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Manuals
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DeWalt Manuals
Portable Generator
DXGN4500
Manual
DeWalt DXGN4500 Manual
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Contents
Table of Contents
Troubleshooting
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Table of Contents
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Replacement Parts
Table of Contents
Section 1 Capacitive Discharge (Brushless)
Introduction
Rotor Assembly
Stator Assembly
Circuit Breakers
Operation
Troubleshooting Flowcharts
If Problem Involves AC Output
Problem 1 - Generator Produces Zero Voltage or Residual Voltage
Problem 2 - Voltage & Frequency Are both High or Low
Problem 3 - Excessive Voltage/Frequency Droop When Load Is Applied
Problem 4 - Generator Produces High Voltage at No-Load
AC Diagnostic Tests
Test 1 - Check No-Load Voltage and Frequency
Test 2 - Check Main Circuit Breaker
Test 3 - Check Continuity of Receptacle Panel
Test 5 - Field Flash Alternator
Test 6 - Check Capacitor
Test 7 - Test Brushless Excitation Winding
Test 8 - Test Brushless Stator Windings
Test 10 - Check Load Voltage and Frequency
Test 11 - Check Load Watts and Amperage
Section 2 Direct Excitation (Brush Type)
Introduction
Stator Assembly
Brush Holder and Brushes
Voltage Regulator
Operation
Troubleshooting Flowcharts
If Problem Involves AC Output (Brush Type)
Problem 5 - Generator Produces Zero Voltage or Residual Voltage
Problem 6 - Voltage & Frequency Are both High or Low
Problem 7 - Excessive Voltage/Frequency Droop When Load Is Applied
Problem 8 - Generator Produces High Voltage at No-Load
AC Diagnostic Tests
Test 1 - Check No-Load Voltage and Frequency
Test 2 - Check Main Circuit Breaker
Test 3 - Check Continuity of Receptacle Panel
Test 4 - Fixed Excitation Test/Rotor
Amp Draw Test
Test Brushed Stator Windings
Test 10 - Check Load Voltage and Frequency
Test 11 - Check Load Watts and Amperage
Test 12 - Adjust Voltage Regulator
Section 3 Engine Diagnostic Tests
Introduction
Problem 9 - Recoil Cord will Not Pull
Problem 10 - Engine Starts Hard and Runs Rough
Problem 11 - Engine Turns over but will Not Start
Problem 12 - Engine "Hunts" / Erratic Idle
Problem 13 - Engine will Not Crank
Problem 14 - Recoil Cord will Not Pull (if so Equipped)
Problem 15 - Engine Cranks but will Not Start
Problem 16 - Engine Starts Hard and Runs Rough
Problem 17 - Engine Starts then Shuts down
Problem 18 - Battery will Not Charge
Problem 19 - Engine "Hunts" / Erratic Idle
Problem 20 - Unit will Not Idle
Problem 21 - Unit RPM will Not Increase from Idle
Problem 22 - no Display from Wattage/Runtime Meter
Problem 23 - Wattage/Runtime Meter Display Is Flashing Erroneous Data
Introduction
Test 14 - Check Fuse
Test 15 - Check Battery & Cables
Test 16 - Check Voltage at Starter
Contactor (SC)
Test 17 - Check Start-Run-Stop Switch
Test 18 - Test OFF-ON Switch
Test 19 - Check Starter Motor
Test 20 - Check Ignition Spark
Test 21 - Check Spark Plug(S)
Test 22 - Check Carburetion
Test 23 - Choke Test
Test 24 - Check Valve Adjustment
Test 25 - Check Engine / Cylinder Leak down
Test / Compression Test
Test 26 - Check Ignition Coil
Test 27 - Check Flywheel
Test 28 - Remove Shutdown Wire
Test 30 - Check / Adjust Governor (Mechanical)
Test 31 - Check Oil Pressure Switch
(If Equipped)
Test 32 - Check Oil Level Switch (if Equipped)
Test 33 - Test Recoil Function
Test 34 - Test Engine Function
Test 35 - Test Battery Charger
Test 36 - Test Idle Control
Section 4 Major Disassembly
Section 5 Electrical Data
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Replacement Parts
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DIAGNOSTIC
REPAIR
MANUAL
DeWalt Series Portable Generators
P O R T A B L E G E N E R AT O R S
M o d e l s :
D X G N 4 5 0 0
D X G N 6 0 0 0
D X G N 7 2 0 0
D X G N 1 4 0 0 0
D X G N R 5 7 0 0
D X G N R 7 0 0 0
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Troubleshooting
Troubleshooting Flowcharts
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Troubleshooting Flowcharts
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