VDO Dayton 4W315C User Manual

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Operating Instructions & Parts Manual

4W315C

 

 

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Dayton® Diesel Electric

Generator

Description

Dayton professional-dutygenerators are rugged and compact. These models provide dependable,trouble-freeservice. The alternators are brushless with revolving fields. Yanmar diesel engines provide long life under heavy use. These engines are governed to maintain engine speed of 3600 RPM under load. 3600 RPM engine speed provides 120/ 240V, 60 Hz power. Additional features include circuit breaker protection,spark-arrestingmuffler, large fuel tank, oil alert system, electric starter, and a pressurized lubrication system.

Unpacking

1.Remove generator from carton.

2.Remove any protective packaging applied to generator for shipment.

3.Check for loose or missing parts. Check for shipping damage. If any parts are missing or damaged, promptly inform dealer where you bought generator.

4.Battery cables are supplied. These cables are in a separate bag inside generator carton. You must install these cables to engine. See “Battery,” page 7 for installation instructions.

Figure 1 – Model 4W315C

Form 5S3125

®

Printed in U.S.A.

 

 

03430

 

 

0703/215/VCPVP

Version B - For Reduction

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Dayton Operating Instructions and Parts Manual

4W315C

Dayton® Diesel Electric Generator

Specifications

ELECTRICAL SPECIFICATIONS

Rated

Maximum

Rated Amperage

Rated Amperage

Wattage*

VA

120V

240V

5000

6500

41.7

20.8

* Single-phase,1.0 power factor

NOTE: Ratings apply to SAE standard conditions. Reduce ratings 31/2% for each 1000 feet above sea level and 1% for each 10° Fahrenheit rise above 60°F.

GENERAL SPECIFICATIONS

Yanmar

Yanmar

Fuel

Fuel Tank

Oil Alert

Electric

Weight

Engine H.P.

Model

Type

Capacity

System

Start

(pounds)

10

L100

Diesel

4.2 gal.

Yes

Yes

241

RECEPTACLE SPECIFICATIONS

120V

120V, 30-Amp

120/240V, 20-Amp

120V Full

Duplex

Twist-Lock

Twist-Lock

Power Switch

Yes

Yes

Yes

Yes

ELECTRICAL COMPONENT SPECIFICATIONS

 

Resistance in Ohms

 

 

 

Stator

Stator

 

Rotor

Rotor

Capacitor,

 

Main

Auxiliary

Primary

Secondary

MFD

Diodes (2)

Winding *

Winding

Winding †

Winding †

450 Volt

800 Volt

0.54

1.38

 

0.61

2.29

50

70 Amp

(*) Connect T2 (green) and T3 (black). Measure resistance between T1 (red) and T4 (yellow). () Resistance between brown and white leads.

(†) Remove diodes to check resistance.

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Model 4W315C

Product Identification

Full Power

Selector Switch

Control Panel

120V OLTS

120

 

SELECTOR

120/240V

 

 

 

0

100

 

 

 

200

 

 

AC

VOLTS

30

 

 

 

 

UT V

 

120 Volt

Receptacles

Hour Meter

120/240 Volt

Receptacle

Circuit

Breaker

Figure 2 – Portable Generator

E

F

 

 

 

 

 

 

 

 

Roll Cage

 

 

Engine Run Lever

120/240V

 

 

 

OLTS

 

 

 

 

 

Engine Stop Lever

 

Fuel Valve (under fuel tank)

 

Alternator

 

 

 

Oil Alert Lamp

 

Fuel Gage

 

Battery Discharge Lamp

 

Fuel Cap

 

 

 

 

Electric Start Switch

 

 

 

 

 

Fuel Tank

 

Decompression

F

E

 

 

 

 

Lever

 

 

Starter Grip

Ground

Lug

 

Spark

 

Arrester

Engine

Battery (Not

included, must

Muffler

be purchased

 

Oil Dipstick

separately)

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Dayton® Diesel Electric Generator

General Safety Information

IMPORTANT: Read these instructions and engine owner’s manual carefully. Become familiar with generator before trying to operate or service it. Know its uses, limitations, and any hazards involved. Improper use of generator can cause severe injury or death from explosion, fire, burns, electrical shock, or carbon monoxide poisoning.

Make certain you read and understand all warnings. Keep these instructions for reference. They are your guide to safe and proper operation of this generator.

Safety information appears throughout these instructions. Pay close attention to them. Below are definitions for the safety information listed throughout this manual.

Under this heading, installation, operat-

ing, and maintenance procedures or practices will be found that, if not carefully followed, WILL result in IMMEDIATE serious personal injury or death.

Under this heading, installation, operat-

ing, and maintenance procedures or practices will be found that, if not carefully followed, COULD result in severe personal injury or death.

Under this heading, installation, operat-

ing, and maintenance procedures or practices will be found that, if not carefully followed, MAY result in minor personal injury, product or property damage.

Engine exhaust contains poisonous

carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death. Use only in wellvented areas. Make sure area has plenty of free-moving,fresh, outside air. Never run generator in an enclosed or confined area. Never run generator inside occupied building.

Early signs of carbon monoxide poisoning resemble the flu, with headaches, dizziness, or nausea. If you have these signs, get fresh air at once! Some people are more affected by carbon monoxide than others. These include pregnant women, persons with heart or lung disease or anemia, those under the influence of alcohol, and those at high altitudes.

Diesel fuel presents a hazard of

fire. Diesel fuel is flammable.

Keep fuel out of children’s reach.

Refuel generator in a well-ventedarea. Do not fill fuel tank in the dark. Do not refuel while engine is running. Unhook all electrical loads and shut off engine before refueling.

Do not overfill fuel tank. Always allow room for fuel to expand. If you overfill tank, fuel can overflow onto hot generator. This can cause fire. After refueling, tightly close fuel tank cap.

Do not spill fuel. If fuel spills, make sure area is dry before starting engine.

Never smoke in refueling area. Never allow open flames or sparks in area.

Store fuel in approved container. Store fuel in a well-ventedarea free of open flames or sparks.

Guard against fire hazard. Keep

operation area well-vented.Keep generator at least three feet away from any object. Do not place flammable objects near generator.

Do not use generator where flammable vapors are present. Some vapors are heavier than air. These vapors settle in low-lyingplaces.

Do not use generator in enclosed spaces. This includes motor home or RV generator compartments.

Guard against electric shock.

Generator produces high voltage. This high voltage can cause severe electric shock. Only responsible adults should use the generator.

Properly ground generator before starting.

Never let anyone operate or service generator without proper instructions.

Avoid contact with live terminals or bare wires.

Do not use generator outdoors in rain or snow.

Do not use generator near standing water or snow.

Do not use if generator is wet or damp.

Do not use generator in highly conductive areas. These areas include metal decking and steelwork.

Only use grounded extension cords.

Do not use any worn or damaged electric cords. Electric shock or damage to generator may result.

On construction sites, you must use a Ground Fault Circuit Interrupter (GFCI). This helps guard against electric shock. OSHA and the National Electrical Code requires this.

Do not wear damp clothing or wet shoes when using generator.

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General Safety Information (Continued)

Guard against burns. Hot engine

parts can cause severe injury. Use caution and remain alert when using generator.

Keep children and animals away from generator while it is running or hot.

Keep all covers and shields in place. Keep them tightly secured.

The muffler becomes very hot during operation. The muffler remains hot for a while after shutdown. Do not touch muffler while it is hot. Do not let muffler touch anything flammable. Let engine cool before transporting or storing.

Have standby installation to

home or building performed by a licensed electrician. Do not let anyone else wire into a utility circuit. Personal injury, equipment damage, or damage to home could occur.

Never connect generator to any

existing electrical circuits. The generator output will back-feedinto the utility power line. This may electrocute a power company line repair person. Also, if generator is powering electrical circuits, the chance of an electrical fire exists.

Battery gives off explosive gases.

Keep sparks, flames, and cigarettes away. Do not remove or install battery cables when engine is cranking or running. Only service or use battery in a well-ventedarea.

Battery contains sulfuric acid.

Battery acid is poisonous if swallowed. Contact with skin or eyes may cause severe burns. Do not tilt generator with battery installed. Tilting could cause battery acid to spill. Wear protective clothing and face shield when servicing. Keep out of children’s reach.

Only a qualified electrical service

person should service and repair generator.

Generator produces high voltage. Use extreme caution when working on electrical parts.

When working on generator, avoid hot muffler, exhaust manifold, and engine parts. Severe burns may occur.

Do not work on generator when tired.

Use only factory approved replacement parts.

Store generator in a well-ventedarea.

Make sure fuel tank is empty. Never store with fuel in tank.

Never operate generator

if engine speed changes greatly

if engine misfires often

if powered items overheat

if electrical output drops

if it is sparking

if it produces smoke or flames

if it vibrates at high levels

if it has a damaged receptacle

Keep generator and nearby areas

clean.

Keep generator free of oil, mud, and other foreign matter.

Remove anything that creates slippery areas around generator.

Remove oily rags and other items that create fire hazards.

Keep a fire extinguisher nearby. Make sure it is rated ABC by the NFPA. They are good for all uses.

Consult your local fire department.

Keep fire extinguisher well maintained. Be familiar with its use.

Know how to stop engine quickly.

Know how to use all controls.

Prolonged exposure to loud noise

can cause hearing loss.

When working around generator, wear approved hearing protection.

Remember neighbors when using generator.

Generator Features

OIL ALERT SYSTEM

The oil alert system protects the engine from low oil damage. This system automatically shuts down the engine and prevents engine restarting if the oil pressure falls too low.

If this system shuts down the engine, the engine will not start until you add oil. The oil alert lamp is near engine starter switch (See Figure 3, page 6). Add oil to engine (See “Engine Oil,” page 8).

See engine owner’s manual for more information.

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Generator Features (Continued)

OIL

CHARGE

OFF

Battery

Oil Alert

Discharge

Lamp

Lamp

 

120/240 VOLT: This position sends full power to the 120/240V receptacle. It also powers the 120V receptacles at reduced wattage capacity.

Figure 3 - Battery Discharge Lamp and Oil

Alert Lamp Location

BATTERY DISCHARGE LAMP

The battery discharge lamp (See Figure 3, above) will light if battery charger is not operating while engine is running. If this happens, the battery will not charge and will eventually run down. Have battery charging circuit repaired by authorized service person.

FULL POWER SELECTOR SWITCH

The full power selector switch is on the control panel. The switch has two positions: 120 VOLT ONLY, and 120/240 VOLT.

120 VOLT ONLY: This position sends full power to the 120V receptacles only. 240V power is not available. Use this position when powering 120V items only.

Figure 4 – Full Power Selector Switch in 120 Volt Only Position

Figure 5 – Full Power Selector Switch in 120/240 Volt Position

IMPORTANT: Do not move the full power selector switch while powering electrical items. Unplug all items before moving switch. Failure to do so can damage switch.

HOUR METER

The hour meter will measure the total run time of the generator, including all idle time. Hour meter is accurate up to 1/10 of an hour.

Figure 6 – Hour Meter

ELECTRIC START

A battery is not supplied with generator. You must provide a 12-volt,45-amp-hourbattery. For more battery information, see “Battery,” page 7.

GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE

This generator has a 120-voltground fault circuit interrupter (GFCI) receptacle. The GFCI receptacle is on the control panel. The GFCI protects you against hazardous

electrical shock caused when your body becomes a path through which electricity travels to reach ground. This could happen when you touch an appliance or cord that is ‘live’ through faulty mechanism, damp or worn insulation, etc.

When protected by the GFCI, you may still feel a shock, but the GFCI should cut it off quickly. A person in normal health should not receive serious injury.

NOTE: Infants and very small children may still be affected.

TEST PROCEDURE

Check the GFCI receptacle every month. This insures it is working right.

1.Push black TEST button. Red RESET button should pop out. This should trip GFCI, resulting in no electrical power at receptacle. Verify this by plugging test lamp with good bulb into receptacle. If lamp does not work, GFCI receptacle is good.

If RESET button does not pop out,

do not use the GFCI receptacle. Contact a qualified electrician for repairs.

2.If the GFCI receptacle tests okay, restore power by pushing the RESET button back in. The test lamp should work at this time.

IMPORTANT: You

 

must press the RESET

 

button firmly and fully.

 

It should lock into

 

place. If the GFCI does

RESET

not lock into place, do

TEST

 

not use receptacle. Contact a qualified electrician for repairs.

Figure 7 – GFCI Receptacle

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Generator Features (Continued)

RECEPTACLE CIRCUIT BREAKER

The circuit breakers protect the receptacles and alternator. Overloading generator will trip circuit breaker. A short circuit in item being powered will also trip breaker. If this occurs, unplug electrical load from receptacle. Let circuit breaker cool down. Push circuit breaker button to reset.

Electric motors need higher starting current. They require up to 3-timestheir rated wattage to start. The starting current needed may be too high. This can cause nuisance circuit breaker tripping. To help prevent this, start electric motors first. Connect additional items to generator after starting motors. If this continues to happen, reduce the total generator load.

2020

Normal

Tripped

Figure 8 – Receptacle Circuit Breaker Button

SPARK ARRESTER

We ship a spark arrester with this generator. You must install spark arrester to muffler (See Figure 9).

A spark arrester is required if using generator in a national forest and other designated state and local areas. Check local codes.

The spark arrester needs periodic cleaning. A dirty spark arrester reduces engine output and increases fuel consumption. It also makes starting difficult. See engine owner’s manual for cleaning instructions.

Muffler

Clamp

Spark

Arrester

Figure 9 - Installing Spark Arrester

Assembly

BATTERY

Battery gives off explosive gases.

Keep sparks, flames, and cigarettes away. Do not remove or install battery cables when engine is cranking or running. Only service or use battery in a well-ventedarea.

Battery contains sulfuric acid.

Contact with skin or eyes may cause severe burns. Do not tilt generator with battery installed. Tilting could cause battery acid to spill. Wear protective clothing and face shield when servicing. Keep out of children’s reach.

If battery acid gets on your skin, wash with water.

If battery acid gets in your eyes, flush with water at least 15 minutes. Call a doctor at once.

Battery acid is poisonous.

If swallowed, drink large amounts of water or milk. Follow with milk

of magnesia or vegetable oil. Call a doctor at once.

If you remove battery, insulate

the red, positive (+) battery cable terminal. Insulate with electrical tape. Exposed terminal may spark when generator runs.

IMPORTANT: Make sure battery connections are the correct polarity. Electric start generators use negative ground,12-voltDC starting system.

A battery is not supplied with generator. You must provide a 12-volt,45-amp-hourbattery. The positive and negative battery cables are supplied with generator. You must install these cables before mounting battery.

Always wear safety glasses when working with battery. Make sure battery terminals are clean. Make sure cable connections are tight.

Always shut down engine before removing or attaching battery cables. Always remove the negative (–)cable first. Always attach negative(–)cable last.

INSTALLING BATTERY CABLES TO ENGINE

1.Attach the red, positive (+) battery cable to the starter solenoid on engine (See

Figure 10).

Starter

Solenoid

Red, Positive (+)

Battery Cable

Figure 10 – Connecting Red, Positive (+) Battery Cable to Starter Solenoid on Engine

2.Attach the black, negative (–)battery cable to the engine block. Use the bolt, nut, and two washers provided with the battery cables. Attach cable as shown in Figure 11, page 8.

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Assembly (Continued)

Black, Negative(–)

Battery Cable

Figure 11 – Connecting Black, Negative (–)Battery Cable to Engine Block

MOUNTING BATTERY TO GENERATOR

1.Secure battery to generator by battery hold-downsystem. This system consists of the battery mounting bracket, hook bolt, and nut (See Figure 12).

Battery Mounting

Nut

Bracket

 

Battery

Hook Bolt

Figure 12 – Battery Hold-DownSystem

2.Locate the red, positive (+) battery cable from starter solenoid. Connect it to the positive (+) battery terminal (See Figure 13).

3.Locate the black, negative (–)battery cable attached to engine block. Connect it to the negative(–)battery terminal (See Figure 13).

Do not overfill fuel tank. Always allow room for fuel to expand. If you overfill tank, fuel can overflow onto hot engine. This can cause fire. After refueling, tightly close fuel tank cap.

Do not spill fuel. If fuel spills, make sure area is dry before starting engine.

Never smoke in refueling area. Never allow open flames or sparks in area.

4.Check battery before starting engine. Make sure fluid levels are full. Make sure battery is charged.

See engine owner’s manual for more information.

Red, Positive Cable

From Starter Solenoid

Store fuel in approved container. Store fuel in a well-ventedarea free of open flames or sparks.

Use clean, fresh, diesel fuel. Use diesel fuel with cetane rating of 45 or higher. Avoid getting dirt, dust, or water in fuel tank. See engine owner’s manual for more information.

 

ENGINE OIL

 

We ship the generator without oil in the

 

engine crankcase. You must add oil before

 

starting engine. See “Engine Lube Oil,”

 

page 9 for specific oil type.

 

CHECKING OIL LEVEL AND ADDING OIL

 

Follow steps below to check oil level.

 

Make sure engine is level and stopped.

Black, Negative

1. Remove dipstick (See Figure 14). Wipe

dipstick clean.

Cable From

Engine Block

2. Insert dipstick into oil filler neck. Do not

 

 

screw it in. Oil level should be at top of

Figure 13 – Connecting Positive and

filler neck. Oil should cover most of

Negative Cables to Battery

dipstick.

 

Installation

3. If level is low, fill to top of oil filler neck

(See Figure 14). Use proper lube oil to

FUEL

preserve your engine.

Diesel fuel pre-

NOTE: If oil level is too low, oil alert

sents a hazard of

fire. Diesel fuel is flammable.

system will shutdown engine and prevent

• Keep fuel out of children’s reach.

engine from restarting.

Refuel generator in a well-ventedarea. Do not fill fuel tank in the dark. Do not refuel while engine is running. Unhook all electrical loads and shut off engine before refueling.

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Model 4W315C

Installation (Continued)

Oil Level

At Top Of

Filler Neck

Dipstick

Oil

Figure 14 – Checking Oil Level

ENGINE LUBE OIL

Nothing affects the performance and durability of your engine more than the lube oil you use. Using inferior oil or not changing oil regularly increases the risk of piston seizure, piston ring sticking, and accelerated wear of cylinder liner, bearing and other moving parts. Your engine life may be seriously shortened. Yanmar recommends CC/CD oil of API engine service classification, stock number 4ZF20.

Always use oil with the right viscosity for the ambient temperature in which you are using the engine. Use the chart below when choosing your engine oil.

Lube Oil Capacity:

4W315C 1.74 qt.

20W 40

10W 30

Locate ground lug on end of generator housing (See Figure 15). Attach a #10 stranded-copperground wire to ground lug. Drive grounding point into ground. Grounding point can be a stake, grounding rod, or pipe. Grounding point should be copper or brass. Attach ground wire to grounding point. You must supply the ground wire and grounding point. They do not come with generator. Follow the National Electrical Code and all state and local codes. Consult your power company or a licensed electrician.

VENTILATION

Use only in wellvented areas. Make

sure area has plenty of free-moving,fresh, outside air. Never run generator in an enclosed or confined area. Never run generator inside occupied building. Engine exhaust contains poisonous carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death.

This generator needs cooling air to run properly. Never block free-flowing,cooling air to generator. Overheating will occur without cooling air. This will damage the generator. Keep generator at least three feet away from any object.

GENERATOR GROUNDING

You must properly earth-ground

generator before starting. This will help guard against deadly electric shock. Only use grounded plugs with generator. Only use grounded extension cords. Only use three-wireordouble-insulatedpower tools.

Grounding generator helps prevent electric shock from a ground fault condition.

Ground Lug

Copper or

Brass

Grounding

Point

Alternator

Ground Wire

Figure 15 – Grounding Generator

For a grounding point, do not use

metal pipe being used to carry combustible materials or gases.

DUST, DIRT, RAIN, AND SNOW

Do not use generator outdoors in

rain or snow. Do not use generator near standing water or snow. Do not use if generator is wet or damp. Operating generator in these conditions increases the risk of electrocution. Severe injury or death can occur.

Do not use generator in extremely dusty or dirty conditions. This will severely affect its life. Keep generator clean. Do not allow

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Installation (Continued)

dust, dirt, rain, or snow to collect on it. Protect generator from outdoor elements.

EXTENSION CORDS

Only use grounded extension cords. Be sure to use extension cord with proper wire gauge size. See chart below.

RECOMMENDED MINIMUM WIRE GAUGES (AWG) FOR EXTENSION CORDS

 

Ampere

AWG for

AWG for

AWG for

 

 

Load

50' Cord

100' Cord

150' Cord

 

2

18

18

18

 

3

18

18

18

 

4

16

16

16

 

5

16

16

16

 

 

 

 

 

 

 

6

16

16

14

 

8

16

14

12

 

10

16

14

12

 

12

14

14

12

 

 

 

 

 

 

 

14

14

12

10

 

16

12

12

10

 

20

10

10

8

 

GROUND FAULT PROTECTION

Ground Fault Circuit Interrupter (GFCI) helps guard against electric shock. On construction sites, you must use a GFCI. OSHA and the National Electric Code requires this.

STANDBY INSTALLATION TO HOME OR BUILDING

Have standby installation

performed by a skilled, licensed electrician. Do not let anyone else wire into a utility circuit. Personal injury, equipment damage, or damage to home could occur.

IMPORTANT: This generator will not power your entire home. Most home utility electric service is more than 60 amps. This will exceed generator output. Only power needed items during a power outage. Make sure total wattage of electrical load does not exceed rated wattage of generator.

You can use this generator as a standby power source. During a power outage, the generator will power selected items in a building. Have generator and additional wiring installed by a skilled, licensed electrician. This is not a do-it-yourselfjob. Follow all local codes.

The electrician must install a doublethrow transfer switch. This isolates existing electrical circuits from the utility power line. If not isolated,

generator output will back-feedinto

utility power line. This may electrocute a power company line repair person.

DETERMINING ELECTRICAL LOAD FOR GENERATOR

You must decide what electrical load your generator can power. Do this before using generator. Use the following four-stepmethod. It will help you select a load that is not too large. Make sure total wattage of all electrical loads does not exceed 5000 watts. Electric motors present a special problem when figuring load. Read Step 3 carefully.

1.Make two lists of items you want powered by generator. List all motors and motor powered appliances in one. List all lights, small appliances, etc. in the other. For standby service to home or building, only include items you must power.

2.Enter running watts of each item except motors. The light bulb or appliance nameplate lists its wattage. Remember, 1KW = 1000 watts.

NOTE: The nameplate may not list wattage. It may only list volts and amps. The formula for finding wattage is: Volts x Amps = Watts. For example: An appliance nameplate states 3 amps at 120 volts. 3 amps x 120 volts = 360 watts.

3.Electric motors present a special problem. They require 3 to 6 times their rated full-loadwattage to start. Chart 2, page 11, shows starting watts (maximumvolt-amperes[VA]) for different size motors. For example: an electric motor nameplate states 5 amps at 120 volts. 5 amps x 120 volts = 600 watts running. Multiply this figure by 3. This will show the starting watts (maximum VA) needed. 600 watts x 3 = 1800 watts (VA) to start. When figuring the generator load for motors, you must use the starting watts (maximum VA) figure. Do not use the running watts figure.

NOTE: Some motors require nearly the same wattage to run as to start. These items include saws, drills, hair dryers, and food mixers. See Chart 1, page 11 for typical appliance wattage examples.

4.Add watts and starting watts (maximum VA) of all items. This total must not be larger than 5000 watts. It is a good idea to have up to 25% extra capacity for future needs or extra equipment.

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Installation (Continued)

TYPICAL ELECTRIC APPLIANCE WATTAGES

Chart to be used as a reference. Data may vary with size, make, and/or model.

CHART 1

 

 

 

Starting

 

 

 

 

 

Running

Watts

 

 

 

Equipment

 

Watts

(Max.VA)

 

 

 

Light bulb (100W)

 

100

100

 

 

 

 

Radio

 

150

150

 

 

 

 

Fan

 

200

600

 

 

 

 

Television

 

400

400

 

 

 

 

Furnace fan—1/3HP with blower

600

1800-2400

 

 

 

 

Vacuum cleaner

 

600

750

 

 

 

 

Sump pump—1/3HP

 

700

2100-2800

 

 

 

 

Refrigerator/freezer

 

800

2400-5000

 

 

 

 

6" Circular saw

 

800

1000

 

 

 

 

Floodlight

 

1000

1000

 

 

 

 

 

 

 

 

 

 

 

 

1/2" Drill

 

1000

1250

 

 

 

 

Toaster/coffeemaker

 

1200

1200

 

 

 

 

Skillet

 

1200

1200

 

 

 

 

14" Chain saw

 

1200

1500

 

 

 

 

Water well pump—1/2HP

1000

3000-6000

 

 

 

 

Hot plate/range (per burner)

1500

1500

 

 

 

 

10" Table saw

 

2000

6000

 

 

 

 

Water heater (storage-type)

5000

5000

 

 

 

 

CHART 2

 

 

 

 

 

 

 

 

 

Approximate

Approximate

Approximate

Approximate

 

 

Starting Watts*

Starting Watts*

Starting Watts*

Starting Watts*

Motor

Approximate

(Max. VA)

(Max. VA)

(Max. VA)

(Max. VA)

HP

Running

Universal Motors

Repulsion

Capacitor

Split Phase

Rating

Watts

(small appliance)

Induction Motors

Motors

Motors

1/8

500

625

1100

 

1500

2250

 

1/4

700

875

1550

 

2100

3150

 

1/3

800

1000

1750

 

2400

3600

 

1/2

1100

1375

2400

 

3300

4950

 

3/4

1400

1750

3100

 

4200

 

1

1700

2125

3750

 

5100

1 1/2

2100

2625

4620

 

6300

2

2450

3075

5400

 

7350

3

3600

7800

 

10800

(*) Always use starting watts (maximum VA), not running watts, when figuring correct electrical load.

(†) Motors of higher horsepower are not generally used.

NOTE: Please check with appliance manufacturer for maximum wattage required.

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4W315C

Dayton® Diesel Electric Generator

Operation

HIGH AND LOW TEMPERATURE OPERATION

Air temperature affects generator output. Output drops 1% for each 10° temperature rise above 60° F. Very low temperatures may make the engine hard to start. See engine owner’s manual for more information.

GENERAL INFORMATION

This generator is not large enough to power your entire home. Do not connect generator to any existing electrical circuits. Plug items directly into generator receptacles. Do not exceed amperage rating of receptacles. Only use grounded cords.

Use only in wellvented areas. Make

sure area has plenty of free-moving,fresh, outside air. Never run generator in an enclosed or confined area. Never run generator inside occupied building. engine exhaust contains poisonous carbon monoxide gas. Overexposure will cause loss of consciousness and will lead to death.

Never connect generator to any

existing electrical circuits. The generator output will back-feedinto the utility power line. This may electrocute a power company line repair person. Also, if generator is powering electrical circuits, the chance of an electrical fire exists.

NOTE: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine operation.

USING RECEPTACLE

NOTE: Do not exceed amperage rating of receptacles. Exceeding rating will trip receptacle circuit breaker.

Use receptacles properly. Improper use could damage generator. Use only grounded extension cords. Power only grounded or double-insulateditems. Do not overload receptacles. These generators have the following receptacles (See Figure 16):

120V, 15-ampduplex receptacle

120V, 15-ampGFCI duplex receptacle

120V, 30-amptwist-lockreceptacle

120/240V, 20-amptwist-lockreceptacle

120V, 15-AmpGFCIDuplex

120V, 15-AmpDuplex

120V OLTS

RTEESSETT

120 ONLY

120 240V

0 ENM

 

000

 

0005

 

HOURS

RES

1/10

ET

 

R

 

ES

 

ET

120V, 30-AmpTwist-Lock

120/240V, 20-AmpTwist-Lock

Figure 16 – Receptacle Locations

POWER CORD AND PLUG REQUIREMENTS

120V, 30-amptwist-lockreceptacle

NEMA L5-30Pplug

Three-wire,30-ampcord 120/240V,20-amptwist-lockreceptacle

NEMA L14-20P(20-amp)plug

Four-wire,20-ampcord

120 Volt

30 Amp

 

 

W

X

L5-30P

 

X

Plug

Ground

G

 

(Green)

(Hot)

 

 

 

W

 

 

 

 

(Neutral)

 

 

 

 

120/240 Volt

 

 

 

 

20 Amp

 

Neutral

 

 

 

120V

120V

 

Ground

X

w

 

L14-20P

Y

X

(Green)

(Hot)

G

 

Plug

Ground

W

Y (Neutral) (Hot)

Figure 17 – Cord and Plug Configurations

PRESTART

Operate generator on a firm, dry, and clean surface. The surface must be level. Protect generator from heavy dust, sand, dirt, rain, or snow. Do not locate generator near standing water or snow. Make sure area is well-vented.

Only responsible adults should use generator. Never let anyone operate

generator without proper instructions.

NOTE: If oil level is too low, oil alert system will keep engine from starting (See “Oil Alert System,” page 5). Make sure oil level is full before starting. SeeEngine Oil, page 8.

Before starting the engine, disconnect all electric loads from generator.

You may need to bleed fuel line to remove trapped air

if starting engine for first time

if starting engine after allowing generator to run out of fuel

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Model 4W315C

Operation (Continued)

BLEEDING FUEL LINE

1.Loosen fuel line clamp and remove fuel line from engine. Place open end of fuel line over a clean container to catch any fuel spilled in step 3, below.

2.Move fuel valve lever to the “O” (open) position (See Figure 18).

3.Allow air to bleed from line. When fuel exits fuel line in a steady stream, reattach fuel line to engine.

4.Add spilled fuel back into fuel tank.

O

S

Fuel Valve

Lever

Figure 18 - Fuel Valve Lever In “O” (open)

Position

3.Move engine run lever to the RUN position (See Figure 19).

Engine Run

Lever

STARTING

Never use gasoline, paint thinner,

or any other flammable liquid as a starting aid. An explosion may occur.

IMPORTANT: The engine speed is preset. The throttle is locked in preset position. Do not adjust throttle. Preset position lets engine run at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.

IMPORTANT: Never start generator with electrical loads connected. Start engine before adding electrical loads.

1.Make sure fuel tank is full. See “Fuel,” page 8 for fuel information.

2.Move fuel valve lever to the “O” (open) position (See Figure 18).

RUN

STOP

Figure 19 - Engine Run Lever

You must fully move engine run/

stop knob to the RUN position to run engine at 3600 RPM. Do not run engine at lower speeds. Running engine at lower speeds will damage generator and powered items.

4.Start the engine. a. Electric Starter

(1)Slowly pull starter rope until you feel strong resistance. Gently return starter rope to engine.

(2)Push decompression lever all the way down (See Figure 20). Decompression lever will stay in this position until you turn starting key.

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Decompression

Lever

Figure 20 - Decompression Lever

(3)Turn the starting key clockwise to the START position (See Figure 21). Hold it there until engine starts.

Starting Key

OIL

CHARGE

OFF

Figure 21 - Starting Key

(4) When engine starts, release key.

IMPORTANT: Do not use electric starter more than ten seconds. Starter motor damage may occur. If engine fails to start, release the key and wait 15 seconds. After 15 seconds, try starting again.

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Dayton® Diesel Electric Generator

Operation (continued)

b.Recoil Starter

(1)Slowly pull starter rope until you feel strong resistance. Gently return starter rope to engine.

(2)Push decompression lever all the way down (See Figure 22). Decompression lever will stay in this position until you pull starter rope.

Decompression

Lever

Figure 22Decompression Lever

(3)Firmly grasp starter grip with both hands. Remove slack from starter rope by lightly pulling starter grip.

(4)To start engine, pull starter rope briskly. You must pull the starter rope all the way out. If not, the engine will not start.

IMPORTANT: Do not let starter grip snap back against engine. Return it gently. This will prevent damage to starter.

Never use gasoline, paint thinner,

or any other flammable liquid as a starting aid. An explosion may occur.

If engine does not start, repeat steps under b. Recoil Starter on this page.

HIGH ALTITUDE OPERATION

This generator will not perform well at high altitudes without proper adjustment. Contact a Yanmar dealer for adjustment information.

ADDING ELECTRICAL LOADS

IMPORTANT: Do not overload generator. Make sure total wattage of all electrical loads does not exceed rated wattage of generator. Overloading may shorten generator life. It could also cause internal damage to generator. Overloading

will trip circuit breaker.

IMPORTANT: Keep full power selector switch in the 120 VOLT ONLY position if only powering 120V items. Only move switch to 120/240 VOLT position if powering 240V items.

1.Check items to be powered. Their nameplate lists their wattage ratings.

NOTE: The wattage ratings for some electrical motors are misleading. They may require 3 to 6 times their rated fullload wattage to start. You must figure total electrical load wattage. Make sure total wattage of all electrical loads does not exceed rated wattage of generator. See “Determining Electrical Load For Generator,” page 10.

2.Start engine. Let engine reach full speed.

3.Connect electrical loads one at a time. If the load consists of electric motors, start them first. Always start the largest first. Start each motor individually.

DISCONNECTING ELECTRIC LOADS

Remove electrical loads one at a time. Remove voltage sensitive items first. Voltage sensitive items include TVs, VCRs, and other home electronic items.

STOPPING ENGINE

Follow the steps below to stop engine.

1.Remove all electrical loads from generator (See “Disconnecting Electrical Loads,” above). Remove electrical loads one at a time.

2.Let engine run for two or three minutes after removing electrical loads. This lets engine cool slightly.

3.Push down engine stop lever (See Figure 23). This releases engine run lever and stops engine. Do not stop engine with the decompression lever.

4.Turn the starter key to the OFF position.

RUN

STOP

Engine Stop Lever

Figure 23 - Pushing Down Engine Stop

Lever

5.Turn fuel valve lever off. Do this by moving valve lever to the “S” position (See Figure 24, page 15).

6.Slowly pull starter rope until you feel strong resistance. Gently return starter rope to engine. This action closes the intake and exhaust valves. This prevents rust from forming while not using engine.

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Dayton Operating Instructions and Parts Manual

Model 4W315C

Operation (continued)

O

S

Fuel Valve Lever

Figure 24 - Fuel Valve Lever In “S” Position

Maintenance and Repairs

Only a qualified electrical service person should service and repair the

alternator on this generator. Use only factory approved replacement parts.

You must always run the engine at full speed. Do not run engine at lower

speeds. At full speed, the engine runs at 3600 RPM under load. The engine must maintain 3600 RPM for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.

Shut off generator before performing

maintenance.

IMPORTANT: Keep generator level when servicing. Never turn generator upside down or stand it on end to service.

NOTE: We supply the engine owner’s manual with generator. Refer to that manual for questions concerning engine maintenance and repairs.

Non-engineparts require little maintenance. Keep generator clean. Use a damp cloth to clean outside surfaces. Never use water to clean generator. Water can cause damage to internal parts. Use vacuum to clean air inlet and outlet louvers of alternator.

SERVICING THE ENGINE

For Yanmar engine replacement parts, contact Grainger Parts at 1-800-323-0620.

Yanmar engine servicing should be handled by your nearest authorized Yanmar engine service firm. Contact Yanmar at 1-847-541-1900for nearest authorized Yanmar engine service firm.

ENGINE MAINTENANCE

Periodic checks and maintenance are very important for keeping the engine in good condition and durable. The chart on page 18 indicates which checks to make and when to make them. The mark “•” indicates that special tools and skills are required. Items marked “•” should be serviced by an authorized Yanmar dealer, unless the owner has the proper tools and is mechanically proficient.

Consult your Yanmar dealer.

Shut off the engine before

performing any maintenance. If the engine must be run, make sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas.

After the engine has been used,

clean the engine immediately with a cloth to prevent corrosion and to remove sediment.

Only use genuine Yanmar parts. The

use of replacement parts which are not of equivalent quality may damage the engine.

HOW TO CHANGE YOUR ENGINE OIL

Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is still warm. The plug is located on the bottom of the cylinder block. Tighten the drain plug and refill with the recommended oil. (See the section under “Preparations for Starting” in the engine owner’s manual.)

CLEANING THE OIL FILTER

Loosen the fixing bolt and then pull out the oil filter. Clean oil filter every six months or 500 hours of operation.

CHANGING THE AIR CLEANER ELEMENT

Do not wash the air cleaner element with detergent because this is a wet-typeelement. Change air cleaner element every six months or 500 hours of operation (or earlier if dirty).

See the section for changing the air cleaner element under “Preparations for Starting” in the engine owner’s manual.

Never run the engine without

the air cleaner element or with a defective element.

NOTE: A clogged element hinders the flow of air to the combustion chamber. This reduces engine output, increases lube oil and fuel oil consumption and makes starting difficult. Make sure you clean your

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Maintenance and Repairs (Continued)

element regularly.

CLEANING AND REPLACING THE FUEL FILTER

The fuel filter also has to be cleaned regularly to insure maximum engine output. Clean fuel filter every six months or 500 hours of operation. Replace fuel filter every year or 1000 hours of operation.

1.Drain the fuel oil from the fuel tank.

2.Loosen the nuts of the fuel cock and pull out the filter from the fuel tank filler port. Wash the filter thoroughly with diesel fuel.

CLEANING THE SPARK ARRESTER

If the engine has been running, the

muffler and the spark arrester will be very hot. Allow these to cool before proceeding.

Remove the lock nut, end cap and diffuser discs and clean off the carbon deposits. Clean spark arrester every three months or 100 hours of operation (or earlier if dirty).

Clamp

Spark

Arrester Diffuser

Discs

Muffler

End Cap

Lock Nut

 

Figure 25 - Spark Arrester

A clogged spark arrester hinders

the flow of exhaust gas. This reduces engine output, increases fuel consumption and makes starting difficult. Make sure you clean your spark arrester regularly.

TIGHTEN CYLINDER HEAD BOLTS

Tightening the cylinder head bolts requires a special tool. Don’t try it yourself. Consult your Yanmar dealer.

CHECKING THE INJECTION NOZZLE, INJECTION PUMP, ETC.

Adjusting the valve head clearance for the intake and exhaust valves.

Lapping of intake and exhaust valves.

Replacing piston ring.

All these require special tools and skills. Consult your Yanmar dealer.

Do not perform the injection nozzle

test near an open fire or any other kind of fire. The fuel spray may ignite. Do not expose bare skin to the fuel spray. The fuel may penetrate the skin and cause injury to the body. Always keep your body away from the nozzle.

CHECKING AND REPLENISHING BATTERY FLUID AND CHARGING THE BATTERY

Battery fluid will be lost through continuous charging and discharging.

The battery electrolyte

contains sulfuric acid. Protect your eyes, skin, and clothing. In case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected.

Batteries generate hydrogen gas,

which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially during charging.

NOTE: Much more fluid is lost during summer than in winter.

Before starting, check for physical damage to the battery and also the electrolyte levels, and replenish with distilled water up to the upper mark if necessary. When actual damage is discovered, replace the battery. Check battery fluid monthly.

Before charging, remove the cap

from each cell of the battery. Charge the battery in a place where there is plenty of ventilation. Discontinue charging if the electrolyte temperature exceeds 45° C (117° F).

Do not charge the battery with the

battery cable still connected. The diodes will be damaged by the high voltage.

Connect the (+) lead of the charger

to the (+) terminal of the battery, and the (–)lead to the(–)terminal. Reversed polarity will damage the charger rectifier or the battery.

Storage

Remove all fuel from fuel tank

before storing generator. Store fuel in approved container. Store fuel in a well-ventedarea free of open flames or sparks.

The muffler becomes very hot

during operation. The muffler remains hot for a while after shutdown. Let engine cool before storing.

IMPORTANT: Keep generator level while in storage. Never store generator upside down or standing on end.

Cover and store generator in a clean, dry place. Do not expose generator to extreme high or low temperatures during storage.

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Dayton Operating Instructions and Parts Manual

Model 4W315C

Storage (Continued)

ENGINE STORAGE

If storing your engine for long periods, make the following preparations.

1.Operate the engine for about 3 minutes and then stop.

CHART 3

2.Stop the engine. Drain the engine lube oil while the engine is still warm and fill with new oil.

3.Pull the recoil starter slowly. Stop when it feels tight. This closes the intake and exhaust valves (in compression position) and helps prevent rust from forming.

4.Wipe the oil and dirt from the engine and store in a dry place.

 

 

 

Service

Service

Service

Service

 

 

 

First

Every

Every

Every

 

Daily

Service

Month

3 Months

6 Months

Year

Item

Check

Monthly

or 20 Hrs.

or 100 Hrs.

or 500 Hrs.

or 1000 Hrs.

 

 

 

 

 

 

 

Check and replenish fuel oil

Drain fuel from fuel tank

Check and replenish lube oil

Check for oil leakage

Check and tighten engine parts

Check and tighten engine head bolts

Change lube oil (first time)

Change lube oil (each time after first)

Clean oil filter (replace if needed)

Replace air cleaner element (Service more frequently when used in dusty areas)

Clean fuel filter

Replace fuel filter

Clean spark arrester

Check fuel injection pump

Check fuel injection nozzle

Check fuel piping (replace if needed)

Adjust valve head clearance for intake and exhaust valves (first time at 20 hrs)

Adjust valve head clearance for intake and exhaust valves (each time after first)

Lap intake and exhaust valves

Replace piston rings

Check battery fluid

Special tools and skills required.

No special tools or skills required.

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Dayton® Diesel Electric Generator

Wiring Diagrams

Green/Yellow

 

Red

 

 

 

 

 

 

 

 

 

 

 

 

120/240V

20A

 

 

 

Red

 

 

Receptacle

 

White

 

 

 

 

 

 

 

T1

Circuit

 

 

 

 

T2

 

Breaker

 

 

 

 

 

 

 

 

 

 

 

 

 

25A

 

 

 

 

Full Pwr

 

 

 

 

 

 

 

 

 

 

 

 

Black

Selector

Red

 

 

 

 

Switch

 

 

 

 

 

 

 

 

 

 

 

 

 

Circuit

 

 

Black

 

 

 

 

Breaker

T3

 

 

 

 

 

25A

 

White

 

 

 

 

 

Black

 

 

 

 

 

 

 

 

 

 

T4

 

 

 

 

Hour

 

 

 

 

 

 

 

 

 

Yellow

White

 

 

 

Meter

 

 

Black

 

 

 

 

 

 

 

Red

 

 

 

 

 

 

 

 

 

 

 

 

Black

 

 

 

 

Red

 

Black Green

 

 

 

 

Black

White

120V, 15A Receptacle

Duplex

 

Green

 

 

White

 

 

 

120V, 15A

 

120V, 30A

Circuit

Receptacle

 

Receptacle

 

 

 

 

Breaker

 

 

 

 

20A

GFCI

 

 

 

 

 

 

 

Circuit

 

 

 

 

Breaker

 

WHITE

 

 

20A

HOT

White

 

 

 

 

 

 

LINE

 

 

 

Green

 

Green

 

Black

 

 

 

 

 

Red

Capacitor

White

 

 

 

 

 

Main

 

 

 

Auxiliary

 

 

 

 

 

White

 

 

 

 

Windings

 

 

 

Phase

 

 

Stator

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T1

T4

T3

T2

T2

T1

T3

T4

Rotor

Stator

T1

T2

T3

T4

 

 

 

 

Green

 

 

 

 

 

White

 

 

 

 

 

 

 

 

 

Red

 

 

Diode

Diode

 

220/240V

 

 

 

 

 

 

 

 

 

L1

L2

 

 

 

 

 

Black

 

 

 

 

 

 

 

 

 

 

 

 

Yellow

 

 

 

 

110/120V

110/120V

 

 

 

 

 

 

 

 

 

Brown

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 26 - Alternator Wiring Diagram

 

 

 

 

 

Key

Charge

 

 

 

 

 

Lamp

 

 

 

 

 

Switch

 

 

 

 

 

 

Green

 

 

Green/White

 

Green

2

Green

Black

Charge

 

Charge Yellow

3

Yellow

 

Coil

Green/White

Regulator

White

4

White

 

 

 

 

 

 

 

 

 

1

Red

 

 

 

White

 

 

 

Fuse

White

Starter

Red

Shutdown

 

Motor/

 

 

 

 

 

Solenoid

 

Solenoid

 

Red

+

-

Black

 

 

Green/White

Battery

 

 

Yellow

 

 

 

 

 

 

Red

Oil

 

 

 

 

P

 

 

 

 

Pressure

Bridge

Red

30

87

 

Switch

 

 

Relay

 

 

 

 

 

 

 

 

 

86

85

White

Black

Green/White

Red

White

 

Low Oil

Pressure Lamp

Black

Figure 27 - Engine Wiring Diagram

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Dayton Operating Instructions and Parts Manual

Model 4W315C

Troubleshooting Chart

NOTE: See engine owner’s manual for engine troubleshooting.

Only a qualified electrical service

person should service and repair generator. Use only factory approved replacement parts.

Symptom

Possible Cause(s)

Corrective Action

No voltage when starting generator with

1. Defective capacitor

1. Replace capacitor

no electrical load

2. Winding short circuit or loose connec-

2. Check resistance of coils (See “Electrical

 

tions

Component Specifications,” page 2)

 

3. Defective rotor diode

3. Replace both diodes on rotor

 

4. Loss of residual magnetism

4. Apply 12-voltbattery to capacitor

 

 

terminals for 2-3seconds

 

 

 

Voltage is less than normal voltage with

1. Engine speed too low

1. Set engine speed to 3720 RPM (62 Hz)

no electrical load

 

with no load

 

2. Clogged spark arrester

2. Clean arrester. See engine owner’s

 

 

manual

 

3. Defective rotor diode

3. Replace both diodes on rotor

 

4. Partial short circuit in winding

4. Check resistance of coils (See “Electrical

 

 

Component Specifications,” page 2)

 

5. Defective capacitor

5. Replace capacitor

 

 

 

Voltmeter reading more than 10% high

Engine speed too high

Set engine speed to 3720 RPM (62 Hz)

with no electrical load

 

with no load

 

 

 

Voltmeter reading correct with no

1. Defective rotor diode

1. Replace both diodes on rotor

electrical load, but more than 10% low

2. Electrical load too high

2. Do not overload generator

when electrical load is added

3. Engine not running properly

3. Contact an authorized engine service

 

 

center

 

 

 

Engine will not start

1. Fuel level too low

1. Add fuel to fuel tank

 

2. Fuel cock not in “O” (open) position

2. Move fuel cock to “O” (open) position

 

3. Diesel fuel not reaching the fuel

3. See qualified Yanmar service person

 

injection pump or nozzle

 

 

4. Speed control lever not in START

4. Move speed control lever to START

 

position

position

 

5. Lube oil level not correct

5. Add lube oil to engine

 

6. Fuel injection nozzle not working right

6. See qualified Yanmar service person

 

7. Recoil starter not pulled quickly and

7. When starting engine with recoil starter,

 

firmly enough

pull starter rope quickly and firmly. You

 

 

must pull starter rope all the way out

 

8. Spark arrester clogged by carbon

8. Clean spark arrester. See “Cleaning the

 

 

Spark Arrester,” page 16

 

9. Battery not discharging

9. Loose battery connections, corrosion on

 

 

battery terminals, or battery dead

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Dayton Operating Instructions and Parts Manual

4W315C

DaytonFor Repair Parts,® Dieselcall1-800Electric-323-0620Generator

24 hours a day - 365 days a year

Please provide following information:

-Modelnumber-Serialnumber (if any)

-Partdescription and number as shown in parts list

Address parts correspondence to:

Grainger Parts

P.O. Box 3074 1657 Shermer Road

Northbrook, IL 60065-3074U.S.A.

1

2

3

F

E

 

5

 

 

 

 

4

 

 

 

9

20

 

 

 

 

 

 

15

 

 

9

 

 

 

 

8

 

 

 

14

 

 

 

 

 

 

 

 

19

6

 

 

 

19

 

 

 

14

7

 

 

 

 

10

 

18

 

 

 

 

 

11

 

12

 

 

 

 

 

 

9

 

16

 

 

13

 

 

8

9

 

 

8

 

 

 

 

14

 

 

 

 

9

 

17

Figure 28 – Repair Parts Illustration for Fuel Tank and Roll Cage

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