DeWalt DXGN6000 - User Manual

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

DeWalt DXGN6000 Specifications

General

Model	DXGN6000
Type	Portable Generator
Starting Watts	6000
Engine Displacement	389cc
Noise Level	68 dBA
Wheel Kit Included	Yes
Electric Start	Yes
Engine Type	4-Stroke
Outlets	4x 120V 20A (5-20R), 1x 120/240V 30A (L14-30R)

Summary

DeWalt Series Portable Generators

Safety and Manual Guidance

Safety Warnings and Definitions

Explains DANGER, WARNING, and CAUTION alerts for safe operation.

Section 1 Capacitive Discharge (Brushless)

Troubleshooting AC Output Problems

Provides flowcharts to diagnose issues with AC output.

Problem 1: Zero or Residual Voltage

Step-by-step guide for diagnosing zero or residual voltage issues.

Problem 2: Voltage & Frequency High;Low

Troubleshooting steps for incorrect voltage and frequency levels.

Problem 3: Voltage;Frequency Droop Under Load

Diagnostic steps for excessive voltage/frequency drop when load is applied.

Problem 4: High Voltage at No-Load

Troubleshooting guide for high no-load voltage conditions.

AC Diagnostic Tests

Test 1: No-Load Voltage & Frequency

Procedure to check generator voltage and frequency without load.

Test 5: Field Flash Alternator

Procedure to restore residual magnetism for generator excitation.

Test 8: Brushless Stator Windings

Test 10: Load Voltage & Frequency

Test 11: Load Watts & Amperage

Test 12: Adjust Voltage Regulator

Section 2 Direct Excitation (Brush Type)

Troubleshooting Brush Type AC Output

Flowcharts for diagnosing AC output problems in brush type generators.

Problem 5: Zero or Residual Voltage (Brush Type)

Diagnostic steps for generators producing no or minimal voltage.

Problem 6: Voltage & Frequency High;Low (Brush Type)

Problem 7: Voltage;Frequency Droop Under Load (Brush Type)

Problem 8: High Voltage at No-Load (Brush Type)

Section 3 Engine Diagnostic Tests

Problem 10: Hard Starting & Rough Running

Diagnostic steps for engines that start hard or run rough.

Problem 11: Engine Cranks, Wont Start

Troubleshooting guide for engines that turn over but do not start.

Problem 12: Erratic Idle; Engine Hunting

Problem 13: Engine Will Not Crank

Problem 15: Engine Cranks, But No Start

Diagnostic steps for engines that crank but do not start.

Problem 16: Engine Starts Hard & Runs Rough

Troubleshooting guide for engines that start hard or run rough.

Problem 17: Engine Starts Then Shuts Down

Problem 19: Engine Hunting; Erratic Idle

Engine Diagnostic Test Procedures

Detailed tests for diagnosing engine-related issues.

Test 19: Starter Motor Check

Test 20: Ignition Spark Check

Test 22: Carburetion Check

Test 25: Engine Compression Test

Procedure for checking engine compression using a leak down tester.

Test 26: Ignition Coil Check

Test 30: Governor Check & Adjustment

Procedure to check and adjust the mechanical governor for speed control.

Test 31: Oil Pressure Switch Check

Section 5 Electrical Data

Wiring Diagram DXGN4500

Electrical schematic for the DXGN4500 model.

Wiring Diagram DXGN6000

Electrical schematic for the DXGN6000 model.

Wiring Diagram DXGN7200

Electrical schematic for the DXGN7200 model.

Wiring Diagram DXGN14000

Electrical schematic for the DXGN14000 model.

Wiring Diagram DXGNR5700

Electrical schematic for the DXGNR5700 model.

Wiring Diagram DXGNR7000

Electrical schematic for the DXGNR7000 model.