Operating instructions

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Operating Instructions & Parts Manual

Dayton Professional-

Duty Electric Generators

Description

Dayton professional-duty generators are rugged and compact to provide dependable,

trouble-free service. The alternators are brushless with revolving fields. Honda gasoline

engines provide long life under heavy use. Overhead valves (OHV) provide high perfor-

mance with lower fuel consumption. 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

(except Model 3LW64A), large fuel tank, and oil alert system. Models 3W739D, 5U936D,

and 3LW64A include electric starter.

Form 5S4175

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.

Figure 2 – Models 3W736C, 3W737D, 5U936D, 3W738E, and 3W739D

Figure 1 – Model 3W735B

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 Models

3W739D, 5U936D, and 3LW64A only.

These cables are in a separate bag inside

generator carton. You must install these

cables to engine. See “Battery,” page 8

for installation instructions.

Model 3LW64A only: handles and top

cover packaged separately inside

generator carton. You must install these

parts.

3LW64A, 3W735B, 3W736C, 3W737D,

3W738E, 3W739D, and 5U936D

Version B - For Reduction G016.J

Figure 3 – Model 3LW64A

Printed in U.S.A.

03430

0100 / 011 / VCPVP

Summary of content (40 pages)

PAGE 1
3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Operating Instructions & Parts Manual 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.
PAGE 2
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Specifications ELECTRICAL SPECIFICATIONS Model Rated Wattage* Rated Amperage 120V Rated Amperage 240V 3W735B 2,200 18.3 — 3W736C 4,000 33.3 16.7 3W737D 5,000 41.7 20.8 5U936D 5,000 41.7 20.8 3W738E 6,000 50 25 3W739D 7,000 60 30 3LW64A 10,000 83.3 41.7 * Single-phase, 1.0 power factor NOTE: Ratings apply to SAE standard conditions.
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Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Product Identification Gas Cap/Fuel Gauge GFCI Receptacle F F U E L Control Panel Full Power Selector Switch Roll Cage 12 0 VO LT S RE SE TE T ST FU LL PO WE 12 ON 0 LY R 12 0 24 0V 12 0/2 120 Volt Receptacles 40 EN 00 M 00 00 HO 05 UR S VO LT S RE SE T 1/1 0 Gas Tank RE SE T Hour Meter 120/240 Volt Receptacle F F U E L Circuit Breaker Choke Lever Fue
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Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® 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.
PAGE 5
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D General Safety Information (Continued) Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm. 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.
PAGE 6
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Generator Features (Continued) from the oil level sensing device. This will cause the oil alert system to shut down engine. See engine owner’s manual for more information. 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.
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Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Generator Features (Continued) RECEPTACLE CIRCUIT BREAKER IMPORTANT: You must press the RESET button firmly and fully. It should lock into place. If the GFCI does not lock into place, do not use receptacle. Contact a qualified electrician for repairs. EL FU 2. If the GFCI receptacle tests okay, restore power by pushing the RESET button back in. The test lamp should work at this time.
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Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Assembly (Continued) BATTERY (MODELS 5U936D, 3W739D, AND 3LW64A ONLY) 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.
PAGE 9
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Assembly (Continued) Nut MOUNTING BATTERY TO GENERATOR Battery Mounting Bracket Do not over tighten positive terminal on starter solenoid. Positive terminal could rotate and cut into negative terminal, causing a short. Battery F F U E L To Engine Block To Starter Solenoid F F U E L NOTE: Model 3LW64A battery is located on opposite side as shown (See Figure 16). 1.
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Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Installation FUEL Gasoline presents a hazard of fire or explosion. Gasoline is flammable. Its vapor is explosive. • 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.
PAGE 11
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Installation (Continued) DUST, DIRT, RAIN, AND SNOW Do not use generator outdoors in rain or snow. Do not use generator near standing water or snow. Do not use if generator is wet or damp. Operating generator in these conditions increases the risk of electrocution. Severe injury or death can occur. Do not use generator in extremely dusty or dirty conditions. This will severely affect its life.
PAGE 12
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Installation (Continued) 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 2 for typical appliance wattage examples. 4. Add watts and starting watts (maximum VA) of all items. This total must not be larger than the rated wattage of your generator.
PAGE 13
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Operation HIGH AND LOW TEMPERATURE OPERATION Air temperature affects generator output. Output drops 1% for each 10° temperature rise above 60° F. Very low temperatures may make the engine hard to start. See engine owner’s manual for more information. Use receptacles properly. Improper use could damage generator. Use only grounded extension cords. Power only grounded or double-insulated items.
PAGE 14
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Operation (Continued) 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. NOTE: You may not need to close choke if engine is warm or air temperature is high. 4.
PAGE 15
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Operation (Continued) 5. As engine warms up, slowly move choke lever fully to the right (See Figure 28). This opens the choke. On Model 3LW64A, the choke will automatically open (See Figure 29). AUTO-IDLE OPERATION ADJUSTING THE IDLE SPEED IMPORTANT: Never start engine with electrical loads connected. Start engine before adding electrical loads. IMPORTANT: Adjust the idle speed only: 1.
PAGE 16
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Operation (Continued) Always set the idle speed before turning on the auto-idle. If idle speed is not set, the larger resistor on the control board may become hot. Heat from the resistor may damage the protective coating on the control board. 5.
PAGE 17
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Operation (Continued) 4. Turn fuel valve lever off. Do this by moving valve lever fully to the left (See Figure 35). Fuel Valve Lever (Off Position) 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.
PAGE 18
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Troubleshooting Chart NOTE: See engine owner’s manual for engine troubleshooting. Only a qualified electrical service person should service and repair generator. Use only factory approved replacement parts. Symptom Possible Cause(s) Corrective Action Engine will not start 1. Insufficient fuel 1. Fill tank with fresh fuel 2. Oil level low 2.
PAGE 19
Dayton Operating Instructions and Parts Manual Models 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Wiring Diagrams Stator Black Receptacle 120V/15A 20A T1 T3 T4 110/120V L1 T2 Capacitor L2 Rotor Yellow Stator White Black Auxiliary Phase Diode Diode Circuit Breaker Yellow Red Green Brown T2 T3 T1 Green/Yellow T4 Main Windings Yellow Black Red Green Figure 36 – Wiring Diagram, Model 3W735B Red Black Red 120/240V 20A Receptacle White Circuit Breaker 25A White ck T
PAGE 20
Dayton Operating Instructions and Parts Manual 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Professional-Duty Electric Generators ® Wiring Diagrams White Red Black Red 120/240V 20A Receptacle s1 s2 White • T1 To Solenoid Circuit Breaker 25A Circuit Breaker 20A Black White Hour Meter White Black Green Black Red Green Main Windings Capacitor White T1 T4 T3 Green Red Black Black Red White White LINE T4 Yellow • Circuit Breaker 20A Red Black T3 120V, 30A
PAGE 21
3W735B Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list 1 Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 22
3W735B Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 23
3W735B Dayton Operating Instructions and Parts Manual Replacement Parts List for Model 3W735B Alternator Assembly Reference Number Description Part No.
PAGE 24
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 25
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual Replacement Parts List for Models 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Alternator Assembly Reference Number Description Part No.
PAGE 26
3LW64A Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 27
3LW64A Dayton Operating Instructions and Parts Manual Replacement Parts List for Model 3LW64A Alternator Assembly Reference Number Description Part No. for Model 3LW64A 1 Stator † 1 2 Rotor † 1 3 Draw bolt 103188-01 1 4 Fan 103191-01 1 5 Balancing disc 103192-01 1 6 Lifting eyes 103193-01 2 7 D.E. Bracket 103194-01 1 8 N.D.E.
PAGE 28
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 29
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual Replacement Parts List for Models 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Fuel Tank and Roll Cage Reference Number Description Part No.
PAGE 30
3LW64A Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year 36 Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 31
3LW64A Dayton Operating Instructions and Parts Manual Replacement Parts List for Model 3LW64A Fuel Tank and Roll Cage (Continued) Reference Number Description Part No.
PAGE 32
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 33
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual Replacement Parts List for Models 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Control Panel Reference Number Description Part No.
PAGE 34
3LW64A Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 35
3LW64A Dayton Operating Instructions and Parts Manual Replacement Parts List for Model 3LW64A Control Panel Reference Number Description Part No.
PAGE 36
3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Dayton Operating Instructions and Parts Manual For Replacement Parts, call 1-800-323-0620 24 hours a day - 365 days a year Please provide following information: -Model number -Serial number (if any) -Part description and number as shown in parts list Address parts correspondence to: Grainger Parts P.O. Box 3074 1657 Shermer Road Northbrook, IL 60065-3074 U.S.A.
PAGE 37
Dayton Operating Instructions and Parts Manual 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Replacement Parts List for Solenoid and Control Board Assemblies and Mounting for Models 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Reference Number Description Part No.
PAGE 38
Dayton Operating Operating Instructions Instructions and and Parts Parts Manual Manual Dayton 3LW64A, 3W735B, 3W736C, 3W737D, 3W738E, 3W739D, and 5U936D Notes ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________
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Dayton Operating Instructions and Parts Manual Notes ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________ __________________________________________________________________________________________________________
PAGE 40
Dayton Operating Instructions and Parts Manual 3W735B, 3W736C, 3W737D, 5U936D, 3W738E, 3W739D, 3LW64A Dayton Professional-Duty Electric Generators NOTE: The five-year limited warranty below covers all non-engine parts of this generator including the alternator. Honda warrants the engine. See engine owner’s manual for engine warranty information. LIMITED WARRANTY DAYTON FIVE-YEAR LIMITED WARRANTY. Professional-Duty Electric Generators, Models covered in this manual, are warranted by Dayton Electric Mfg.