VDO Dayton 4W315C User Manual
Operating Instructions & Parts Manual
Version B - For Reduction G016.J
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.
®
4W315C
Dayton Diesel Electric
Generator
Description
Dayton professional-duty generators are rugged and compact. These models provide
dependable, trouble-free service. 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-arresting
muffler, 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
Dayton Operating Instructions and Parts Manual
®
Dayton Diesel Electric Generator
Specifications
ELECTRICAL SPECIFICATIONS
Rated Maximum Rated Amperage Rated Amperage
Wattage* VA 120V 240V
5000 6500 41.7 20.8
4W315C
* Single-phase, 1.0 power factor
NOTE: Ratings apply to SAE standard conditions. Reduce ratings 3
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
1
/2% for each 1000 feet above sea level and 1% for each 10°
(*) 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.
2
107358
Dayton Operating Instructions and Parts Manual
Version B - For Reduction G016.J
Model 4W315C
Product Identification
Full Power
Selector Switch
Control Panel
1
2
0
V
O
L
T
S
F
U
L
L
P
1
O
2
0
W
O
E
N
R
L
Y
S
E
L
E
C
T
1
O
2
R
0
/
2
4
0
V
1
0
2
1
0
0
/
2
0
4
0
2
V
0
O
0
L
T
S
A
3
C
0
V
O
L
T
S
O
U
T
P
U
T
V
O
L
T
A
G
E
120 Volt
Receptacles
Hour Meter
F
E
Roll Cage
N
U
R
P
O
T
S
Engine Run Lever
Engine Stop Lever
120/240 Volt
Receptacle
Circuit
Breaker
Figure 2 – Portable Generator
Starter Grip
Battery Discharge Lamp
Electric Start Switch
Decompression
Lever
Engine
Alternator
Oil Alert Lamp
Fuel Valve (under fuel tank)
EF
Fuel Gage
Oil Dipstick
Fuel Cap
Muffler
Fuel Tank
Ground
Lug
Spark
Arrester
Battery (Not
included, must
be purchased
separately)
107358
®
3
Dayton Operating Instructions and Parts Manual
®
Dayton Diesel Electric Generator
4W315C
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, operating, 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, operating, 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, operating, 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 pre-
sents a hazard of
fire. Diesel fuel is flammable.
• Keep fuel out of children’s reach.
• Refuel generator in a well-vented
area. 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-vented area 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 flam-
mable vapors are present. Some
vapors are heavier than air. These
vapors settle in low-lying places.
• 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.
107358
4
Dayton Operating Instructions and Parts Manual
Version B - For Reduction G016.J
Model 4W315C
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.
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 replace-
ment parts.
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.
existing electrical circuits. The generator output will back-feed into 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.
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-vented area.
107358
Never connect
generator to any
Battery gives off
explosive gases.
Store generator in
a well-vented area.
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
5
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.
®
Dayton Operating Instructions and Parts Manual
®
Dayton Diesel Electric Generator
4W315C
Generator Features
(Continued)
OIL
CHARGE
OFF
Battery
Discharge
Lamp
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
Oil Alert
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 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-hour
battery. For more battery information, see
“Battery,” page 7.
GROUND FAULT CIRCUIT INTERRUPTER
RECEPTACLE
This generator has a 120-volt ground 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
TEST
not lock into place, do
not use receptacle.
Contact a qualified
electrician for repairs.
Figure 7 – GFCI Receptacle
107358
6
Dayton Operating Instructions and Parts Manual
Version B - For Reduction G016.J
Model 4W315C
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-times their
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.
20
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.
20
TrippedNormal
Muffler
Clamp
Figure 9 - Installing Spark Arrester
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-vented area.
Battery contains
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.
the red, positive (+) battery cable
terminal. Insulate with electrical tape.
Exposed terminal may spark when
generator runs.
sulfuric acid.
If you remove
battery, insulate
IMPORTANT: Make sure battery connec-
tions are the correct polarity. Electric start
generators use negative ground, 12-volt
DC starting system.
A battery is not supplied with generator. You
must provide a 12-volt, 45-amp-hour
battery. 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.
107358
®
7
Dayton Operating Instructions and Parts Manual
®
Dayton Diesel Electric Generator
4W315C
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-down system. This system consists
of the battery mounting bracket, hook
bolt, and nut (See Figure 12).
Battery Mounting
Bracket
Battery
Figure 12 – Battery Hold-Down System
Nut
Hook Bolt
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).
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
Black, Negative
Cable From
Engine Block
Figure 13 – Connecting Positive and
Negative Cables to Battery
Installation
FUEL
Diesel fuel pre-
fire. Diesel fuel is flammable.
• Keep fuel out of children’s reach.
• Refuel generator in a well-vented
area. 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.
sents a hazard of
• 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.
• Store fuel in approved container.
Store fuel in a well-vented area 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.
1. Remove dipstick (See Figure 14). Wipe
dipstick clean.
2. Insert dipstick into oil filler neck. Do not
screw it in. Oil level should be at top of
filler neck. Oil should cover most of
dipstick.
3. If level is low, fill to top of oil filler neck
(See Figure 14). Use proper lube oil to
preserve your engine.
NOTE: If oil level is too low, oil alert
system will shutdown engine and prevent
engine from restarting.
107358
8
Dayton Operating Instructions and Parts Manual
Version B - For Reduction G016.J
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:
4W315C1.74 qt.
107358
20W 40
10W 30
VENTILATION
Use only in well-
vented 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-wire or
double-insulated power tools.
Grounding generator helps prevent electric
shock from a ground fault condition.
Locate ground lug on end of generator
housing (See Figure 15). Attach a #10
stranded-copper ground 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.
Ground Lug
Copper or
Brass
Grounding
Point
Alternator
Figure 15 – Grounding Generator
metal pipe being used to carry combustible materials or gases.
Ground Wire
For a grounding
point, do not use
DUST, DIRT, RAIN, AND SNOW
Do not use genera-
tor 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
®
9
Loading...