Dayton 4W315B Operating instructions

Operating Instructions & Parts Manual 3ZC06B and 4W315B

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.

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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 (model 4W315B only), electric starter (model

4W315B only), 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 for model

4W315B only. 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 3ZC06B

Figure 2 – Model 4W315B

Form 5S3125

Version B - For Reduction G016.J

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Dayton Operating Instructions and Parts Manual

® Dayton Diesel Electric Generator

Specifications

ELECTRICAL SPECIFICATIONS

Model

3ZC06B

Rated

Wattage*

3000

Maximum

VA

4000

4W315B 5000 6500

Rated Amperage

120V

25

41.7

Rated Amperage

240V

12.5

20.8

* Single-phase, 1.0 power factor

NOTE: Ratings apply to SAE standard conditions. Reduce ratings 3 1/2% for each 1000 feet above sea level and 1% for each 10° Fahrenheit rise above 60°F.

GENERAL SPECIFICATIONS

Model

3ZC06B

Yanmar

Engine H.P.

6

4W315B 9

Yanmar

Model

L60

L90

Fuel

Type

Diesel

Diesel

Fuel Tank

Capacity

0.9 gal.

4.2 gal.

Oil Alert

System

No

Yes

Electric

Start

No

Yes

Weight

(pounds)

168.5

241

RECEPTACLE SPECIFICATIONS

Model

120V

Duplex

120V, 30-Amp

Twist-Lock

3ZC06B Yes Yes

4W315B Yes Yes

120/240V, 20-Amp

Twist-Lock

Yes

Yes

120V Full

Power Switch

Yes

Yes

ELECTRICAL COMPONENT SPECIFICATIONS

Model

3ZC06B

4W315B

Stator

Main

Winding *

0.71

0.54

Resistance in Ohms

Stator

Auxiliary

Winding

Rotor

Primary

Winding †

2.17

0.54

1.38

0.61

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

( ) Resistance between br own and white leads.

(†) Remove diodes to check resistance.

Rotor

Secondary

Winding †

2.07

2.29

Capacitor,

MFD

450 Volt

40

50

Diodes (2)

800 Volt

70 Amp

70 Amp

2


Models 3ZC06B and 4W315B

Product Identification

Full Power

Selector Switch

Control Panel

120

LTS

120 Volt

Receptacles

Voltmeter

120/240 Volt

Receptacle

Circuit

Breaker

120

ON

LY

FU

LL P

OW

ER

SELECTOR

0 100

200

AC

VO

LTS

30

UT

VO

LTA

GE

120

/24

0V

120

/24

OLT

S

E

F

Roll Cage

Engine Run Lever

RUN

STO

P

Engine Stop Lever

Fuel Valve (under fuel tank)

Alternator

Oil Alert Lamp (4W315B only)

Battery Discharge Lamp (4W315B only)

Electric Start Switch

(4W315B only)

F

E Decompression

Lever

Fuel Gage

Fuel Cap

Fuel Tank

(Different size and location,

Model 3ZC06B)

Starter Grip

Figure 3 – Portable Generator (Model 4W315B Shown)

Engine

3

Ground

Lug

Spark

Arrester

Oil Dipstick

Muffler

Battery (Model

4W315B only not included, must be purchased separately)

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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, COULD 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.

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-lying places.

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

RV generator compartments.

• 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.

Diesel fuel presents 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 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 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.

4



General Safety Information

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

Guard against burns. Hot engine

• 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 replacement parts.

Store generator in a well-vented area.

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

Never connect generator to any 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.

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.

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 (MODEL 4W315B

ONLY)

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 4, page 6). Add oil to engine

(see Engine Oil, page 8).

See engine owner’s manual for more information.

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5





(continued)

120/240 VOLT full power switch position:

The voltmeter will show about 240V under load.

0

100 200

300

A C VOLTS

OFF

CHARGE

OIL

Battery

Discharge

Lamp

Oil Alert

Lamp

Figure 5 – Full Power Selector Switch in 120

Volt Only Position

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

Figure 7 – Voltmeter

ELECTRIC START (MODEL 4W315B ONLY)

Model 4W315B has an electric starter. 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.

Figure 4 - Battery Discharge Lamp and Oil

Alert Lamp Location

BATTERY DISCHARGE LAMP (MODEL

4W315B ONLY)

The battery discharge lamp (see Figure 4, 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 6 – 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.

VOLTMETER

The voltmeter is on the control panel. The voltmeter shows the generator output voltage (see Figure 7).

120 VOLT ONLY full power switch position:

The voltmeter will show about 120V under load.

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 20

Normal Tripped

Figure 8 – Receptacle Circuit Breaker Button

6




(continued)

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.

Figure 9 - Installing Spark Arrester

Assembly

Muffler

Clamp

BATTERY (MODEL 4W315B ONLY)

Spark

Arrester

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 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.

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

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-volt

DC starting system.

Model 4W315B has an electric starter. 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.

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.

Black, Negative (–)

Battery Cable

Figure 11 – Connecting Black, Negative (–)

Battery Cable to Engine Block

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7




Assembly

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).

Nut

Battery Mounting

Bracket

Battery

(continued)

Hook Bolt

Figure 12 – Battery Hold-Down System

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.


Black, Negative

Cable From

Engine Block

Figure 13 – Connecting Positive and

Negative Cables to Battery

Installation

FUEL

Diesel fuel presents 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 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.


Red, Positive Cable

From Starter Solenoid

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 (model 4W315B only).

Oil Level

At Top Of

Filler Neck

Dipstick

Figure 14 – Checking Oil Level

Oil

8



Installation

(continued)

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.

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.

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

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.

Alternator

Ground Wire

Lube Oil Capacity:

3ZC06B 1.16 qt.

4W315B 1.74 qt.

20W 40

10W 30

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.

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

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

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 dust, dirt, rain, or snow to collect on it.

Protect generator from outdoor elements.

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9




Installation

(continued)

EXTENSION CORDS

8

10

12

14

4

5

6

16

20

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

16

16

16

16

16

14

14

12

10

16

16

16

14

14

14

12

12

10

GROUND FAULT PROTECTION

12

12

12

10

16

16

14

10

8

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.

You must provide the GFCI device.

Purchase GFCI at any electrical supply house. Check the Yellow Pages for the nearest supply house.

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-yourself job.

Follow all local codes.

The electrician must install a double-throw transfer switch. This isolates existing electrical circuits from the utility power line. If not isolated, generator output will back-feed into 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-step method. It will help you select a load that is not too large. Make sure total wattage of all electrical loads does not exceed

3000 watts (model 3ZC06B) or 5000 watts

(model 4W315B). 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 up to 3-times their rated wattage to start. Chart 2, page 11, shows starting watts (maximum volt-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 3000 watts (model 3ZC06B) or 5000 watts (model 4W315B). It is a good idea to have up to 25% extra capacity for future needs or extra equipment.

10



TYPICAL ELECTRIC APPLIANCE WATTAGES

CHART 1

Equipment

Light bulb (100W)

Radio

Fan

Television

Furnace fan—1/3 HP with blower

Vacuum cleaner

Sump pump—1/3 HP

Refrigerator/freezer

6" Circular saw

Floodlight

1/2" Drill

Toaster/coffeemaker

Skillet

14" Chain saw

Water well pump—1/2 HP

Hot plate/range (per burner)

10" Table saw

Water heater (storage-type)

1200

1200

1000

1500

2000

5000

700

800

800

1000

1000

1200

Running

Watts

100

150

200

400

600

600

1200

1500

3000

1500

6000

5000

2100

2400

1000

1000

1250

1200

Starting

Watts

(Max.VA)

100

150

600

400

1800

750

CHART 2

Motor

HP

Rating

1/8

1/4

1/3

1/2

3/4

Approximate

Running

Watts

275

400

450

600

850

Approximate

Starting Watts*

(Max. VA)

Universal Motors

(small appliance)

400

500

600

750

1000

1

1 1/2

1000

1600

1250

1750

2300

3200

2 2000 2350 3900

3 3000 † 5200

* 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.

Approximate

Starting Watts*

(Max. VA)

Repulsion

Induction Motors

600

850

975

1300

1900

Approximate

Starting Watts*

(Max. VA)

Capacitor

Motors

850

1050

1350

1800

2600

3000

4200

5100

6800

Approximate

Starting Watts*

(Max. VA)

Split Phase

Motors

1200

1700

1950

2600

†

†

†

†

†

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11




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.


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-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.

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-insulated items. Do not overload receptacles. These generators have the following receptacles (see Figure

16):

• 120V, 15-amp duplex receptacle

• 120V, 30-amp twist-lock receptacle

• 120/240V, 20-amp twist-lock receptacle

120 Volt

30 Amp

Ground

(Green)

120/240 Volt

20 Amp

Y

(Hot)

120V, 15-Amp Duplex

V olts

120V, 30-Amp

Twist-Lock

O nly

Full P ow er

0

Sele r

100

200

AC VOLTS

30

120

/24

0V

Ou tpu t V olta ge

120/240V, 20-Amp

Twist-Lock

Figure 16 – Receptacle Locations

120

/24

0 V olts

POWER CORD AND PLUG REQUIRE-

MENTS

120V, 30-amp twist-lock receptacle

• NEMA L5-30P plug

• Three-wire, 30-amp cord

120/240V, 20-amp twist-lock receptacle

• NEMA L14-20P (20-amp) plug

• Four-wire, 20-amp cord

Ground

(Green)

Y

(Hot)

X

(Hot)

X

(Hot)

W

(Neutral)

Y X

G

Neutral

120V 120V w

Y X

G

Ground

L5-30P

Plug

L14-20P

Plug

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 and 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

(Model 4W315B only – see Oil Alert

System, page 5). Make sure oil level is full before starting. See Engine Oil, page 8.

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

12



Operation

(continued)

O

S

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

Follow the directions below to bleed fuel line.

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.

Fuel Valve

Lever

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

Position

3. For Model 3ZC06B: Push engine run/ stop knob down to the RUN position

(see Figure 19). Turn engine run/stop knob clockwise to tighten. Tighten firmly.

STOP

RUN

Start

Model

3ZC06B

Engine Run/

Stop Knob

STARTING

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

Engine Run

Lever

Model

4W315B

Figure 19 - Engine Run/Stop Knob (Model

3ZC06B) and Engine Run Lever (Model

4W315B)

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.

For Model 4W315B: Move engine run lever to the RUN position (see Figure

19).

4. Start the engine.

a. Electric Starter (Model 4W315B only)

(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.

Decompression

Lever

OIL

OIL

Figure 20 - Decompression Lever

®

13




Operation

(continued)

(3) Turn the starting key clockwise to the START position (see Figure 21).

Hold it there until engine starts.

Starting Key

Rubber Plug

OIL

OIL

Engine

Starting

Oil Hole

OIL

CHARGE

OFF

Figure 22 - Rubber Plug On Rocker Arm

Cover

Figure 21 - Starting Key (Model 4W315B only)

(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.

In cold weather, your engine may be hard to start. If so, remove the rubber plug on the rocker arm cover (see Figure

22). Add 2 cc of engine oil in hole.

Replace rubber plug. Repeat starting procedure.

Never use gasoline, paint thinner, or any other flammable liquid as a starting aid. An explosion may occur.

Keep rubber plug on rocker arm in place when not adding oil for starting.

Rain, dirt, and other debris may enter the engine. This can damage the engine.

b. Recoil Starter (Models 3ZC06B and

4W315B)

(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 23).

Decompression lever will stay in this position until you pull starter rope.

Decompression

Lever

OIL

OIL


(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.

In cold weather, your engine may be hard to start. If so, remove the rubber plug on the rocker arm cover (see Figure

22). Add 2 cc of engine oil in hole.

Replace rubber plug. Repeat starting procedure.

Never use gasoline, paint thinner, or any other flammable liquid as a starting aid. An explosion may occur.

Keep rubber plug on rocker arm in place when not adding oil for starting.

Rain, dirt, and other debris may enter the engine. This can damage the engine.

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.

14



Operation

(continued)

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 up to 3-times their rated 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 Genera-

tor, 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. For Model 3ZC06B: Turn engine run/ stop knob counterclockwise to release.

The run/stop knob will return to the

STOP position automatically (see Figure

24).

For Model 4W315B: Push down engine stop lever (see Figure 24). This releases engine run lever and stops engine. Do not stop engine with the decompression lever.

ST

OP

RUN

STOP

Model

3ZC06B

Engine Run/

StopKnob in Stop

Position

Model

4W315B

Engine Stop Lever

Figure 24 - Releasing Engine Run/Stop

Knob (Model 3ZC06B) and Pushing Down

Engine Stop Lever (Model 4W315B)

4. For Model 4W315B: Turn the starter key to the OFF position.

5. Turn fuel valve lever off. Do this by moving valve lever to the “S” position

(see Figure 25).

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.

S

O

Fuel Valve Lever

Figure 25 - 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.

®

15





(continued)

Non-engine parts 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 Parts Company of America at 1-

800-323-0620.

Yanmar engine servicing should be handled by your nearest authorized

Yanmar engine service firm. Contact

Yanmar at 1-714-630-9415 for 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.

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

After the engine has been used, use of replacement parts which are not of equivalent quality may damage the engine.

Only use genuine

Yanmar parts. The

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 operation.

CHANGING THE AIR CLEANER ELE-

MENT

Do not wash the air cleaner element with detergent because this is a wet-type element. Change air cleaner element every six months or 500 hours 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 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 operation. Replace fuel filter every year or 1000 hours 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 muffler and the spark arrester will be very hot. Allow these to cool before proceeding.

If the engine has been running, the

Remove the lock nut, end cap and diffuser discs and clean off the carbon deposits.

Clean spark arrester every three months or

100 hours operation (or earlier if dirty).

Clamp

Spark

Arrester

Diffuser

Discs

Muffler

End Cap

Figure 26 - Spark Arrester

Lock Nut

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.

16




(continued)

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 BAT-

TERY FLUID AND CHARGING THE

BATTERY (MODEL 4W315B ONLY)

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).

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

Do not charge the battery with the

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-vented area 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.

ENGINE STORAGE

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

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

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

3. Remove the rubber plug on the rocker arm cover and add about 2cc of lube oil. Put the plug back in place (see

Figure 27).

Rubber

Plug

Engine

Starting

Oil Hole

OIL

OIL

Figure 27 - Rubber Plug On Rocker Arm

Cover

4. Recoil starting

Push the decompression lever down

(non-compression position, see Figure

28) and hold it while you pull the recoil starter 2 or 3 times. (Do not start the engine.)

Electric starting

Push the decompression lever down

(non-compression position, see Figure

28) and hold it. With key in START position, turn engine for 2 to 3 seconds.

(Do not start the engine.)

Decompression

Lever

OIL

OIL


5. Pull the decompression lever up. 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.

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

®

17




Item

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

Daily

Check

Service

Monthly

Service

First

Month or 20 Hrs.

Service

Every

3 Months or 100 Hrs.

Service

Every

6 Months or 500 Hrs.

Service

Every

Year or 1000 Hrs.

Special tools and skills required

No special tools or skills required

18



Wiring Diagrams

Green/Yellow

120/240V 20A

Receptacle

Red

White

Red

Green

120V, 15A

Receptacle

120V, 30A

Receptacle

White

T1

Circuit

Breaker

25A

Black

T2

Full Pwr

Selector

Switch

Red

Red

Circuit

Breaker

25A

T4

Yellow

Black

T3

Black

White

Black

Black

Red

Green

Yellow Voltmeter

Red

*

Red

Black

White

Green

* Remove Jumper Bar, This Side Only

Capacitor

White

White

T1 T4 T3 T2

Main

Windings

Auxiliary

Phase

Green

T2 T1

Red

Black

T3

Yellow

T4

Diode

Rotor

Diode

Stator

White

Brown

Black

Circuit

Breaker

20A

Black

Circuit

Breaker

20A

T2

Stator

T3 T1 T4

220/240V

L1

110/120V 110/120V

L2

Figure 29 - Alternator Wiring Diagram

Charge

Coil

Green/White

Green/White

Charge

Regulator

Green

Yellow

White

Fuse

White

4

1

2

3

Green

Green

Yellow

White

Red

Key

Switch

Charge

Lamp

White

Starter

Motor/

Solenoid

Red

Shutdown

Solenoid

Green/White

Red +

Bridge

-

Black

Battery

Red 30

86

Red

87

Relay

85 White

Yellow

P

Oil

Pressure

Switch

Black

Green/White

Red White

Low Oil

Pressure Lamp

Black

Figure 30 - Engine Wiring Diagram (Model 4W315B only)

Black

19


®


Dayton Diesel Electric Generator

Please provide following information:

-Model number

-Serial number (if any)

-Part descriptions and number as shown in parts list

Address parts correspondence to:

Parts Company of America

1657 Shermer Road

Northbrook, IL 60062-5362

3ZC06B

1

5

2

5

4

8

3

9

11

5

4

10

9

7

6

14

12

10

13

13

10

Figure 31 – Replacement Parts Illustration for Model 3ZC06B Roll Cage

20


Model 3ZC06B Roll Cage

11

12

13

14

8

9

6

7

10

Reference

Number

1

2

3

4

5

Description

Roll cage

Spreader

5/16-18 x 1 1/2" Bolt

5/16" Washer

5/16-18 Nut

1/2-20 x 1" Screw

1/2" Lockwasher

Shock mounts

5/16-18 x 3/4" Bolt

5/16" Washer

Shock mount

Ground strap

1/4-20 x 1/2" Screw

#8-18 x 1/2" Sems screw

Safety information decal

Operation decal

( ) Not shown.

Part No. For

Model 3ZC06B

100478-01

099945-01

04110002

WP-5C

NEC-5C

26302006

WLI-8

17529000

26007004

WLE-5

26020000

14138000

M10908-74

100410-01

099947-01

100473-01

3ZC06B

2

4

1

1

1

1

2

5

2

2

3

Quantity

1

1

2

5

7

21


®




-Model number





1657 Shermer Road


4W315B

1

F

E

2

3

5

9

15

9

4

9

8

7

12

6

13

16

11

10

8

14

13

9

8

17

20

18

14

19

19

14

Figure 32 – Replacement Parts Illustration for Model 4W315B Fuel Tank and Roll Cage

22


Model 4W315B Fuel Tank and Roll Cage

18

19

20

15

16

17

11

12

13

14

8

9

6

7

10

Reference

Number

1

2

3

4

5

Description

Fuel tank assembly

1/4-20 x 3/4" Screw

1/4" Washer

1/4-20 Nut

Roll cage

Spreader

5/16-18 x 1 1/2" Bolt

5/16" Washer

5/16-18 Nut

1/2-20 x 1" Screw

1/2" Lockwasher

Shock mounts

5/16-18 x 3/4" Bolt

5/16" Washer

Shock mount

Battery bracket

Hook bolt

Ground strap

1/4-20 x 1/2" Screw


Safety information decal

Operation decal

Battery cable (positive)

Battery cable (negative)

( ) Not shown.

Part No. For

Model 4W315B

099935-01

HC4-6C

WP-4C

NTC-4C

099943-01

099945-01

04110002

WP-5C

NEC-5C

26302006

WLI-8

17529000

26007004

WLE-5

26020000

099749-01

099750-01

14138000

M10908-74

100410-01

099947-01

099948-01

099873-01

099873-02

23

4W315B

5

3

2

2

5

9

1

2

2

Quantity

1

4

4

4

1

4

1

1

2

1

1

1

1

1

2


®

3ZC06B and 4W315B




-Model number





1657 Shermer Road


22

14

9

1

2

8

7

5

6

9

10

4

3

25

11

12

13

15

16

17

18

19

20

21

23

24

Figure 33 – Replacement Parts Illustration for Models 3ZC06B and 4W315B Alternator Assembly

24


Models 3ZC06B and 4W315B Alternator Assembly

3ZC06B and 4W315B

18

19

20

21

22

15

16

17

23

24

25

†

11

12

13

14

8

9

6

7

10

Reference

Number

1

2

3

4

5

Description

End cover

M5 x 13 Screw

Bushing

Terminal block (4-block)

Terminal block (2-block)

Ground lug

#10-16 x 3/8" Screw

Stator bolt

5/16" Lockwasher

Bearing housing

Capacitor

Stator

Fan bracket

M8 x 20 Screw

Rotor nut

Washer

Draw bolt

Bearing

Diode

Rotor

Fan

Engine flange

3/8-16 x 5/8" Bolt

3/8" Lockwasher

Foam pad

Alternator assembly complete

(†) Includes reference numbers 1 through 25.

27001010

27003013

099842-01

27003003

27003012S

099839-02S

27003008

27003007

26322006

WLE-6

099892-01

099723-01

Part No. For Models:

Model 3ZC06B

099844-01

099701-01

099760-01

099863-01

099863-02

17587000

M11084-26

099847-01

WLE-5

099843-01

27004002S

099840-02S

27003002

27003015

27001010

27003013

099842-02

27003003

27003012S

099839-03

27003008

27003007

26322006

WLE-6

099892-01

099723-02

Model 4W315B

099844-01

099701-01

099760-01

099863-01

099863-02

17587000

M11084-26

099847-02

WLE-5

099843-01

27005003S

099840-03S

27003002

27003015

1

1

1

2

1

1

1

1

1

1

4

4

1

4

1

1

4

4

1

1

1

Quantity

1

6

1

1

1

25


®

3ZC06B and 4W315B




-Model number





1657 Shermer Road


1

8

RESET

RESET

120 VOLTS

0 100

200

AC

V

OL

TS

30

11

2

2

3

4

120 ONLY

FULL POWER

SELECTOR

120/240V

OUTPUT VOLTAGE

120/240 VOLTS

RESET

RESET

6

13

5

10

9

7

6

12 12

Figure 34 – Replacement Parts Illustration for Models 3ZC06B and 4W315B Control Panel

26


Models 3ZC06B and 4W315B Control Panel

3ZC06B and 4W315B

10

11

12

13

7

8

9

Reference

Number

1

2

3

4

5

6

Description

Control panel

20 Amp Circuit breaker *

120V, 30A Twist-lock receptacle *

120V, 15A Duplex receptacle *

Full power selector switch *



120/240V, 20A Twist-lock receptacle *

Voltmeter

Bushing


Control box

U-nut

Switch Plug

Panel schematic decal

( ) Not shown.

(*) Includes fastening hardware.

Part No. For Models:

Model 3ZC06B

099775-10

22616009

099833-01

099836-01

099956-01

22616009

—

099834-01

099748-01

099760-01

100410-01

100149-01

22261000

099997-01

099872-01

Model 4W315B

099775-05

22616009

099833-01

099836-01

099956-01

—

22616011

099834-01

099748-01

099760-01

100410-01

100149-01

22261000

099997-01

099872-01

8

1

4

1

1

1

1

2

2

1

Quantity

1

2

1

1

1

27


®




-Model number





1657 Shermer Road


4W315B

3

2

5

17

16

15

20

12

6

13

10

12

11

3

3

18

9

7

8

19

24

24

23

21

24

24

22

14

Figure 35 – Replacement Parts Illustration for Model 4W315B Switch Control Box

28


Model 4W315B Switch Control Box

11

12

13

14

8

9

6

7

10

Reference

Number

1

2

3

4

5

18

19

20

21

22

15

16

17

23

24

Description

Switch control box

Low oil light

Key switch, lamp, and harness assembly

#8-18x 1/2" Sems screw

Strain relief bushing

1/4-20 x 5/8" Hex Head Sems

Relay

#10-32 Hex locknut

Adhesive-backed PVC foam

Connector

#6-32 x 1/2" Hex tapping screw

#6 Internal-tooth lockwasher

Full bridge

#8-32 x 3/8" Screw

Grommet

#10 Flat washer

#10-32 x 3/4" Hex-head screw

Solenoid

M4 x 8 Hex-head screw

M3 x 8 Hex-head screw

Control Box Cover

Cable

Conduit

1/4-28 Keps Nut

Wire Nut

( ) Not shown.

15020000

WP-3C

26499000

26490000

26494000

26492000

101038-01

101036-01

101035-01

101039-01

101042-01

Part No. For Model:

Model 4W315B

101037-01

22721000

099936-01

100410-01

099760-01

101040-01

26498000

NTF-3C

RN12000100

24477004

M10908-3

WLI-1C

26509000

26002006

4W315B

4

1

1

2

1

1

1

1

1

4

1

1

4

1

5

1

1

2

1

1

Quantity

1

1

1

4

1

29


®



Troubleshooting Chart

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

Symptom

No voltage when starting generator with no electrical load

Voltage is less than normal voltage with no electrical load

Voltmeter reading more than 10% high with no electrical load

Voltmeter reading correct with no electrical load, but more than 10% low when electrical load is added

Engine will not start person should service and repair generator. Use only factory approved replacement parts.

Only a qualified electrical service

Possible Cause(s)

1. Defective capacitor

2. Winding short circuit or loose connections

3. Defective rotor diode

4. Loss of residual magnetism

1. Engine speed too low

2. Clogged spark arrester


4. Partial short circuit in winding

5. Defective capacitor

1. Engine speed too high


2. Electrical load too high

3. Engine not running properly

1. Fuel level too low

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

3. Diesel fuel not reaching the fuel injection pump or nozzle

4. Speed control lever not in START position

5. Lube oil level not correct

6. Fuel injection nozzle not working right

7. Recoil starter not pulled quickly and firmly enough

8. Spark arrester clogged by carbon

9. Battery not discharging

Corrective Action

1. Replace capacitor

2. Check resistance of coils (see Electrical

Component Specifications, page 2)

3. Replace both diodes on rotor

4. Apply 12-volt battery to capacitor terminals for 2-3 seconds

1. Set engine speed to 3720 RPM (62 Hz) with no load

2. Clean arrester. See engine owner’s manual


4. Check resistance of coils (see Electrical

Component Specifications, page 2)

5. Replace capacitor

1. Set engine speed to 3720 RPM (62 Hz) with no load


2. Do not overload generator

3. Contact an authorized engine service center

1. Add fuel to fuel tank

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

3. See qualified Yanmar service person

4. Move speed control lever to START position

5. Add lube oil to engine.

6. See qualified Yanmar service person

7. When starting engine with recoil starter, pull starter rope quickly and firmly. You must pull starter rope all the way out.

8. Clean spark arrester. See Cleaning the

Spark Arrester, page 16

9. Loose battery connections, corrosion on battery terminals, or battery dead

30

Dayton Operating Instructions and Parts Manual 3ZC06B and 4W315B

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31


3ZC06B and 4W315B



NOTE: The five-year limited warranty below covers all non-engine parts of this generator including the alternator. Yanmar warrants the engine. See engine owner’s manual for engine warranty information.

LIMITED WARRANTY

Dayton Five-Year Limited Warranty. Professional-duty electric generator alternators, Models 3ZC06B and 4W315B, are warranted by Dayton Electric Mfg. Co. (Dayton) to the original user against defects in workmanship or materials under normal use for five years after date of purchase. Any part which is determined by Dayton to be defective in material or workmanship and returned to an authorized service location, as Dayton designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at

Dayton’s option. For limited warranty claim procedures, see PROMPT DISPOSITION below. This limited warranty gives purchasers specific legal rights which vary from state to state.

Limitation of Liability. To the extent allowable under applicable law, Dayton’s liability for consequential and incidental damages is expressly disclaimed. Dayton’s liability in all events is limited to, and shall not exceed, the purchase price paid.

Warranty Disclaimer. Dayton has made a diligent effort to illustrate and describe the products in this literature accurately; however, such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose, or that the products will necessarily conform to the illustrations or descriptions.

Except as provided below, no warranty or affirmation of fact, expressed or implied, other than as stated in “LIMITED WARRANTY” above is made or authorized by Dayton.

Product Suitability. Many states and localities have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While Dayton attempts to assure that its products comply with such codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, please review the product application, and national and local codes and regulations, and be sure that the product, installation, and use will comply with them.

Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some states do not allow limitations on how long an implied warranty lasts, consequently the above limitation may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties of merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.

Prompt Disposition. Dayton will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address, date and number of dealer’s invoice, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, file claim with carrier.

Manufactured for Dayton Electric Mfg. Co., Niles, IL 60714 U.S.A.

Manufactured for Dayton Electric Mfg. Co.

Niles, Illinois 60714

© 1993 W.W. Grainger, Inc.

Printed in U.S.A.

03430

1193/325/VP

100851-01

Rev. B

01/94


®

Dayton 4W315B Operating instructions

Dayton Diesel Electric

Generator

Description

Unpacking

Specifications

Product Identification

General Safety Information

General Safety Information

Generator Features

Generator Features

Generator Features

Assembly

Assembly

Installation

Installation

Installation

Operation

Operation

Operation

Operation

Maintenance and Repairs

Maintenance and Repairs

Maintenance and Repairs

Storage

Wiring Diagrams

Model 3ZC06B Roll Cage

Model 4W315B Fuel Tank and Roll Cage

Models 3ZC06B and 4W315B Alternator Assembly

Models 3ZC06B and 4W315B Control Panel

Model 4W315B Switch Control Box

Troubleshooting Chart

LIMITED WARRANTY

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