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DeWalt DXGN4500 - User Manual

DeWalt DXGN4500
56 pages
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DIAGNOSTIC
REPAIR
MANUAL
PORTABLE GENERATORS
DeWalt Series Portable Generators
Models:
DXGN4500
DXGN6000
DXGN7200
DXGN14000
DXGNR5700
DXGNR7000

Table of Contents

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DeWalt DXGN4500 Specifications

General IconGeneral
BrandDeWalt
ModelDXGN4500
CategoryPortable Generator
LanguageEnglish

Summary

Safety

Read This Manual Thoroughly

Section 1 Capacitive Discharge (Brushless)

Introduction

Overview of generator components and basic operation principles.

Rotor Assembly

Details on the generator's rotating component, poles, and diodes.

Stator Assembly

Description of the stator's three internal windings and configurations.

Circuit Breakers

Explanation of circuit breakers for generator overload protection.

Operation

Steps for startup, on-speed, field excitation, and output.

Troubleshooting Flowcharts

Guides for diagnosing AC output issues based on symptoms.

AC Diagnostic Tests

Procedures for diagnosing generator electrical issues.

Test 1 - Check No-Load Voltage and Frequency

Procedure to measure output voltage and frequency without load.

Test 2 - Check Main Circuit Breaker

Method to test the integrity of the main circuit breaker.

Test 3 - Check Continuity of Receptacle Panel

Verifies continuity of the receptacle panel and wiring connections.

Test 5 - Field Flash Alternator

Procedure to restore residual magnetism for excitation.

Test 6 - Check Capacitor

Steps to test the generator's capacitor for proper function.

Test 7 - Test Brushless Excitation Winding

Checks the resistance and continuity of the excitation winding.

Test 8 - Test Brushless Stator Windings

Tests stator windings for shorts or open circuits.

Test 10 - Check Load Voltage and Frequency

Measures output voltage and frequency under load.

Test 11 - Check Load Watts and Amperage

Verifies generator performance under electrical load.

Section 2 Direct Excitation (Brush Type)

Introduction

Overview of brush-type generator components and operation.

Stator Assembly

Details on the stator's windings and wire color coding.

Brush Holder and Brushes

Description of the brush holder, brushes, and slip rings.

Voltage Regulator

Explains the function of the voltage regulator and its connections.

Operation

Covers startup, on-speed, field excitation, and AC output.

Troubleshooting Flowcharts

Guides for diagnosing AC output issues in brush-type generators.

AC Diagnostic Tests

Procedures for diagnosing generator electrical issues.

Test 1 - Check No-Load Voltage and Frequency

Measures output voltage and frequency without load.

Test 2 - Check Main Circuit Breaker

Method to test the integrity of the main circuit breaker.

Test 3 - Check Continuity of Receptacle Panel

Verifies continuity of the receptacle panel and wiring connections.

Test 4 - Fixed Excitation Test;Rotor Amp Draw Test

Tests rotor excitation and current draw using a battery.

Test Brushed Stator Windings

Checks stator windings for shorts to ground or between windings.

Test 10 - Check Load Voltage and Frequency

Measures output voltage and frequency under load.

Test 11 - Check Load Watts and Amperage

Verifies generator performance under electrical load.

Test 12 - Adjust Voltage Regulator

Procedure to adjust the generator's voltage regulator.

Section 3 Engine Diagnostic Tests

Introduction

Guides for engine troubleshooting and test procedures.

Problem 9 - Recoil Cord Will Not Pull

Troubleshooting steps for a recoil cord that won't pull.

Problem 10 - Engine Starts Hard and Runs Rough

Diagnosing issues causing difficult starting or rough running.

Problem 11 - Engine Turns Over But Will Not Start

Steps to diagnose why the engine cranks but won't ignite.

Problem 12 - Engine Hunts; Erratic Idle

Troubleshooting steps for unstable engine speed or erratic idling.

Problem 13 - Engine Will Not Crank

Diagnosing why the engine fails to crank when the start switch is activated.

Problem 14 - Recoil Cord Will Not Pull (If So Equipped)

Troubleshooting for recoil cord issues on equipped models.

Problem 15 - Engine Cranks But Will Not Start

Steps to diagnose why the engine cranks but fails to start.

Problem 16 - Engine Starts Hard and Runs Rough

Diagnosing causes of difficult starting and rough engine operation.

Problem 17 - Engine Starts Then Shuts Down

Troubleshooting for engines that start and then stop shortly after.

Problem 18 - Battery Will Not Charge

Steps to diagnose why the generator's battery is not charging.

Problem 19 - Engine “Hunts”; Erratic Idle

Diagnosing unstable engine speed and erratic idling issues.

Problem 20 - Unit Will Not Idle

Troubleshooting steps for a generator that will not idle correctly.

Problem 21 - Unit RPM Will Not Increase From Idle

Diagnosing why the engine RPM does not increase from idle.

Problem 22 - No Display from Wattage;Runtime Meter

Steps to troubleshoot a non-functional wattage/runtime meter.

Problem 23 - Wattage;Runtime Meter Display is Flashing Erroneous Data

Diagnosing issues with incorrect data on the meter display.

Test 14 - Check Fuse

Procedure to inspect and test the fuse for continuity.

Test 15 - Check Battery & Cables

Inspecting battery, posts, and cables for corrosion or tightness.

Test 16 - Check Voltage at Starter Contactor (SC)

Verifying voltage at the starter contactor during cranking.

Test 17 - Check Start-Run-Stop Switch

Testing the functionality of the START-RUN-STOP switch.

Test 18 - Test OFF-ON Switch

Verifying the operation of the OFF-ON switch for engine shutdown.

Test 19 - Check Starter Motor

Inspecting the starter motor for proper operation and potential issues.

Test 20 - Check Ignition Spark

Using a spark tester to verify ignition system function.

Test 21 - Check Spark Plug(s)

Inspecting spark plugs for fouling, damage, or wear.

Test 22 - Check Carburetion

Steps to check fuel supply, choke, and carburetor for starting issues.

Test 23 - Choke Test

Testing the choke's effect on engine surging or RPM.

Test 24 - Check Valve Adjustment

Procedures for adjusting engine valve clearance.

Test 25 - Check Engine; Cylinder Leak Down Test; Compression Test

Assessing engine sealing and compression capability.

Test 26 - Check Ignition Coil

Testing the ignition coil for resistance and spark output.

Test 27 - Check Flywheel

Checking flywheel magnetism and key for ignition issues.

Test 28 - Remove Shutdown Wire

Testing the shutdown wire for integrity and shorts.

Test 30 - Check; Adjust Governor (Mechanical)

Adjusting the governor for correct engine speed and frequency.

Test 31 - Check Oil Pressure Switch (if equipped)

Diagnosing engine shutdown due to low oil pressure or faulty switch.

Test 32 - Check Oil Level Switch (if equipped)

Testing the oil level switch for proper operation.

Test 33 - Test Recoil Function

Checking the recoil starter for ease of pull and return.

Test 34 - Test Engine Function

Basic check for engine seizure or internal failure.

Test 35 - Test Battery Charger

Verifying the generator's battery charging system.

Test 36 - Test Idle control

Testing the low idle control system and its components.

Section 4 Major Disassembly

Introduction

Overview of the general disassembly process for the generator.

Section 5 Electrical Data

Introduction

Guidance on accessing wiring diagrams and schematics.

Wiring Diagram and Electrical Schematic, DXGN4500

Electrical schematic for the DXGN4500 model generator.

Wiring Diagram and Electrical Schematic, DXGN6000

Electrical schematic for the DXGN6000 model generator.

Wiring Diagram and Electrical Schematic, DXGN7200

Electrical schematic for the DXGN7200 model generator.

Wiring Diagram and Electrical Schematic, DXGN14000

Electrical schematic for the DXGN14000 model generator.

Wiring Diagram and Electrical Schematic, DXGNR5700

Electrical schematic for the DXGNR5700 model generator.

Wiring Diagram and Electrical Schematic, DXGNR7000

Electrical schematic for the DXGNR7000 model generator.

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