GENERATOR CONTROL PANEL
Figure 4. Generator Control Panel
The defi nitions below describe the controls and functions of the Generator Control Panel (Figure 4).
1.Main Circuit Breaker—This three-pole, 350A main breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.
2.Voltage Regulator Control — Allows ±15% manual adjustment of the generator’s output voltage.
3.Ammeter Change-Over Switch — This switch allows the AC ammeter to indicate the current fl owing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.
4.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.
5.Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz.
6.AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.
7.AC Voltmeter — Indicates the output voltage present at the U,V, and W Output Terminal Lugs.
Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.
The Control Box is equipped with the following major components:
Over-Current Relay
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs to the load.
In the event of a short circuit or over current condition, it will automatically trip the 350 amp main breaker.
To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the main circuit breaker in the closed position (ON).
PAGE 18 — 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
Reporting Safety Defects
Administrator
Nhtsa
Table of Contents
DCA125USI 60 Hz Generator
Parts Ordering Procedures
Ordering parts has never been easier
Safety Information
Safety Messages
General Safety
Generator 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
Electrical Safety
Device. All installations should be
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 Panel Familiarization
Output Terminal Familiarization
Terminal legs O and Ground are considered bonded grounds
Removing the Plastic Face Plate Hard Wire Hookup Panel
VAC Gfci Receptacles
Twist Lock Dual Voltage 120/240 VAC Receptacles
Connecting Loads
Over Current Relay
Single Phase Load
Three Phase Load
Load Application
Generator Outputs
Generator Output Voltages
HOW to Read the AC Ammeter and AC Voltage Gauges
Generator OUTPUTS/GAUGE Reading
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
Maintenance
General Inspection AIR Cleaner
Air Cleaner with Dust Indicator
Fuel Addition
Fuel Tank Inspection
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
TIRES/WHEELS/LUG Nuts
Tire Wear/Infl ation
Suspension
Lug Nut Torque Requirements
Start all wheel lug nuts by hand
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
Sample Parts List
Explanation of Code in Remarks Column
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
Muffler
Gasket
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
Seal Rubber
Washer
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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