DeWalt DXGN4500 Manual
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DeWalt DXGN4500 Manual

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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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Summary of Contents for DeWalt DXGN4500

  • Page 1 DIAGNOSTIC REPAIR MANUAL DeWalt Series Portable Generators 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...

  • Page 2: Read This Manual Thoroughly

    Safety Read This Manual Thoroughly Throughout this publication and on tags and decals This diagnostic manual has been written and published affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company CAUTION blocks are used to alert personnel to special service personnel when servicing the products described instructions about a particular operation that may be herein.

  • Page 3: Table Of Contents

    Table of Contents Safety ............... ii AC Diagnostic Tests ..........15 Read This Manual Thoroughly ......... ii Test 1 – Check No-Load Voltage and Frequency ..15 Replacement Parts ..........ii Test 2 – Check Main Circuit Breaker .....15 Section 1 Capacitive Discharge (Brushless) ....1 Test 3 –...
  • Page 4 Table of Contents Test 22 – Check Carburetion .........32 Test 23 – Choke Test ..........32 Test 24 – Check Valve Adjustment ......32 Test 25 – Check Engine / Cylinder Leak Down Test / Compression Test ......33 Test 26 – Check Ignition Coil .........34 Test 27 –...

  • Page 5: Section 1 Capacitive Discharge (Brushless)

    Capacitive Discharge (Brushless) Section 1 Introduction winding causes voltage to increase which also increases the charge/discharge value of the capacitor. This creates Figure 1-1. A typical brushless type portable a stronger magnetic field in the rotor and higher AC generator needs 4 major components to function: a prime output.

  • Page 6: Circuit Breakers

    Section 1 Capacitive Discharge (Brushless) Circuit Breakers On-Speed Operation Figure 1-3. Each individual circuit on the generator As the engine accelerates, the voltage that is induced is protected by a circuit breaker to prevent overload. into the stator windings increases rapidly, due to the increasing speed at which the rotor operates.

  • Page 7: Troubleshooting Flowcharts

    Section 1 Capacitive Discharge (Brushless) Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the AC Diagnostic Tests . Test numbers used in the flow charts correspond to the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 8: Problem 2 - Voltage & Frequency Are Both High Or Low

    Section 1 Capacitive Discharge (Brushless) Problem 2 – Voltage & Frequency Are Both High or Low GO TO FREQUENCY GOOD, LOW OR PROBLEM 1 RESIDUAL VOLTAGE GO TO TEST 30 – CHECK & ADJUST NO-LOAD FREQUENCY & VOLTAGE GOOD BUT ENGINE GOVERNOR PROBLEM 3 THEY DROOP TO MUCH WHEN LOAD IS APPLIED...

  • Page 9: Ac Diagnostic Tests

    Section 1 Capacitive Discharge (Brushless) AC Diagnostic Tests Test 2 – Check Main Circuit Breaker Introduction Procedure The generator has circuit breakers located on the control The Diagnostic Tests in this section may be performed in panel. If outlets are not receiving power, make sure conjunction with the Troubleshooting Flowcharts .

  • Page 10: Test 5 - Field Flash Alternator

    Section 1 Capacitive Discharge (Brushless) NOTE: Only one outlet on each receptacle needs to be been started for a long period of time, the residual tested. magnetism could be lost within the rotor. Field flashing the rotor while connected in parallel with the capacitor will Results force a charge of electricity through the excitation If any other reading than continuity was measured,...

  • Page 11: Test 6 - Check Capacitor

    Section 1 Capacitive Discharge (Brushless) If the field flash was successful, the generator should produce approximately 240 VAC at the μf main circuit breaker of the generator when the 59.0 START-RUN-STOP is set to START. IMPORTANT NOTE: Do not field flash alternator more than two times in sequence.

  • Page 12: Test 8 - Test Brushless Stator Windings

    Section 1 Capacitive Discharge (Brushless) Test windings for a short to ground: Connect one meter lead to an excitation winding and connect the other meter lead to a power Make sure all leads are isolated from each other winding. INFINITY should be measured. and are not touching the frame.
  • Page 13 Section 1 Capacitive Discharge (Brushless) If load is within limits but frequency and voltage still • If the appliance, tool or motor does not give drop excessively, refer to flow chart. wattage, multiply volts times ampere rating to determine watts (volts x amps = watts). Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to •...
  • Page 14 Section 1 Capacitive Discharge (Brushless) Rotor And Stator Resistance Generator Power / Series Model Engine Type Alternator Rotor Ohms Exciter Ohms Capacitor µF Type Sensing Ohms DXGN4500 PD422MHI005 CD/A GX270 S16W-105 3.510 0.570 3.129 20.00 DXGN6000 PD532MHI005 CD/A GX340 S16W-130 3.950...

  • Page 15: Section 2 Direct Excitation (Brush Type)

    Direct Excitation (Brush Type) Section 2 Introduction Brush Holder and Brushes The brush holder has a positive (+) and a negative (-) Figure 1-1. A typical brush type portable generator brush, and is retained to the rear bearing carrier by needs 4 major components to function: prime mover, means of two Taptite screws.

  • Page 16: Operation

    Section 2 Direct Excitation (Brush Type) Operation Initially, the AC power winding voltage sensed by the regulator is low. The regulator reacts by increasing the Startup flow of excitation current to the rotor until voltage increases to a desired level. The regulator then maintains When the engine is started, residual magnetism from the the desired voltage.

  • Page 17: Troubleshooting Flowcharts

    Section 2 Direct Excitation (Brush Type) Troubleshooting Flowcharts Introduction Use the Flow Charts in conjunction with the AC Diagnostic Tests . Test numbers used in the flow charts correspond to the numbered tests in the AC Diagnostic Tests . The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 18: Problem 7 - Excessive Voltage/Frequency Droop When Load Is Applied

    Section 2 Direct Excitation (Brush Type) FREQUENCY GO TO GOOD, LOW OR PROBLEM 5 RESIDUAL VOLTAGE NO-LOAD FREQUENCY & TEST 29 – CHECK & ADJUST GO TO VOLTAGE GOOD BUT ENGINE GOVERNOR PROBLEM 7 THEY DROOP TOO MUCH WHEN LOAD IS APPLIED GO TO PROBLEM 5, FREQUENCY IS GOOD TEST 12 –...

  • Page 19: Ac Diagnostic Tests

    Section 2 Direct Excitation (Brush Type) AC Diagnostic Tests Results Introduction No Load Voltage No Load Frequency The Diagnostic Tests in this chapter may be performed in 223.2 – 256.8 VAC 62.5 – 62.0 Hz conjunction with the Troubleshooting Flow Charts. Test numbers in this chapter correspond to numbered tests in Refer to flow chart.

  • Page 20: Test 4 - Fixed Excitation Test/Rotor

    Section 2 Direct Excitation (Brush Type) Test 4 – Fixed Excitation Test/Rotor Procedure Amp Draw Test Set DMM to measure Resistance. Figure 1-7. Connect DMM to each receptacle General Theory on unit. Supplying a fixed DC current to the rotor will induce a NOTE: Only one outlet on each receptacle needs to be magnetic field in the rotor.
  • Page 21 Section 2 Direct Excitation (Brush Type) While the unit is running and with jumper wires rings. If resistance is measured, inspect or replace connected to the brush assembly as described in brushes. If resistance was NOT measured across Steps 1, 2, and 3; connect one jumper wire to the the slip rings, replace rotor.

  • Page 22: Test Brushed Stator Windings

    Section 2 Direct Excitation (Brush Type) Results If all wires test good for a short to ground, refer to flow chart. If current was outside parameters in Steps 23 and 24, remove brushes and measure resistance. Test 10 – Check Load Voltage and If voltage was not measured in Step 8 at either the Frequency receptacle or the stator connection terminal strip,...

  • Page 23: Test 12 - Adjust Voltage Regulator

    Section 2 Direct Excitation (Brush Type) *Compressor (1 HP) 2000 Oil Fired Space Heater (85,000 Btu) *Compressor (3/4 HP) 1800 Oil Fired Space Heater (30,000 Btu) *Compressor (1/2 HP) 1400 *Paint Sprayer, Airless (1/3 HP) Curling Iron Paint Sprayer, Airless (hand held) *Dehumidifier Radio 50 to 200...
  • Page 24 Section 2 Direct Excitation (Brush Type) Figure 1-11. Voltage Regulator Adjustment Screw Rotor And Stator Resistance Generator Power / BCW / WRM Series Model Engine Alternator Rotor Ohms Exciter Ohms Type Sensing Ohms Winding Ohms 0.662 / DXGNR7000 PM0167000.01 DE/B 420cc 0L2239 59.33...

  • Page 25: Section 3 Engine Diagnostic Tests

    Engine Diagnostic Tests Section 3 Introduction Use the Flow Charts in conjunction with the detailed instructions in Section X.X. Test numbers used in the flow charts correspond to the numbered tests in Section X.X. The first step in using the flow charts is to identify the correct problem on the following pages.

  • Page 26: Problem 11 - Engine Turns Over But Will Not Start

    Section 3 Engine Diagnostic Tests Problem 11 – Engine Turns Over But Will Not Start CHECK TEST 20 – TEST 28 – REMOVE CHECK FUEL FUEL GOOD CHECK WIRE 18 / SHUTOFF GOOD SUPPLY SPARK SHUTDOWN LEAD VALVE SPARK SPARK REPLENISH TEST 26 –...

  • Page 27: Problem 12 - Engine "Hunts" / Erratic Idle

    Section 3 Engine Diagnostic Tests Problem 12 – Engine “Hunts” / Erratic Idle TEST 20 – TEST 24 – CHECK TEST 23 – STILL CHECK VALVE GOOD CHOKE TEST SURGING IGNITION ADJUSTMENT SPARK SURGING GOOD BAD - ENGINE MISS APPARENT ADJUST / RE-TEST TEST 22 –...

  • Page 28: Problem 15 - Engine Cranks But Will Not Start

    Section 3 Engine Diagnostic Tests Problem 15 – Engine Cranks But Will Not Start CHECK CHECK FUEL TEST 20 – PULL CHOKE FUEL SHUTOFF FULL OUT GOOD GOOD CHECK FULL OUT SUPPLY VALVE SPARK PULL OUT REPLENISH FUEL TURN SUPPLY TEST 21 –...

  • Page 29: Problem 16 - Engine Starts Hard And Runs Rough

    Section 3 Engine Diagnostic Tests Problem 16 – Engine Starts Hard and Runs Rough TEST 21 – TEST 20 – CHECK CHOKE CHECK FUEL CHECK CHECK GOOD GOOD GOOD POSITION AND GOOD SUPPLY SPARK PLUG SPARK OPERATION LOW FUEL ENGINE MISS PUSH IN AFTER IS APPARENT STARTING...

  • Page 30: Problem 18 - Battery Will Not Charge

    Section 3 Engine Diagnostic Tests Problem 18 – Battery Will Not Charge TEST 14 – TEST 35 – CHECK GOOD BATTERY GOOD END TEST FUSE CHARGER REPLACE FUSE REPLACE Problem 19 – Engine “Hunts” / Erratic Idle *Acceptable running limits for the engine are between 59-62 Hertz. TEST 23 –...

  • Page 31: Problem 20 - Unit Will Not Idle

    Section 3 Engine Diagnostic Tests Problem 20 – Unit Will Not Idle *Acceptable running limits for the engine are between 59-62 Hertz. TEST 1 – CHECK TEST 36 – TEST NO-LOAD VOLTAGE GOOD IDLE CONTROL AND FREQUENCY (STEPS 1 - 11) FOUND BAD COMPONENT FOLLOW REPLACE FAULTY...

  • Page 32: Problem 22 - No Display From Wattage/Runtime Meter

    Section 3 Engine Diagnostic Tests Problem 22 – No Display from Wattage/Runtime Meter PRODUCING TEST 39 – TEST 38 – DOES CHECK PROPER CHECK ENGINE OUTPUT STATOR VOLTAGE RUN? VOLTAGE? WINDING TO PCB GOOD GOOD GO TO PROBLEM 11, GO TO PROBLEM 5, ENGINE WILL NOT ZERO OR RESIDUAL START...

  • Page 33: Introduction

    Section 3 Engine Diagnostic Tests Introduction Recharge battery if necessary. Replace battery if necessary. The Diagnostic Tests in this chapter may be performed in If battery is good but engine will not crank, refer to conjunction with the Flow Charts of Section 3.1 and flow charts.

  • Page 34: Test 18 - Test Off-On Switch

    Section 3 Engine Diagnostic Tests Remove all wires from START-RUN-STOP Switch Connect one meter lead to female side of (SW1). connector and the other meter test lead to a clean frame ground. Connect one meter lead to Terminal 2 and the other meter lead to Terminal 1.

  • Page 35: Test 20 - Check Ignition Spark

    If battery voltage was indicated and Starter Motor test engine ignition system. One can also be purchased tried to engage (pinion engaged) but engine did not from DeWalt (Part No. 0C5969). crank, check for mechanical binding of engine or Disconnect spark plug lead from spark plug.

  • Page 36: Test 22 - Check Carburetion

    Section 3 Engine Diagnostic Tests • Varnished carburetor If engine starts hard or will not start, look for the following: • Physical damage to AC generator. Check Rotor for contact with Stator. • Starting under load. Make sure all loads are disconnected or turned off before attempting to crank and start engine.

  • Page 37: Test 25 - Check Engine / Cylinder Leak Down

    Section 3 Engine Diagnostic Tests Figure 1-10. Loosen rocker arm jam nut. Turn • Starts hard pivot ball stud while checking clearance between • Lack power rocker arm and valve stem with a feeler gauge. • Runs rough • Vibration •...

  • Page 38: Test 26 - Check Ignition Coil

    Section 3 Engine Diagnostic Tests Check Compression To check engine compression, remove spark plug. Insert an automotive type compression gauge into the spark plug hole. Crank engine until there is no further in pressure. The highest reading obtained is engine compression pressure.

  • Page 39: Test 27 - Check Flywheel

    Section 3 Engine Diagnostic Tests Flywheel Key ground exists on this wire, the engine will be inhibited from producing spark. This test will check the integrity of In all cases, the flywheel’s taper is locked on the the wire. crankshaft taper by the torque of the flywheel nut. A keyway is provided for alignment only and theoretically Procedure carries no load.

  • Page 40: Test 31 - Check Oil Pressure Switch

    Section 3 Engine Diagnostic Tests throttle and, with a pair of pliers, rotate Remove oil pressure gauge and install oil pressure GOVERNOR SHAFT fully clockwise (CW). switch. Use minimum amount of force against a. Set a DMM to measure resistance. governor shaft.

  • Page 41: Test 33 - Test Recoil Function

    Section 3 Engine Diagnostic Tests Check power to the AC charger at the outlet. If volt- age is not present try another outlet. If voltage is present move to step 2. NOTE: Unplug wall charger from generator panel between each step outlined below! Check in-line fuse.
  • Page 42 Section 3 Engine Diagnostic Tests Remove C1 plug between system control board the coil. Set DMM to read DC volts. From male side of plug, place the leads on pins. With low idle switch position, 12VDC should measured. If voltage was not measured, replace system control board.

  • Page 43: Section 4 Major Disassembly

    Major Disassembly Section 4 Introduction Each generator model has a unique method of disassembly. Figure 4-1 is a simplified version of disassembly that does not go into step by step instructions. The figure below represents the basic disassembly and sequence of steps needed to remove the fuel tank, stator, rotor, and the engine.
  • Page 44 Section 4 Major Disassembly Exploded View – DXGNR7000 Diagnostic Repair Manual...
  • Page 45 Section 4 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION Frame Rail (Matte Yellow) Rubber Foot Pan Head Screw (ST4x16) Socket Head Cap Screw (M3x10) Curved Head Bolt (M8x40) Axle Pin Control Panel Assembly Fixed Axle Block Outlet Cover Bolt (M6x50) Nut (M3) Wheel Assembly Control Panel Face Plate Weldment...
  • Page 46 Section 4 Major Disassembly ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION Fuel Shut Off Valve Pan Head Screw (M5x10) Roll Over Valve CO Warning Decal Frame Back Rail (Matte Yellow) Warning Decal Bolt (M8x25) Muffler Exhaust Gasket Muffler Spark Arrestor Bolt (M8x16) Hose (Carbon Canister To Roll Over Valve) Hose Clamp Hose Clamp...

  • Page 47: Section 5 Electrical Data

    Electrical Data Section 5 Introduction Go to www.generac.com (http://www.generac.com/service-support/product-support-lookup) for the most current wiring diagrams and electrical schematics. Use model or serial number. Diagnostic Repair Manual...
  • Page 48 Section 5 Electrical Data Wiring Diagram and Electrical Schematic, DXGN4500 004157 Diagnostic Repair Manual...
  • Page 49 Section 5 Electrical Data Wiring Diagram and Electrical Schematic, DXGN6000 004163 Diagnostic Repair Manual...
  • Page 50 Section 5 Electrical Data Wiring Diagram and Electrical Schematic , DXGN7200 004179 Diagnostic Repair Manual...
  • Page 51 Section 5 Electrical Data Wiring Diagram and Electrical Schematic, DXGN14000 004431 Diagnostic Repair Manual...
  • Page 52 Section 5 Electrical Data Wiring Diagram and Electrical Schematic, DXGNR5700 Diagnostic Repair Manual...
  • Page 53 Section 5 Electrical Data Wiring Diagram and Electrical Schematic, DXGNR7000 Diagnostic Repair Manual...
  • Page 54 Section 5 Electrical Data Diagnostic Repair Manual...
  • Page 56 DEWALT Industrial Tool Co. Part No. 0L6146 Rev. B 06/28/2018 701 East Joppa Road Specifications are subject to change without notice. Baltimore, MD 21266 No reproduction allowed in any form without prior written con- 1-888-431-6871 sent from DeWalt. www.dewalt.com...

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