FX07-RLRT

FX001-RLRT

521/58-RLRT

FX051-RLRT

FX022-RLRT

FX003-RLRT

FX004-RLRT

FX006-RLRT

RA008-RLRT

SSALCLLAB"2

ELBATSUJDA2

SSALCLLAB"2 ELBATSUJDA2

SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

SSALCLLAB"2 ELBATSUJDA"3

TPO6/5-2ELBATSUJDA

EYE"3

TPO6/5-2ELBATSUJDA

EYE"3

EYELLAB"3E61-057

ELBATSUJDAEYE"3E61R58/532TS

LEEHWHT5H5.71R57/512TS

C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4

C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4

B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4

C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

"8/3-2

C41-502

)4(SAIB

C41-502

)4(SAIB

C41-502

)4(SAIB

C51-502

)4(SAIB

D51R57/522TS

)4(LAIDAR

)4(SAIB

)4(LAIDAR

)6(LAIDAR

)8(LAIDAR

"5X"41.sbl0053

"5X"41sbl0053

"5X"41.sbl0053

"5.5X"41sbl0053

"6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4

"7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4

"7X"61sbl0007-)2(GUL8XELFQMOOLERIW4

"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4

"7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4

"7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6

"7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6

GUL5FAEL4TALFREBBURELOP4

GUL5FAEL5TALFREBBURELOP4

GUL5FAEL5MOOLERIW4

TALFELOP4

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 13

DCA-400SSK — 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

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.

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.

PAGE 14 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 6 on the remaining brakes.

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 15

DCA-400SSK — 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.

Suspension

The leaf suspension springs and associated components (Figure 4) should be visually inspected every 6,000 miles for

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.

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 or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

Figure 4. Major Suspension Components

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

DCA-400SSK — TRAILER SAFETY GUIDELINES

stnemeriuqeReuqroTnoisnepsuS.3elbaT

SNUG FIT ONLY

NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT

PARTS MUST ROTATE FREELY.LOCKING

ASSEMBLY

BOLT

SHOULDER TYPE

SHACKLE BOLT

05-XAM03-NIM

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.

stnemeriuqeReuqroTeriT.4elbaT

eziSleehWssaPtsriF

SBL-TF

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 17

DCA-400SSK — TRAILER-WIRING DIAGRAM

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TRAILER-BRAKE TROUBLESHOOTING

gnitoohselbuorTekarBcirtcelE.5elbaT

motpmyS esuaCelbissoP noituloS

tnettimretnIrosekarBoN

sekarB

?stiucrictrohsynA.tcerrocdnadniF

?rellortnocytluaF.tcerrocdnatseT

?eruceseriwdnuorG.erucesdnadniF

sekarBrosekarBkaeW

ediSenOotlluP

?dezinorhcnyssekarB.tcerroC

sekarBgnikcoLrotneb,esoolstnenopmocekarB

?nekorb

sekarBysioN?detacirbulmetsyS.etacirbuL

?seriwnekorbrostiucricnepoynA.tcerrocdnadniF

?snoitcennocesoolynA.riaperdnadniF

?sgninilrostengamnolioroesaerG.ecalperronaelC

?dedorrocsnoitcennoCtcerrocdnanaelC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?dnuor-fo-tuosmurdekarB.ecalpeR

.noisorrocfoesuac

.stnenopmocecalpeR

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

sekarBgniggarD?detsujdaleehwehtfosgniraeB.tsujdA

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 19

DCA-400SSK — TRAILER-BRAKE TROUBLESHOOTING

gnitoohselbuorTekarBciluardyH.6elbaT

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL?nekorbrotneb,esoolstnenopmocekarB.stnenopmocecalpeR

sekarBysioN?detacirbulmetsyS.etacirbuL

sekarBgniggarDthgirnirotcerrocssenkcihtgninilekarB

?dezalggninilekarB.ecalperrohsinrubeR

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserperiT.yllauqeseritllaetalfnI

?elxaemasehtnodehctamnuseriT.serithctaM

?dnuor-fo-tuosmurdekarB.ecalpeR

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

?noitisopgnorw

?diulftcerrocrodiulfekarbhguonEstraprebburecalpeR

dnaseohswenllatsnI

.sgninil

.diulf4todhtiwllif

PAGE 20 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-400SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 21

DCA-400SSK — OPERATION AND SAFETY DECALS

PAGE 22 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — SPECIFICATIONS

snoitacificepS.7elbaT

snoitacificepSrotareneG

ledoMKSS004-ACD

epyT rotarenegsuonorhcnysepytdetcetorpnepo,detalitnevfles,dleifgnivloveR

noitcennoCerutamrAlartueNhtiwratS

esahP3

tuptuOybdnatS)WK0.253(AVK044

tuptuOemirP)WK0.023(AVK004

egatloVV084roV042

ycneuqerFzH06

deepSmpr0081

rotcaFrewoP8.0

rewoPCA.xuAzH06,esahPelgniS

egatloVV021

tuptuO)2xWK4.2(WK8.4

ledoM2-E041D6ASUSTAMOK

epyT relooc-retfahtiwdegrahc-obrut,noitcejnitcerid,delooc-retaw,elcyC4

srednilyCfo.oNsrednilyc6

ekortSxeroB )mm561xmm041(.ni5.6x.ni5.5

tuptuOdetaRmpr0081/PH874

tnemecalpsiD)cc04251(.ni.uc039

gnitratScirtcelE

yticapaCtnalooC)sretil85(.lag9.61

yticapaCliOebuL)sretil47(.lag5.91

snoitacificepSenignE

tarh/)L5.77(.lag4.02

noitpmusnoCleuF

tarh/)L6.14(.lag0.11

yrettaB2xHA002-V21

leuFleuFleseiD2#

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 23

daollluf

daol2/1

tarh/)L8.95(.lag8.51

tarh/)L0.52(.lag6.6

daol4/3

daol4/1

DCA-400SSK — GENERAL INFORMATION

DCA-400SSK FAMILIARIZATION

Generator

genergener

The MQ Power Model DCA-400SSK is a 320 kW 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 Control Panel

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

Auto/Start/Stop Controller (S/N 3696510~)

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Warning Lamp Module

Engine Speed Switch (S/N3701667~)

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Starter Switch (Up to S/N3696509)

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Panel Light

Auto On/Off Engine Controller

Panel Light Switch

Pilot Lamp

Output Terminal Panel

gener

genergener

atorator

ator

atorator

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 1060 amps

Over-Current Relay

High Idle Adjust Trimmer

Current Transformer

Automatic Voltage Regulator

Open Delta Excitation System

The DCA-400SSK generator is equipped with the state of the art " 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 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 " according the demands of the required load.

Engine Controller Alarm System

The DCA-400SSK generator is equipped with various alarms and LED status indicators. These alarms and status indicators are provided to add safety to the generator when operating under normal conditions. The DCA-400SSK generator is designed to shutdown in the event of low oil, high coolant temperature, low battery and other operation conditions that may cause severe damage to the generator.

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

utomatic utomatic

utomatic

utomatic utomatic

" excitation system. The open delta

oltage Regulator oltage Regulator

oltage Regulator

oltage Regulator oltage Regulator

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

(AVR) is supplied

" and responds

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

Three120/240V output receptacles, 50 amp

Two 120V receptacles, 20 amp

3 Circuit Breakers 240V @50 amps

2 GFCI Circuit Breakers 125V@ 20amps

PAGE 24 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — GENERAL INFORMATION

Engine

The DCA-400SSK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D140E-2 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 16 for engine specifications.

Electronic Governor System

The electronic governor system replaces the standard mechanical governor system. The frequency regulation improves from ±3.0% regulation with the mechanical governor to ±0.25% regulation with the electronic governor system.

Jacket Water Heater (OPTIONAL)

The jacket water heater is a 1500-watt heater designed to keep the coolant warm in the engine block for fast starts and load acceptance. The heater is thermostatically controlled and once an acceptable engine temperature is achieved it will cycle on and off, operating only about 1/3 of the time, which makes it more efficient than the direct block type heater. It is designed to keep the engine coolant between 100 and 120 degrees Fahrenheit.

Under normal conditions, 20 to 15 minutes is required to raise the engine temperature of a cold engine to 100 degrees Fahrenheit.

Battery Charger

The battery charger will operate in a ‘BOOST’ mode until the battery’s current acceptance falls to 70% of the charger’s rating. The charger will then go into a ‘FLOAT’ mode, where it discharges a lower voltage until an AC failure, or the battery is discharged.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 25