DeWalt DXGN14000, Manual

Page 1: ...AGNOSTIC REPAIR MANUAL P O R T A B L E G E N E R ATO R S 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 D X G N R 5 7 0 0 D X G N R 7 0 0 0 ...

Page 2: ...ts safety will be endangered by the service procedure selected All information illustrations and specifications in this manual are based on the latest product information available at the time of publication When working on these products remember that the electrical system and engine ignition system are capable of violent and damaging short circuits or severe electrical shocks If you intend to pe...

Page 3: ... Droop When Load is Applied 14 Problem 8 Generator Produces High Voltage at No Load 14 AC Diagnostic Tests 15 Test 1 Check No Load Voltage and Frequency 15 Test 2 Check Main Circuit Breaker 15 Test 3 Check Continuity of Receptacle Panel 15 Test 4 Fixed Excitation Test Rotor Amp Draw Test 16 Test Brushed Stator Windings 18 Test 10 Check Load Voltage and Frequency 18 Test 11 Check Load Watts and Amp...

Page 4: ... Check Ignition Coil 34 Test 27 Check Flywheel 35 Test 28 Remove Shutdown Wire 35 Test 30 Check Adjust Governor Mechanical 35 Test 31 Check Oil Pressure Switch if equipped 36 Test 32 Check Oil Level Switch if equipped 36 Test 33 Test Recoil Function 37 Test 34 Test Engine Function 37 Test 35 Test Battery Charger 37 Test 36 Test Idle control 37 Section 4 Major Disassembly 39 Section 5 Electrical Da...

Page 5: ...ation winding causes voltage to increase which also increases the charge discharge value of the capacitor This creates a stronger magnetic field in the rotor and higher AC output NOTE Voltage will only increase from no load to full load and will stop increasing at that point Rotor Assembly The 2 pole rotor must be operated at 3600 rpm to supply a 60 Hertz AC frequency The term 2 pole means the rot...

Page 6: ...voltage starts to decay The charging and discharging causes a voltage to be induced back into the rotor which will produce voltage The greater the current flow through the rotor windings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the greater the voltage that is induced into ...

Page 7: ... TO PROBLEM 2 GO TO PROBLEM 1 GO TO PROBLEM 4 GO TO PROBLEM 3 VOLTAGE FREQUENCY BOTH HIGH OR LOW FREQUENCY GOOD VOLTAGE HIGH ZERO VOLTAGE ZERO FREQUENCY FREQUENCY GOOD LOW OR RESIDUAL VOLTAGE TEST 1 CHECK NO LOAD VOLTAGE FREQUENCY NO LOAD VOLTAGE FREQUENCY GOOD VOLTAGE FREQUENCY FALLS OFF UNDER LOAD VERIFY ROTOR IS SPINNING GO TO PROBLEM 1 BAD BAD GOOD GOOD TEST 2 CHECK MAIN CIRCUIT BREAKER RESET ...

Page 8: ...HIGH NO LOAD FREQUENCY VOLTAGE GOOD BUT THEY DROOP TO MUCH WHEN LOAD IS APPLIED GO TO PROBLEM 23 REDUCE LOAD END TEST Problem 3 Excessive Voltage Frequency Droop When Load is Applied TEST 10 CHECK LOAD VOLTAGE FREQUENCY TEST 11 CHECK LOAD WATTS AMPERAGE GOOD GOOD BAD OVERLOADED NOT OVERLOADED TEST 30 CHECK ADJUST ENGINE GOVERNOR STOP TESTS REPLACE TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY FREQUEN...

Page 9: ... flow chart Test 2 Check Main Circuit Breaker Procedure The generator has circuit breakers located on the control panel If outlets are not receiving power make sure breakers are set to ON or Closed If a breaker is suspected to have failed test as follows 1 Set DMM to measure resistance 2 With generator shut down disconnect all wires from suspected circuit breaker terminals to prevent interaction 3...

Page 10: ...n energizing cord similar to Figure 1 7 and connect as shown in Figure 1 8 2 Set START RUN STOP switch to OFF IMPORTANT NOTE Do NOT energize the capacitor for more than 1 second at a time 3 Momentarily turn on energizing cord one second 4 Disconnect energizing cord from capacitor Figure 1 7 Construction of Energizing Cord Figure 1 8 Connecting Energizing Cord 0 01 Ohms 000343 Electrocution Potenti...

Page 11: ...e capacitor Results 1 Refer to flow chart 2 Visually observe the capacitor a A capacitor that has gone bad has a tendency to explode Use caution when dealing with an exploded capacitor the gel from inside a capacitor can cause skin irritation b A capacitor is defective if terminal connections are loose on the canister c A capacitor is defective if it wobbles while sitting on a flat surface d If an...

Page 12: ...ng lead Connect the other test lead to the other stator power winding lead of the same winding Stator resistance should be as referenced in the specifications 5 Repeat step 4 with the other power windings Stator resistance should be as referenced in the specifications Test windings for a short to ground 1 Make sure all leads are isolated from each other and are not touching the frame 2 Connect one...

Page 13: ... running watts of all other connected loads Wattage Reference Guide Device Running Watts Device Running Watts Air Conditioner 12 000 Btu 1700 Hand Drill 250 to 1100 Air Conditioner 24 000 Btu 3800 Hedge Trimmer 450 Air Conditioner 40 000 Btu 6000 Impact Wrench 500 Battery Charger 20 Amp 500 Iron 1200 Belt Sander 3 1000 Jet Pump 800 Chain Saw 1200 Lawn Mower 1200 Circular Saw 6 1 2 800 to 1000 Ligh...

Page 14: ...Type Alternator Rotor Ohms Power Sensing Ohms Exciter Ohms Capacitor µF DXGN4500 PD422MHI005 CD A GX270 S16W 105 3 510 0 570 3 129 20 00 DXGN6000 PD532MHI005 CD A GX340 S16W 130 3 950 0 360 2 446 25 00 DXGN7200 PD612MHB005 CD A GX390 S16W 150 4 380 0 326 2 012 31 50 DXGN14000 PD123MHB007 CD A GX630 S20SF 160 6 570 0 124 0 600 35 00 ...

Page 15: ...ocated on Wire 2 and Wire 6 Some generators have color coded wires Always use the appropriate schematic and wiring diagram for unit Brush Holder and Brushes The brush holder has a positive and a negative brush and is retained to the rear bearing carrier by means of two Taptite screws Wire 4 connects to the positive brush and Wire 0 to the negative brush Rectified and regulated excitation current i...

Page 16: ...h and slip ring This excitation current flows through the rotor windings and through the negative slip ring and brush on white field negative wire The greater the current flow through the rotor windings the more concentrated the lines of flux around the rotor become The more concentrated the lines of flux around the rotor that cut across the stationary stator windings the greater the voltage that ...

Page 17: ...ltage Problem 6 Voltage Frequency Are Both High or Low GO TO PROBLEM 6 GO TO PROBLEM 5 GO TO PROBLEM 8 GO TO PROBLEM 7 VOLTAGE FREQUENCY BOTH HIGH OR LOW FREQUENCY GOOD VOLTAGE HIGH ZERO VOLTAGE ZERO FREQUENCY FREQUENCY GOOD LOW OR RESIDUAL VOLTAGE TEST 1 CHECK NO LOAD VOLTAGE FREQUENCY NO LOAD VOLTAGE FREQUENCY GOOD VOLTAGE FREQUENCY FALLS OFF UNDER LOAD VERIFY ROTOR IS SPINNING GO TO PROBLEM 5 B...

Page 18: ...OAD FREQUENCY VOLTAGE GOOD BUT THEY DROOP TOO MUCH WHEN LOAD IS APPLIED GO TO PROBLEM 23 REDUCE LOAD END TEST TEST 10 CHECK LOAD VOLTAGE FREQUENCY TEST 11 CHECK LOAD WATTS AMPERAGE GOOD GOOD BAD OVERLOADED NOT OVERLOADED TEST 29 CHECK ADJUST ENGINE GOVERNOR REPLACE ALTERNATOR BAD STOP TESTS FREQUENCY AND VOLTAGE O K FREQUENCY O K BUT VOLTAGE IS STILL HIGH TEST 29 CHECK ADJUST ENGINE GOVERNOR TEST ...

Page 19: ...ected to a 240 VAC Receptacle 6 Read AC voltage 7 Connect an AC frequency meter as described in Step 5 8 Read AC frequency Results Refer to flow chart Test 2 Check Main Circuit Breaker Procedure The generator has circuit breakers located on the control panel If outlets are not receiving power make sure breakers are set to ON or Closed If a breaker is suspected to have failed test as follows 1 Set ...

Page 20: ...ortional voltage output from the stator windings NOTE A standard 12 Volt battery is needed for this procedure NOTE Always use the unit specific schematics and wiring diagrams for brush orientation Procedure 1 Remove positive and negative wires connected to the brush assembly 2 Connect one jumper wire to where the positive brush wire was connected to on the brush assembly 3 Connect another jumper w...

Page 21: ...he other jumper wire to measure resistance of the brushes and the rotor Refer to chart for resistance If the correct resistance was not measured remove brushes and measure resistance across the slip rings If resistance is measured inspect or replace brushes If resistance was NOT measured across the slip rings replace rotor 18 Set DMM to measure DC amperage Refer to Section 1 2 Measuring Current NO...

Page 22: ...tor replace alternator assembly 2 If all wires test good for a short to ground refer to flow chart Test 10 Check Load Voltage and Frequency Procedure Perform this test the same as Test 1 but apply a load to the generator equal to its rated capacity With load applied check voltage and frequency Frequency should not drop below about 59 Hertz with load applied Voltage should not drop below about 220 ...

Page 23: ...schematics and wiring diagrams for brush orientation Procedure 1 Remove cover from end of alternator assembly 2 Remove two screws holding the voltage regulator AVR to the bearing carrier 3 Leave AVR connected to stator and brushes 4 Set DMM to measure AC voltage 5 See Figure 1 10 Connect DMM across a 240VAC socket Figure 1 10 DMM Test Leads Connected to a 240 VAC Receptacle 6 Ensure all material i...

Page 24: ... Adjustment Screw Rotor And Stator Resistance Series Model Generator Type Engine Alternator Rotor Ohms Power Sensing Ohms Exciter Ohms BCW WRM Winding Ohms DXGNR7000 PM0167000 01 DE B 420cc 0L2239 59 33 0 662 0 223 2 440 0 469 DXGNR5700 PM0165700 01 DE B 389cc 0J8363 61 48 10 0 681 10 2 81 10 N A ...

Page 25: ...ED AN INTERNAL ENGINE FAILURE HAS OCCURED VISUALLY INSPECT EXTERNAL COMPONENTS FOR A FAILURE THAT WOULD CAUSE THE ENGINE TO BE SIEZED REPLACE BAD BAD GOOD GOOD TEST 33 TEST RECOIL FUNCTION TEST 34 TEST ENGINE FUNCTION REPAIR OR REPLACE REPAIR OR REPLACE BAD BAD GOOD GOOD GOOD GOOD TEST 20 CHECK SPARK CHECK FUEL SUPPLY CHECK CHOKE POSITION AND OPERATION TEST 21 CHECK SPARK PLUG TEST 22 CHECK CARBUR...

Page 26: ...TEST 22 CHECK CARBURETION TEST 24 CHECK VALVE ADJUSTMENT CHECK FLYWHEEL KEY TEST 25 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST REPLENISH FUEL SUPPLY REPLACE IGNITION COIL REPAIR OR REPLACE AS NECESSARY REFER TO ENGINE SERVICE MANUAL BAD BAD g TEST 28 REMOVE WIRE 18 SHUTDOWN LEAD NO SPARK GOOD BAD BAD BAD BAD REPLACE SWITCH BAD CHECK ENGINE OIL LEVEL TEST 32 CHECK OIL LEVEL SWITCH TEST 1...

Page 27: ...BLE S BAD REPLACE BAD GOOD NO VOLTAGE MEASURED BAD 12 VDC MEASURED REPLACE STARTER MOTOR IF DEFECTIVE GOOD CHECK FOR MECHANICAL BINDING OF THE ENGINE OR ROTOR TEST 15 CHECK BATTERY CABLES TEST 17 CHECK START RUN STO P SWITCH TEST 19 CHECK STARTER MOTOR TEST 16 CHECK VOLTAGE AT STARTER CONTACTOR NOTHING FOUND FIX BAD COMPONENT BAD VISUALLY INSPECT FOR OBSTRUCTIONS THAT WOULD CAUSE BINDING OF THE RE...

Page 28: ...LL OUT TEST 17 TEST START RUN STOP SWITCH TEST 21 CHECK SPARK PLUG TEST 22 CHECK CARBURETION TEST 24 CHECK VALVE ADJUSTMENT TEST 25 CHECK ENGINE CYLINDER LEAK DOWN TEST COMPRESSION TEST REPLENISH FUEL SUPPLY REPAIR OR REPLACE AS NECESSARY REFER TO ENGINE SERVICE MANUAL P N 0C1103A FOR FURTHER ENGINE SERVICE INFORMATION BAD g TEST 28 REMOVE WIRE 18 SHUTDOWN LEAD FULL OUT NO SPARK BAD GOOD BAD BAD B...

Page 29: ...COMPRESSION TEST REPLACE SPARK PLUG PUSH IN AFTER STARTING REPLENISH FUEL SUPPLY REPAIR OR REPLACE AS NECESSARY REFER TO ENGINE SERVICE MANUAL P N 0C1103A FOR FURTHER ENGINE SERVICE INFORMATION GOOD GOOD GOOD GOOD GOOD ENGINE MISS IS APPARENT LOW FUEL BAD ADJUST VALVES AND RETEST BAD BAD TEST 30 CHECK AND ADJUST GOVERNOR BAD REPLACE REPLACE MAGNETO GOOD TEST 27 CHECK FLYWHEEL REPLACE SWITCH REPLAC...

Page 30: ...TERY CHARGER BAD BAD REPLACE REPAIR OR REPLACE GOOD GOOD BAD BAD ENGINE MISS APPARENT GOOD TEST 23 CHOKE TEST TEST 20 CHECK SPARK TEST 21 CHECK SPARK PLUG S Acceptable running limits for the engine are between 59 62 Hertz ADJUST RE TEST TEST 24 CHECK VALVE ADJUSTMENT NO SURGING STILL SURGING TEST 22 CHECK CARBURETION GOOD TEST 30 CHECK AND ADJUST GOVERNOR BAD REPLACE REPLACE MAGNETO GOOD TEST 27 C...

Page 31: ...limits for the engine are between 59 62 Hertz REPLACE FAULTY COMPONENT GOOD FOUND BAD COMPONENT TEST 36 TEST IDLE CONTROL STEPS 1 11 FOLLOW TROUBLESHOOTING PROCEDURES BAD TEST 1 CHECK NO LOAD VOLTAGE AND FREQUENCY Acceptable running limits for the engine are between 59 62 Hertz REPLACE FAULTY COMPONENT FOUND BAD COMPONENT TEST 36 TEST IDLE CONTROL STEPS 12 13 ...

Page 32: ...VOLTAGE BAD BAD YES NO REPLACE PCB GOOD GOOD GOOD GO TO PROBLEM 11 ENGINE WILL NOT START NO REPLACE CT TEST 40 CHECK CT RESISTANCE YES YES DISPLAY FROM WATTAGE RUNTIME METER DISPLAY IS FLASHING DASHES AND THE FIRMWARE VERSION TEST 41 CHECK FUEL SENDER RESISTANCE BAD NO YES BAD GOOD GO TO PROBLEM 22 NO DISPLAY FROM WATTAGE RUNTIME METER NO CHECK FUEL SENDER WIRING FOR OPEN REPAIR OR REPLACE WIRE WI...

Page 33: ...generator during cranking If voltage is below 11 VDC measure at battery terminals during cranking If battery voltage is below 11 VDC recharge replace battery If battery or cables are still suspected connect an alternate battery and cables to generator and retest Results 1 Clean battery posts and cables as necessary Make sure battery cables are tight 2 Recharge battery if necessary 3 Replace batter...

Page 34: ...oint A from switch harness 2 Connect one meter lead to female side of connector and the other meter test lead to a clean frame ground 3 Actuate switch back and forth between ON and OFF CONTINUITY should only be measure in the OFF position Results 1 If switch failed Step 3 replace OFF ON switch 2 If OFF ON switch is good refer to flow chart Test 19 Check Starter Motor The following conditions affec...

Page 35: ... or sticking Figure 1 5 Check Pinion Gear Operation Test 20 Check Ignition Spark Procedure A commercially available spark tester may be used to test engine ignition system One can also be purchased from DeWalt Part No 0C5969 1 Disconnect spark plug lead from spark plug 2 Attach high tension lead to spark tester terminal 3 See Figure 1 6 and Figure 1 7 Ground spark tester clamp by attaching to cyli...

Page 36: ... and check for foreign matter in bottom of carburetor bowl 3 The float is plastic and can be removed for access to needle for cleaning 4 With all of this removed carburetor cleaner can be used to clean carburetor before assembly 5 After cleaning carburetor with approved carburetor cleaner blow dry with compressed air and assemble Shelf life of gasoline is 30 days A fuel stabilizer must be used to ...

Page 37: ...rheating High oil consumption General Theory The Cylinder Leak Down Tester Figure 44 checks sealing compression ability of engine by measuring air leakage from combustion chamber Compression loss can present many different symptoms This test detects the section of the engine where the fault lies before disassembling the engine Procedure 1 Remove spark plug 2 Gain access to flywheel Remove valve co...

Page 38: ...ible and cannot be serviced If coil is defective replace assembly The air gap between the coil and flywheel magnet is fixed and non adjustable See Figure 1 13 The ignition coil assembly consists of a ignition coil b spark plug high tension lead and c spark plug boot Figure 1 13 Ignition Coil Procedure 1 Disconnect Wire 18 at bullet connector and repeat Test 20 2 If unit produces spark a short to g...

Page 39: ...e wire is used to shut down the unit when either the switch is placed in OFF or a low oil condition occurs A ground is applied to the magneto in both instances which inhibits spark and shuts down unit If a short to ground exists on this wire the engine will be inhibited from producing spark This test will check the integrity of the wire Procedure 1 Turn off fuel supply 2 Remove flywheel cover blow...

Page 40: ...oil pressure switch is rated at 10 psi for single cylinder engines 3 Remove oil pressure gauge and install oil pressure switch a Set a DMM to measure resistance b Connect meter test leads across switch terminals With engine shut down the meter should read CONTINUITY c Crank and start engine The meter should read INFINITY d Connect one test lead to Wire 0 disconnected from LOP Connect the other tes...

Page 41: ... lead on the positive batter connection and the negative lead to the control panel ground The voltage should be 13 5 to 14VDC If voltage is not present replace charger If voltage is present install the black negative cable to the battery and allow 24 hours to charge 4 If battery will not accept a charge replace battery Test 36 Test Idle control General Theory Certain units are equipped with a low ...

Page 42: ...em control board 12 If voltage was measured set DMM to read Ohms Place leads on female side of plug of coil The coil should read 29 5 Ohms If coil reads open replace Generator will not switch off low idle when load is applied 13 Check idle control transformer Remove plugs from idle control transformer 14 Set DMM to read Ohms The leads of the idle control transformer CT should read 53 9 Ohms If idl...

Page 43: ...ethod 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 Figure 4 1 Typical Disassembly Steps 004974 1 2 3 4 5 6 ...

Page 44: ...Section 4 Major Disassembly 40 Diagnostic Repair Manual Exploded View DXGNR7000 ...

Page 45: ...lt M8x45 30 2 Carriage Head Bolt M8x46 31 1 Frame 32 15 Nut M8 33 4 Nut M10 34 4 Rubber Vibration Mount 35 2 Bent Foot Frame ITEM QTY DESCRIPTION 36 2 Rubber Foot 37 2 Socket Head Cap Screw M3x10 38 1 Axle Pin 39 2 Fixed Axle Block 40 4 Bolt M6x50 41 2 Wheel Assembly 42 2 Flat Washer 43 2 Cotter Pin 44 1 Bolt M6x20 45 1 Special Lock Washer 46 2 Nut M6 47 1 Flat Washer 48 1 Nut M6 49 1 Ground Wire ...

Page 46: ... Limit Board 86 1 Canister Bracket 87 4 Bolt M6x12 88 1 Fuel Hose 09 6x65 89 1 Fuel Filter 90 1 Fuel Hose 09 6x80 91 4 Hose Clamp 92 1 Engine 420 cc 93 1 Starter Motor 94 1 Starter Relay 95 1 Two Headed Bolt 96 1 Sensor Cover 97 1 Exhaust Manifold 98 2 Nut M8 99 1 Cylinder Exhaust Gasket 100 1 Air Cleaner Bracket 101 1 Alternator Scroll 102 1 Bolt M5x10 103 1 Battery Cable Positive Red 104 1 Batte...

Page 47: ...Manual 43 Section 5 Electrical Data 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 ...

Page 48: ...Section 5 Electrical Data 44 Diagnostic Repair Manual Wiring Diagram and Electrical Schematic DXGN4500 004157 ...

Page 49: ...Section 5 Electrical Data Diagnostic Repair Manual 45 Wiring Diagram and Electrical Schematic DXGN6000 004163 ...

Page 50: ...Section 5 Electrical Data 46 Diagnostic Repair Manual Wiring Diagram and Electrical Schematic DXGN7200 004179 ...

Page 51: ...Section 5 Electrical Data Diagnostic Repair Manual 47 Wiring Diagram and Electrical Schematic DXGN14000 004431 ...

Page 52: ...5M 2 23M 3 M 1 D M E FM 3M 71M G 3 HM I B J K 0 M 7 M M 1M 81M 63 M 3 M 8 3 M 1 6 M 3 1M M 162 M 22 M 9M M 1 6 M 236 M M 61M 3 1M 3 M M 31 M 611 3M 31 2 1 1M M 3 C M 6 M 2 M M C M 2 63 M 6 M C 2M C M C M 8 M 2 3 M 2 M 2 1 M 6 M 2 M 16 23 M 2 3 M 2 M M 31 M 2 3 M 3 M 3 1 3 1M 3 1 M M 3 1 3 1M M M 31 M 1 M 1 4L A 3M ...

Page 53: ...Section 5 Electrical Data Diagnostic Repair Manual 49 Wiring Diagram and Electrical Schematic DXGNR7000 ...

Page 54: ...Section 5 Electrical Data 50 Diagnostic Repair Manual ...

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Page 56: ...018 Specifications are subject to change without notice No reproduction allowed in any form without prior written con sent from DeWalt DEWALT Industrial Tool Co 701 East Joppa Road Baltimore MD 21266 1 888 431 6871 www dewalt com ...