DAYLIFF DG1200E Installation instructions

DG
Installation &
Operating Manual
Portable Petrol Generators
DG7500PS
DG1200E/3000P/E
5000P/ /7500P6500E
DG3800PT/
6500PT/9000PT
DG4000PSi

GENERATOR SPECIFICATIONS
1.
1
2.
SAFETY WARNINGS 3
CONTROLS
3.
3
ELETRICAL CONNECTIONS
4.
4
GENERATOR OPERATION
5.
4
INDEX
© Davis & Shirtliff Ltd 2023
Contents herein are not warranted
ROUTINE MAINTENANCE
6.
4
TROUBLE SHOOTING
7.
5
WARRANTY
8.
7

1
1. GENERATOR SPECIFICATIONS
The Dayliff range of portable petrol generators are dependable quality products specially
designed for mains standby and remote site power supply applications. Particular
features are:-
• Reliable and economic air cooled OHV petrol engines equipped with large size
exhausts and air cleaners for low noise operation.
• High efficiency square core alternators providing consistent AC power output.
• .DC output option for powering DC appliances
• Option of strong tubular frame, trolley mount (T-suffix), canopied (S-suffix) and
Economy (E-suffix) low-cost models suited for less severe applications.
• Integrated control panel with selection of different controls for operational
convenience.
• Fuseless type over current protection.
• DG1200EOil alert system to stop engine in the event of low oil level (not ).
• .High capacity fuel tank for extended operation
Also available is the high specification DG4000PSi model that includes inverter
technology with the following features:-
• High specification petrol engine incorporating automatic speed control that
adjusts engine speed to load leading to reduced operating fuel consumption,
reduced emissions and quieter operation.
• Square core alternator fitted with a digital inverter that gives regulated 50Hz
frequency and perfect sine wave output suitable for all types of sensitive electronic
equipment.
Congratulations on selecting a Dayliff DG Generator. They are manufactured
to the highest standards and if installed and operated correctly will give
many years of efcient and trouble free service. Careful reading of this
Installation Manual is therefore important, though should there be any
queries they should be referred to the equipment supplier.
DG7500PS/
DG11000PS
DG1200P/3000P/E
5000P/ /7500P6500E
DG3800PT/
6500PT/9000PT DG4000PSi

2
Dayliff DG generators are of compact design and their advanced features, reliability and
economy of operation make them the ideal solution for all small scale power supply
requirements.
*Acoustic Set with AMF, noise level: 70dBA@7m, ** T Suffix indicates Trolley Mount, ***I denotes inverter set
DERATING: Given outputs are sea level ratings. Sets should be derated at 1% for every
0 0
100m higher than 100m above sea level, and 2% for every 5 C temperature above 20 C
for naturally aspirated engines
ELECTRICAL DATA
Alternator: Self exciting, 2 pole Power Output: 50Hz, 240V, single phase
Voltage Regulator: AVR Power Factor: 1
Speed:3000rpm Direct Current:12V/8.3A
GENERAL DATA
Fuel
tank
capacity
(litres)
Starter
Opera-
ting
Period
(Hrs)
Model Rated
(kVA)
Max
(kVA)
Output
Model
Engine
Capacity
(cc)
Max
Power (HP)
4.0
15
420 1665.5 GK420, 4T
7.8
7.1
28 Electric/Recoil
GK420, 4T 420 16
5.55
7.0 Recoil
5.5
98 3.5
1.0 156F,4T
0.9
7.7
7.0
15
12
Recoil
Recoil
212
220
7
7
2.5
2.8
2.3
2.5
GK210,4T
170,4T
6.6
17 Recoil
223 7.5 3.53.2 GK225,4T
Electric/Recoil
Recoil
Electric/Recoil
7.8
25
25
420
420
16
16
4.5
5.5
4
5
GK420,4T
LV420,4T
6.2
28 Electric/RecoilElectric/Recoil
459 18
7.0
6.5 GK460, 4T
6.5
25
420 166.56 GK420, 4T Electric/Recoil
Electric/Recoil
10 5.0
223 7.5
4.0
3.6 GK225,Vi
DG 7500PS*
DG 6500PT**
DG 1200E
DG 3000P
DG 3800PT**
DG 5000P
DG 9000PT**
DG 7500P
DG 4000PSi***
DG 3000E
DG 6500E
SPECIFICATIONS
Model
460
590
685
685
L
(mm)
685
630
600
685
720
1000
720
366
433
512
512
W
(mm)
512
470
440
460
530
520
530
370
460
550
550
H
(mm)
550
530
430
525
610
740
610
25
41
74.4
Weight
(kg)
85
50
39.3
42
76
72.6
126
85
DG3000P
DG5000P
DG7500P
DG3800PT**
DG6500PT**
DG9000PT**
DG1200E
DG7500PS*
DG4000PSi***
Hour Meter Voltmeter
Digital Multimeter-Volts,Hz & Hours
Digital Multimeter-Volts,Hz & Hours
Digital Multimeter-Volts,Hz & Hours
Breaker
on
Indicator
Oil
Alert
System
AC Power Output
1 No. Plug Socket
1 No. Plug Socket+1 No. CEE Socket
2 No. Plug Socket
1 No. Plug Socket
1 No. Plug Socket+1 No. CEE Socket
2 No. Plug Socket
DG3000E
DG6500E

3
2. SAFETY WARNINGS
Instruction
Manual
!
Gasoline
Read and carefully understand the Instruction Manual
before use.
Avoid proximity to fire when refueling highly
inflammable!
Ensure good ventilation around the generator and do
not operate indoors.
Exhaust gases are very poisonous
Do not use generator on a slope.
Fuel spillage may occur and cause a fire.
Do not restrict the exhaust silencer.
There is a danger of overheating and fire.
Do not connect generators together.
Generator damage will occur.
Ensure a competent trained person is used in case of
overhaul.
3. CONTROLS
All generators are fitted with the following:-
Ÿ2no. 3 pin AC outlets, +ve and -ve DC connections. DG950 with one outlet.
ŸEngine on/off switch.
ŸMagnetic circuit breaker electric cutout.
ŸVoltmeter (not DG950)
W
L
H

4
6. ROUTINE MAINTENANCE
For Diesel engines see separate engine manual. The below instructions apply to petrol
versions only.
ENGINE OIL
ŸCheck engine oil daily. If low refill with SAE30.
ŸEnsure total load does not exceed the generator rating. Maximum power output must
only be used briefly or generator damage will occur.
ŸDC output to be used for charging automotive and solar 12V batteries only. Ensure
correct polarity when connecting cables, i.e +ve to +ve and -ve to -ve generator to
battery terminals.
ŸEnsure the generator is properly earthed. Consult a qualified electrician if in doubt.
ŸCHECK ENGINE OIL. Operating without oil will cause severe engine damage and
invalidate the warranty.
ŸTo start ensure ignition ‘ON’, fuel valve ‘ON’ and choke ‘ON’. Then either pull starter
cord (manual start) or turn key (electric start). For electric start do not turn the engine
on for more than 5 seconds. If ti fails to start release the switch and wait 15 seconds
before re-trying. Switch off choke when engine has started.
ŸCheck output voltage is 240V on the voltmeter. If not adjust engine speed. If the speed
setting is correct and the voltage is low then the generator is overloaded and load must
be reduced.
ŸIf more than an appliance is connected apply load progressively with greatest load
first.
Ÿ Close fuel valve whenever generator is not operating.
ŸDG950 generators use two-stroke engines and oil must be pre-mixed with petrol at
the ratio of 50:1. Use fuel tank cap as an oil measure adding one inverted capfull for
each litre of fuel. Engine damage will occur without pre-mixed oil.
5. GENERATOR OPERATION
WARNING
Always start generator before applying load by switching the
circuit breaker and stop the generator after disconnecting
load. Starting and stopping under load will damage the
generator and powered accessories.
4. ELECTRICAL CONECTIONS
WARNING
If the generator is to be connected for standby power use
ensure a qualied electrician is employed. The generator must
be isolated from the utility power when connected or serious
damage will result to the generator and house power circuits.
ŸEnsure total load does not exceed the generator rating. Maximum power output must
only be used briefly or generator damage will occur.

5
No Electrical
output Circuit breaker tripped
Reduce generator load
Check for short circuit in load
Loose connection in output cable
Right engine oil to drain
Oil leakage
from muffler or
air cleaner Engine has tipped over
Engine does
not start
Clean carburettorCarburettor is blocked
Clean and adjust plugSpark plug is wet / dirty
Clean air cleanerAir cleaner dirty
Reduce oil to suitable level
Too much engine oil
Oil sensor is activated. Add oil
(Oil sensor prevents engine
from running if oil level is low)
Insufficient engine oil
No fuel
Check fuel cock open
Clean if fuel filter blocked
Battery flat (Electric start) Charge/replace battery
7. TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
ŸChange engine oil after first month or after 20hrs operation and thereafter every 3
months or 50 hours of operation, in both cases whichever is sooner.
AIR CLEANER
Check the air cleaner every 3 months or after 50 hours operations, whichever is the
sooner. Clean by blowing away accumulated dust and soaking in kerosene.
SPARK PLUG
A correctly set spark plug in good condition is essential for efficient engine operation.
Check the plug every 3 months or after 50 hours operation, clean with a wire brush and
set the electrode gap to 0.7-0.8mm. If general conduction is unsatisfactory it should be
changed with a NGK (BPR5ES) or similar.

6
PROBLEM POSSIBLE CAUSE SOLUTION
Check engine speed
Reduce generator load
Low Electrical
output
Low output voltage
Excessive electrical load

8. TERMS OF WARRANTY
If equipment failure occurs in the normal course of service having been competently
installed and when operating within its specified duty limits warranty will be provided as
follows:-
Ÿ Up to 1 year - The item will be replaced or repaired at no charge.
The warranty on equipment supplied or installed by others is conditional upon the
defective unit being promptly returned free to a Davis & Shirtliff ofce and collected
thereafter when repaired. No element of site repair is included in the warranty and any site
attendance costs will be payable in full at standard charegeout rates. Also proof of
purchase including the purchase invoice must be provided for a warranty claim to be
considered.
ŸIn lieu of any warranty, condition or liability implied by law, the liability of Davis &
Shirtliff (hereafter called the Company) in respect of any defect or failure of equipment
supplied is limited to making good by replacement or repair (at the Company’s
discretion) defects which under proper use appear therein and arise solely from faulty
design, materials or workmanship within a specified period. This period commences
immediately after the equipment has been delivered to the customer and at its
termination all liability ceases. Also the warranty period will be assessed on the basis
of the date that the Company is informed of the failure.
ŸThe warranty applies solely to equipment supplied and no claim for
consequential damages, however arising, will be entertained. Also the warranty
specifically excluded defects caused by fair wear and tear, the effects of careless
handling, lack of maintenance, faulty installation, incompetence on part of the
equipment user, Acts of God or any other cause beyond the Company’s reasonable
control. Also, any repair or attempt at repair carried out by any other party invalidates
all warranties.
i) General Liability
ii) Standard Warranty
7

INS302G-02/20