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VDO Dayton 4W315C manual

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Table of contents for the manual

  • Page 1

    Operating Instructions & Parts Manual Description Dayton professional-duty generators ar e rugged and compact. These models provide dependable, trouble-fr ee service. The alternators are brushless with revolving fields. Y anmar diesel engines provide long life under heavy use. These engines ar e governed to maintain engine speed of 3600 RPM und[...]

  • Page 2

    Dayton Operating Instructions and Parts Manual 2 Dayton Diesel Electric Generator ® 4W315C 107358 Specifications Rated Maximum Rated Amperage Rated Amperage W attage* V A 120V 240V 5000 6500 41.7 20.8 ELECTRICAL SPECIFICA TIONS * Single-phase, 1.0 power factor NOTE: Ratings apply to SAE standard conditions. Reduce ratings 3 1 / 2 % for each 1000 f[...]

  • Page 3

    Dayton Operating Instructions and Parts Manual 3 Model 4W315C Version B - For Reduction G016.J ® 107358 EF R U N S T O P E F 1 2 0 O N L Y F U L L P O W E R O U T P U T V O L T A G E A C V O L T S 0 1 0 0 1 2 0 / 2 4 0 V 2 0 0 3 0 S E L E C T O R 1 2 0 / 2 4 0 V O L T S 1 2 0 V O L T S Figure 2 – Portable Generator Oil Dipstick Battery (Not incl[...]

  • Page 4

    Dayton Operating Instructions and Parts Manual 4 Dayton Diesel Electric Generator ® 4W315C 107358 General Safety Information Engine exhaust contains poisonous carbon monoxide gas. Overexposur e will cause loss of consciousness and will lead to death. Use only in well- vented areas. Make sur e area has plenty of free-moving, fr esh, outside air . N[...]

  • Page 5

    Dayton Operating Instructions and Parts Manual 5 Model 4W315C Version B - For Reduction G016.J ® 107358 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 [...]

  • Page 6

    Dayton Operating Instructions and Parts Manual 6 Dayton Diesel Electric Generator ® 4W315C 107358 Generator Features (Continued) FULL POWER SELECTOR SWITCH The full power selector switch is on the control panel. The switch has two posi- tions: 120 VOL T ONL Y , and 120/240 VOL T . 120 VOL T ONL Y : This position sends full power to the 120V recept[...]

  • Page 7

    Dayton Operating Instructions and Parts Manual 7 Model 4W315C Version B - For Reduction G016.J ® 107358 RECEPT ACLE CIRCUIT BREAKER The circuit br eakers protect the r eceptacles and alternator . Overloading generator will trip circuit br eaker . A short circuit in item being powered will also trip br eaker . If this occurs, unplug electrical load[...]

  • Page 8

    Dayton Operating Instructions and Parts Manual 8 Dayton Diesel Electric Generator ® 4W315C 107358 • 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 r efueling, tightly close fuel tank cap. • Do not spill fuel. If fuel spills, make sure area is [...]

  • Page 9

    Dayton Operating Instructions and Parts Manual 9 Model 4W315C Version B - For Reduction G016.J ® 107358 Oil Level At T op Of Filler Neck Dipstick Oil Figure 14 – Checking Oil Level Installation (Continued) Lube Oil Capacity: 4W315C 1.74 qt. 10W 30 20W 40 For a grounding point, do not use metal pipe being used to carry combus- tible materials or [...]

  • Page 10

    Dayton Operating Instructions and Parts Manual 10 Dayton Diesel Electric Generator ® 4W315C 107358 IMPORT ANT : 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 no[...]

  • Page 11

    Dayton Operating Instructions and Parts Manual 11 Model 4W315C Version B - For Reduction G016.J ® 107358 TYPICAL ELECTRIC APPLIANCE WA TT AGES Chart to be used as a refer ence. Data may vary with size, make, and/or model. CHART 1 Starting Running W atts Equipment W atts (Max.V A) Light bulb (100W) 100 100 Radio 150 150 Fan 200 600 T elevision 400 [...]

  • Page 12

    Dayton Operating Instructions and Parts Manual 12 Dayton Diesel Electric Generator ® 4W315C 107358 W (Neutral) X (Hot) Ground (Green) 120 Volt 30 Amp G W X L5-30P Plug Operation HIGH AND LOW TEMPERA TURE OPERA TION Air temperature af fects generator output. Output drops 1% for each 10 ° tempera- ture rise above 60 ° F . V ery low tempera- tures [...]

  • Page 13

    Dayton Operating Instructions and Parts Manual 13 Model 4W315C Version B - For Reduction G016.J ® 107358 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) [...]

  • Page 14

    Dayton Operating Instructions and Parts Manual 14 Dayton Diesel Electric Generator ® 4W315C 107358 RUN STOP Engine Stop Lever Figure 23 - Pushing Down Engine Stop Lever Figure 22- Decompr ession Lever Decompression Lever b. Recoil Starter (1) Slowly pull starter rope until you feel strong r esistance. Gently r eturn starter rope to engine. (2) Pus[...]

  • Page 15

    Dayton Operating Instructions and Parts Manual 15 Model 4W315C Version B - For Reduction G016.J ® 107358 O S Fuel V alve Lever Figure 24 - Fuel V alve 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 r eplacement parts[...]

  • Page 16

    Dayton Operating Instructions and Parts Manual 16 Dayton Diesel Electric Generator ® 4W315C 107358 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 disco[...]

  • Page 17

    Dayton Operating Instructions and Parts Manual 17 Model 4W315C Version B - For Reduction G016.J ® 107358 Special tools and skills requir ed. No special tools or skills requir ed. Service Service Service Service First Every Every Every Daily Service Month 3 Months 6 Months Y ear Item Check Monthly or 20 Hrs. or 100 Hrs. or 500 Hrs. or 1000 Hrs. Che[...]

  • Page 18

    Dayton Operating Instructions and Parts Manual 18 Dayton Diesel Electric Generator ® 4W315C 107358 Wiring Diagrams Circuit Breaker 25A 120/240V 20A Receptacle T4 120V, 15A Receptacle 120V, 30A Receptacle White White Green Black Red Black Red Black White T3 Red Green Stator 110/120V T1 T2 T3 T4 L2 L1 110/120V 220/240V Rotor Stator White Brown Auxil[...]

  • Page 19

    Dayton Operating Instructions and Parts Manual 19 Model 4W315C Version B - For Reduction G016.J ® 107358 Tr oubleshooting Chart Only a qualified electrical service person should service and repair generator . Use only factory approved r eplacement parts. Corrective Action 1. Replace capacitor 2. Check resistance of coils (See “Electrical Compone[...]

  • Page 20

    Dayton Operating Instructions and Parts Manual 20 Dayton Diesel Electric Generator ® 4W315C 107358 For Repair Parts, call 1-800-323-0620 24 hours a day - 365 days a year 4W315C E F 3 1 2 4 5 18 19 14 19 14 15 9 9 17 8 10 11 13 12 6 9 20 14 9 8 9 8 7 16 Figure 28 – Repair Parts Illustration for Fuel T ank and Roll Cage Please provide following in[...]

  • Page 21

    Dayton Operating Instructions and Parts Manual 21 Model 4W315C Version B - For Reduction G016.J ® 107358 Repair Parts List for Fuel T ank and Roll Cage 4W315C Reference Part No. for Number Description Model 4W31SC: Quantity 1 Fuel tank assembly 099935-01 1 2 1/4-20 x 3/4" Screw * 4 3 1/4" W asher WP-4C 4 4 1/4-20 Nut 103880-01 4 5 Roll c[...]

  • Page 22

    Dayton Operating Instructions and Parts Manual 22 Dayton Diesel Electric Generator ® 4W315C 107358 4W315C 1 6 2 10 12 15 16 13 14 17 18 19 20 21 23 23 22 3 9 8 4 7 5 11 24 Figure 29 – Repair Parts Illustration for Alternator Assembly For Repair Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Mod[...]

  • Page 23

    Dayton Operating Instructions and Parts Manual 23 Model 4W315C Version B - For Reduction G016.J ® 107358 Repair Parts List for Alternator Assembly 4W315C Reference Part No. for Number Description Model 4W31SC: Quantity 1 End cover 099844-01 1 2 M5 x 13 Screw 099701-01 6 3 Bushing 099760-01 1 4T erminal block (4-block) 099863-01 1 5T erminal block [...]

  • Page 24

    Dayton Operating Instructions and Parts Manual 24 Dayton Diesel Electric Generator ® 4W315C 107358 4W315C 1 3 14 11 1 2 0 V O L T S RESET TEST 2 4 2 1 2 0 /2 4 0 V O L T S R E S E T R E S E T 7 6 6 9 10 12 12 13 FULL POWER SELECTOR 5 8 120 ONLY 120/240V E N M 0000 00 05 H O U R S 1/10 Figure 30 – Repair Parts Illustration for Contr ol Panel For [...]

  • Page 25

    Dayton Operating Instructions and Parts Manual 25 Model 4W315C Version B - For Reduction G016.J ® 107358 Repair Parts List for Contr ol Panel 4W315C Reference Part No. for Number Description Model 4W315C: Quantity 1 Control panel, fr ont 103349-02 1 2 20 Amp Circuit br eaker *22616009 2 3 120V , 30A T wist-lock receptacle *099833-01 1 4 120V , 15A[...]

  • Page 26

    Dayton Operating Instructions and Parts Manual 26 Dayton Diesel Electric Generator ® 4W315C 107358 4W315C 17 16 15 7 8 9 14 21 23 4 4 4 4 10 11 12 13 12 20 18 19 3 6 3 5 22 2 3 1 Figure 31 – Repair Parts Illustration for Switch Contr ol Box For Repair Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following informatio[...]

  • Page 27

    Dayton Operating Instructions and Parts Manual 27 Model 4W315C Version B - For Reduction G016.J ® 107358 4W315C Repair Parts List for Switch Contr ol Box Reference Part No. for Number Description Model 4W315C: Quantity 1 Switch control box 101037-01 1 2 Low oil light 22721000 1 3 Key switch, lamp, and harness assembly 099936-01 1 4 1/4-28 Keps nut[...]

  • Page 28

    Dayton Operating Instructions and Parts Manual Dayton Diesel Electric Generator ® 4W315C Manufactured for Dayton Electric Mfg. Co. Niles, Illinois 60714 U.S.A. NOTE: The five-year limited warranty below covers all non-engine parts of this generator including the alternator . Y anmar warrants the engine. See engine owner’ s manual for engine warr[...]