SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn.
The electrical voltage required to operate the generator can cause severe
injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.
NEVER insert any objects into the output ![](/images/new-backgrounds/1098536/9853619xi3.webp)
![](/images/new-backgrounds/1098536/9853619xi4.webp)
receptacles during operation. This is extremely dangerous.The possibility exists of electrical shock, electrocution or death.
Backfeed to a utility system can cause
electrocution and/or property damage. NEVER connect the generator to a building’s electrical system without a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious injury or even death.
Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.
NOTICE
ALWAYS make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death by electrocution can result from operating an ungrounded generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the generator is being transferred to a load.
NEVER use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation.
NEVER grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death.
PAGE 10 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)
Model DCA125USI
This Manual Must Accompany the Equipment AT ALL Times
Proposition 65 Warning
Administrator
Reporting Safety Defects
Nhtsa
Table of Contents
DCA125USI 60 Hz Generator
Parts Ordering Procedures
Ordering parts has never been easier
Safety Information
Safety Messages
Generator Safety
General Safety
Always know the location of the nearest
Engine Safety
Before servicing equipment
Never use fuel as a cleaning agent
Fuel Safety
Towing Safety
From fuel vapors or if fuel is spilled on a hot engine
Device. All installations should be
Electrical Safety
Never use gas piping as an electrical ground
Battery Safety
Environmental Safety
Specifications
DCA125USI
Dimensions
Dimensions
Installation
Typical Generator Grounding Application
Mounting
Outdoor Installation
Indoor Installation
Generator Grounding
General Information
Major Components
Generator Control Panel
Owing from the U,V, and W Output Terminal Lugs to the load
Page
Engine Operating Panel
Engine Operating Panel
Fuel Gauge Indicates amount of diesel fuel available
Module
Output Terminal Familiarization
Output Terminal Panel Familiarization
Terminal legs O and Ground are considered bonded grounds
VAC Gfci Receptacles
Removing the Plastic Face Plate Hard Wire Hookup Panel
Twist Lock Dual Voltage 120/240 VAC Receptacles
Connecting Loads
Over Current Relay
Three Phase Load
Single Phase Load
Load Application
Generator Outputs
Generator Output Voltages
Generator OUTPUTS/GAUGE Reading
HOW to Read the AC Ammeter and AC Voltage Gauges
AC Voltmeter Gauge Reading
3Ø-240/139 Uvwo Terminal Output Voltages
Output Terminal Panel Connections
Uvwo Terminal Output Voltages
3Ø-208V/1Ø-120V Uvwo Terminal Output Voltages
3Ø-480/277V Uvwo Terminal Output Voltages
1Ø-240/120V Uvwo Terminal Output Voltages
Lubrication OIL
INSPECTION/SETUP
Circuit Breakers
Fuel Check
Refueling Procedure
Only use #2 diesel fuel when refueling
Coolant ANTIFREEZE/SUMMER COOLANT/ Water
Cleaning the Radiator
AIR Cleaner FAN Belt Tension
Operation in Freezing Weather
Wiring
Battery
Battery Cable Installation
Alternator
Starting
Generator START-UP Procedure
Before Starting
Starting Manual
Pre-Heat Lamp
Emergency Shutdown Procedure
Generator SHUT-DOWN Procedures
Normal Shutdown Procedure
To shutdown the generator, use the following procedure
General Inspection AIR Cleaner
Maintenance
Air Cleaner with Dust Indicator
Fuel Tank Inspection
Fuel Addition
AIR Removal
Replacing Oil Filter
Radiator Cleaning
Check OIL Level
Flushing OUT Radiator and Replacing Coolant
Battery Charger & Jacket Water Heater Power Connections
Trailer Maintenance
Trailer Maintenance
Coupler Type of hitch used on the trailer for towing
Hydraulic Surge Brakes
Brake Adjustment
Brakes
Through 8 and as listed below
Tire Wear/Infl ation
TIRES/WHEELS/LUG Nuts
Suspension
Start all wheel lug nuts by hand
Lug Nut Torque Requirements
Never use an pneumatic air gun to tighten wheel lug nuts
Trailer Wiring Diagram
Trailer/Towing Vehicle Wiring Diagram
Generator Wiring Diagram
Generator Wiring Diagram
Engine Wiring Diagram
Engine Wiring Diagram
Controller Wiring Diagram
Controller Wiring Diagram
Troubleshooting Generator
Troubleshooting Diagnostic Lamp
Method of Operation
Page
Explanation of Code in Remarks Column
Sample Parts List
Xxxxx only Not Used on
Suggested Spare Parts
To 3 units
Generator Assy
Field Assy
Part Name QTY. Remarks
Includes Items W/#
FAN
Control BOX Assy
Selector Switch
Push Button Switch
Diagonastic Switch
Switch Bracket
Control BOX Assy
Water Temperature Gauge
Switch Cover
Alarm Lamp
SWITCH, Panel Light
Engine and Radiator Assy
Bracket AIR Cleaner
AIR Cleaner
INDICATOR, AIR Cleaner
BAND, AIR Cleaner
Engine and Radiator Assy
Blow by Hose
Connector
AIR Duct Hose
Hose Joint
Engine and Radiator Assy
FAN Shroud
BRACKET, Inter Cooler
Cooler Hose
BRACKET, FAN Shroud
Output Terminal Assy
Terminal Cover
Terminal Board
Output Terminal Bolt
Output Window
Battery Assy
Battery Band
Battery
Battery Sheet
Battery Bolt SET
Muffler Assy
Gasket
Muffler
Bolt SET
Fuel Tank Assy
Fuel Sender Unit
Fuel Tank
Fuel Tank CAP
Connect Hose
Enclosure ASSY. Part
Enclosure ASSY. PART1
Enclosure ASSY. Part
Over COVER, Front Frame
Back Plate
Duct
COVER, Radiator CAP
Enclosure ASSY. Part
Rear Frame
Enclosure ASSY. Part
Washer
Seal Rubber
Manual PAK
Rubber Seals Assy
Part Name
Nameplate and Decals Assy
Engine & Radiator Group
Battery Group
Control BOX Group
Output Terminal Group
Nameplate and Decals Assy
Fuel Tank Group
Enclosure Group
Terms and Conditions of Sale Parts
Freight Policy
Page
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