DeWalt DXGN4500 User Manual

DeWalt DXGN4500

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DIAGNOSTIC

REPAIR

MANUAL

PORTABLE GENERATORS

DeWalt Series Portable Generators

Models:

DXGN4500

DXGN6000

DXGN7200

DXGN14000

DXGNR5700

DXGNR7000

Table of Contents

Read this Manual Thoroughly2
Replacement Parts2
Table of Contents3
Section 1 Capacitive Discharge (Brushless)5
- Introduction5
- Rotor Assembly5
- Stator Assembly5
- Circuit Breakers6
- Operation6
- Troubleshooting Flowcharts7
- AC Diagnostic Tests9
- Test 1 - Check No-Load Voltage and Frequency9
- Test 2 - Check Main Circuit Breaker9
- Test 3 - Check Continuity of Receptacle Panel9
- Test 5 - Field Flash Alternator10
- Test 6 - Check Capacitor11
- Test 7 - Test Brushless Excitation Winding11
- Test 8 - Test Brushless Stator Windings12
- Test 10 - Check Load Voltage and Frequency12
- Test 11 - Check Load Watts and Amperage12
Section 2 Direct Excitation (Brush Type)15
- Introduction15
- Stator Assembly15
- Brush Holder and Brushes15
- Voltage Regulator15
- Operation16
- Troubleshooting Flowcharts17
AC Diagnostic Tests19
Test 1 - Check No-Load Voltage and Frequency19
Test 2 - Check Main Circuit Breaker19
Test 3 - Check Continuity of Receptacle Panel19
Test 4 - Fixed Excitation Test/Rotor20
- Amp Draw Test20
Test Brushed Stator Windings22
Test 10 - Check Load Voltage and Frequency22
Test 11 - Check Load Watts and Amperage22
Test 12 - Adjust Voltage Regulator23
Section 3 Engine Diagnostic Tests25
Introduction25
- Problem 9 - Recoil Cord will Not Pull25
- Problem 10 - Engine Starts Hard and Runs Rough25
- Problem 11 - Engine Turns over but will Not Start26
- Problem 12 - Engine "Hunts" / Erratic Idle27
- Problem 13 - Engine will Not Crank27
- Problem 14 - Recoil Cord will Not Pull (if so Equipped)27
- Problem 15 - Engine Cranks but will Not Start28
- Problem 16 - Engine Starts Hard and Runs Rough29
- Problem 17 - Engine Starts then Shuts down29
- Problem 18 - Battery will Not Charge30
- Problem 19 - Engine "Hunts" / Erratic Idle30
- Problem 20 - Unit will Not Idle31
- Problem 21 - Unit RPM will Not Increase from Idle31
- Problem 22 - no Display from Wattage/Runtime Meter32
- Problem 23 - Wattage/Runtime Meter Display Is Flashing Erroneous Data32
Introduction33
Test 14 - Check Fuse33
Test 15 - Check Battery & Cables33
Test 16 - Check Voltage at Starter33
- Contactor (SC)33
Test 17 - Check Start-Run-Stop Switch33
Test 18 - Test OFF-ON Switch34
Test 19 - Check Starter Motor34
Test 20 - Check Ignition Spark35
Test 21 - Check Spark Plug(S)35
- Test 22 - Check Carburetion36
- Test 23 - Choke Test36
- Test 24 - Check Valve Adjustment36
- Test 25 - Check Engine / Cylinder Leak down37
  - Test / Compression Test37
- Test 26 - Check Ignition Coil38
- Test 27 - Check Flywheel39
- Test 28 - Remove Shutdown Wire39
- Test 30 - Check / Adjust Governor (Mechanical)39
- Test 31 - Check Oil Pressure Switch40
  - (If Equipped)40
- Test 32 - Check Oil Level Switch (if Equipped)40
- Test 33 - Test Recoil Function41
- Test 34 - Test Engine Function41
- Test 35 - Test Battery Charger41
- Test 36 - Test Idle Control41
Section 4 Major Disassembly43
Section 5 Electrical Data47

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DeWalt DXGN4500 Specifications

General

Brand	DeWalt
Model	DXGN4500
Category	Portable Generator
Language	English

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