DEWALT DXGN6000 6000 Watt Commercial Generator User Manual

DEWALT DXGN6000 6000 Watt Commercial Generator

All information provided in this manual is believed to be correct at the time of printing. The manufacturer reserves the right to correct any errors and omissions.

SAFETY GUIDELINES AND DEFINITIONS

DANGER
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home.

Only use
OUTSIDE and far away from windows, doors and vents. This instruction manual contains information important for you to know and understand so that your generator may properly, safely, and effectively applied and operated. All operators, users and subsequent owners of this generator must read and understand all instructions before operating the generator. Save these instructions for future reference. To help you recognize information important to protecting

YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS
we use the symbols below.

Indicates and imminently hazardous
situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury.

Indicates a practice not related to personal
injury which, if not avoided, may result in property damage. Certain States and Jurisdictions require that engine driven equipment be fitted with spark arresting mufflers. Depending on the generator model, spark-arresting mufflers may or
may not be fitted. If spark-arresting mufflers are required for your location and the generator muffler is not spark arresting, contact your local dealer for instructions for a retrofit.

If the product will be used around flammable materials, such as agricultural crops, forests, brush, grass, or other similar items, then an approved spark arrester should be installed and is legally required in the State of California. The California statutes requiring a spark arrester are Sections 13005(b), 4442and 4443. Spark Arresters are also required on some U.S. Forest Service land and may also be legally required under other statutes and ordinances. An approved spark arrester is available from our product dealers, or may be ordered from DEWALT Industrial Tool Co., 701 East Joppa Road, Baltimore, MD 21286. 1-888-431-6871.

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system for this generator complies with the standards set forth by the California Air Resources Board (CARB) and the Environmental Protection Agency (EPA). The respective engine manufacturers administer warranties for the exhaust emission system. Refer to the engine documentation for warranty information. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

RISK OF ASPHYXIATION DO NOT OPERATE THIS GENERATOR WITHIN AN ENCLOSED AREA. THE EXHAUST GASES OF THIS GENERATOR EMIT “DEADLY” CARBON MONOXIDE. EXPOSURE TO CARBON MONOXIDE CAN
CAUSE CARBON MONOXIDE POISONING, HEADACHES, NAUSEA, SEVERE SICKNESS OR DEATH. RISK OF ELECTROCUTION OR SHOCK THIS GENERATOR SET PRODUCES ELECTRICAL CURRENT. THEREFORE, SAFETY
GUIDELINES MUST BE FOLLOWED. IMPROPER USE OF THIS GENERATOR CAN RESULT IN ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE, SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY QUALIFIED TO
DO SO.

THIS GENERATOR SET IS DESIGNED TO BE OPERATED IN DRY CONDITIONS AND FOR OUTDOOR AREAS ONLY. NEVER OPERATE THIS GENERATOR INDOORS. NEVER OPERATE THIS GENERATOR IN RAIN, SNOW, SLEET OR GENERALLY WET CONDITIONS. DAMAGE TO THE GENERATOR, BODILY INJURY, OR DEATH COULD RESULT FROM ELECTROCUTION. IF THIS GENERATOR IS CONNECTED TO A BUILDING, HOME, BUSINESS, OR ANY OTHER ELECTRICAL CIRCUIT NORMALLY FED BY UTILITY POWER, STEPS MUST BE TAKEN TO INSURE THE GENERATOR OUTPUT AND THE UTILITY POWER ARE POSITIVELY ISOLATED. THIS IS TYPICALLY ACCOMPLISHED THROUGH THE USE OF A PROPERLY INSTALLED TRANSFER SWITCH. FAILURE TO ISOLATE THE UTILITY AND GENERATOR ELECTRICAL SYSTEMS WILL RESULT IN GENERATOR DAMAGE AND COULD RESULT IN INJURY OR DEATH TO UTILITY WORKERS DUE TO THE BACKFEED OF ELECTRICITY.

TO AVOID BACKFEEDING INTO UTILITY SYSTEMS, ISOLATION OF THE RESIDENCE ELECTRICAL SYSTEM IS REQUIRED. BEFORE CONNECTION OF A GENERATOR TO THE RESIDENCE ELECTRICAL SYSTEM TURN OFF THE MAIN SWITCH. BEFORE MAKING PERMANENT CONNECTIONS A DOUBLE THROW TRANSFER SWITCH MUST BE INSTALLED. TO AVOID ELECTROCUTION OR PROPERTY DAMAGE, ONLY A TRAINED ELECTRICIAN SHOULD CONNECT GENERATOR TO RESIDENCE ELECTRICAL SYSTEM. CALIFORNIA LAW REQUIRES ISOLATION OF THE RESIDENCE ELECTRICAL SYSTEM BEFORE CONNECTING A GENERATOR TO RESIDENCE ELECTRICAL SYSTEMS.

TEMPORARY CONNECTION NOT RECOMMENDED DUE TO BACKFEEDING. ALWAYS FOLLOW LOCAL CODES AND REGULATIONS THAT APPLY TO THE INSTALLATION OF ANY ITEM THAT CONCERNS THIS PRODUCT.

1. NFPA 70 – National Electrical Code.
2. NFPA 37 – Standard for Installation and Use of Stationary Combustible Engines.
3. Agricultural Wiring handbook of Farm Standby Electric Power.

DO NOT MODIFY OR MISAPPLY YOUR GENERATOR SET. OPERATION OF THE GENERATOR OTHER THAN INTENDED COULD RESULT IN GENERATOR SET DAMAGE, BODILY INJURY OR EVEN DEATH FROM ELECTROCUTION. NEVER TOUCH A RECEPTACLE OR BARE WIRE. ELECTROCUTION OR SHOCK COULD RESULT.

RISK OF FIRE OR EXPLOSION
ALWAYS INSURE THAT AT LEAST 6 FEET OF CLEARANCE ON ALL SIDES OF THE GENERATOR ARE MAINTAINED DURING OPERATION. FAILURE TO MAINTAIN PROPER CLEARANCE COULD DAMAGE YOUR GENERATOR AND POTENTIALLY LEAD TO FIRES. GASOLINE IS HIGHLY FLAMMABLE AND ITS VAPORS ARE EXPLOSIVE. FAILURE TO PROPERLY HANDLE GASOLINE CAN RESULT IN EXPLOSION OR FIRE. DO NOT PERMIT SMOKING WITHIN 50FT OF THIS GENERATOR SET.

NEVER REFILL A HOT GENERATOR WITH FUEL. NEVER REFILL THE GENERATOR WHILE IT IS RUNNING. SPILLAGE ONTO THE ENGINE OR GENERATOR COULD RESULT IN AN EXPLOSION OR FIRE. ALWAYS ALLOW THE GENERATOR SET TO COOL BEFORE REFILLING. DO NOT STORE THIS GENERATOR SET IN ANY LOCATION WHERE GASOLINE FUMES COULD POTENTIALLY COME INTO CONTACT WITH SPARKS, A PILOT LIGHT OR AN OPEN FLAME. IMPROPER STORAGE OF THIS GENERATOR COULD RESULT IN AN EXPLOSION OR FIRE.

INSPECT THE SPARK ARRESTORPERIODICALLY. SPARK ARRESTORS ARE REQUIRED IN SOME AREAS AND MINIMIZE THE RISK OF FIRE FROM SPARKS EMMITTED FROM THE EXHAUST. DO NOT OPERATE THIS GENERATOR IF THE AMBIENT TEMPERATURE EXCEEDS 104ºF/40ºC. DO NOT EXCEED THE RATED CAPACITY OF THE GENERATOR. THE TOTAL ELECTRICAL LOADS AT EACH OUTLET MUST BE ADDED TO DETERMINE THE TOTAL ELECTRICAL LOAD. THE TOTAL LOAD MUST NOT EXCEED THE RATED CAPACITY OF THE GENERATOR. IF THE DRIVEN APPARATUS DOES NOT LIST WATTAGE, BUT ONLY AMPERAGE, WATTAGE MAY BE DETERMINED BY MULTIPLYING AMPERAGE TIMES VOLTAGE (WATTS = AMPS X VOLTS).

GENERAL SAFETY

Always follow National and Local electrical codes pertaining to generators. All local and national codes supersede rules or information provided in this manual. REFER TO LOCAL AND NATIONAL ELECTRICAL CODES TO DETERMINE GROUNDING REQUIREMENTS AS THIS CAN VARY PER APPLICATION. THE GENERATOR IS GROUNDED INTERNALLY NEUTRAL TO FRAME. WHERE APPLICATIONS REQUIRE EXTERNAL GROUNDING, A CONNECTION MUST BE MADE FROM THE GENERATOR TO A SOLID EARTH GROUND. A CONTINUOUS LENGTH OF SPLICE-FREE COPPER CABLE, NO SMALLER THAN 6 AWG, SHALL BE USED FOR THE CONDUCTOR.

• When moving or transporting this generator, take proper precautions to avoid fuel spillage. Further, always use common sense when lifting this generator. An adequate number of people and proper lifting methods must be used.
• Do not cover the generator while it is running or immediately after shutdown. Always allow time to cool down before covering.
• Do not operate this generator unless it is in good mechanical and electrical condition.
• Always keep hands, body parts, hair and clothing well away from the rotating parts of the generator.
• Do not start this generator with connected devices turned “ON”. Always make sure that connected devices are disconnected from the generator or turned “OFF” before starting the generator.
• Generators operating on job or construction sites may be required to have GFCI (Ground Fault Circuit Interrupters) receptacles.
• Use only grounded extension cords in good condition and make sure that the wire size within the extension cords is of sufficient size to safely carry the surge output of the generator.
• Never handle extension cords or electrical circuits if standing in water or if standing in a damp area.

RISK OF BODILY INJURY KEEP HANDS, BODY PARTS, HAIR AND CLOTHING AWAY FROM THE “HOT” PARTS OF THE GENERATOR SET DURING AND AFTER OPERATION. THE EXHAUST SYSTEM, AND THE GENERATOR IN GENERAL, CAN REMAIN VERY HOT EVEN AFTER BEING SHUT DOWN.

DO NOT TAMPER WITH THE ENGINE-GOVERNED SPEED. THE GENERATOR OPERATES AT A NOMINAL SPEED OF 3600 RPM. INCREASES IN SPEED OVER THE 3600 RPM NOMINAL WILL INCREASE THE CHANCE OF PERSONAL INJURY DUE TO ROTATIONAL STRESSES ON THE ROTATING MEMBERS. OPERATION OF THE GENERATOR AT SPEEDS BELOW THE NOMINAL 3600 RPM COULD CAUSE DAMAGE TO THE GENERATOR OR DRIVEN APPARATUS DUE TO LOW VOLTAGE OUTPUT.

BATTERY SAFETY STORAGE BATTERIES PRODUCE AND RELEASE EXPLOSIVE HYDROGEN GAS WHEN CHARGING. THE SLIGHTEST SPARK, FLAME OR BURNING ASH CAN IGNITE THESE GASES CAUSING A SERIOUS
EXPLOSION THAT COULD RESULT IN BLINDNESS OR OTHER SERIOUS INJURIES. WEAR EYE PROTECTION, RUBBER APRON AND RUBBER GLOVES WHEN WORKING AROUND A BATTERY OR PERFORMING BATTERY
SERVICE. BATTERY FLUID IS AN EXTREMELY CAUSTIC SULFURIC ACID, WHICH CAN CAUSE SEVERE BURNS. ALWAYS DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY BEFORE PERFORMING BATTERY SERVICE OR BEFORE PERFORMING ANY ELECTRICAL SERVICE ON THE GENERATOR OR ENGINE.

ENVIRONMENTAL PROTECTION INSPECT THE EXHAUST SYSTEM REGULARLY TO ENSURE IT IS FUNCTIONING PROPERLY. LEAKY EXHAUST SYSTEMS WILL INCREASE NOISE LEVELS. DIRECT THE “LOUD” SIDES OF THE
GENERATOR INTO OPEN SPACES AVOIDING REVERBERATION FROM WALLS OR BUILDINGS THUS AMPLIFYING THE SOUND. NEVER DRAIN OR DISPOSE OF ENGINE OIL INTO THE GROUND OR DOMESTIC WASTE WATER SYSTEMS

LIFTING HOOK ASSEMBLY
Attach the lifting hook (A) to the carrier with 3/8 x 2.00” bolts (B) and 3/8 nyloc nuts (C) as shown in the illustration. Tighten the bolts firmly.

RAISING OR SUSPENDING GENERATOR
Failure to properly connect lifting cables, chains or straps can cause property damage, serious injury or death, and void the manufacturer’s warranty. Always use cables, chains or straps rated at 2000 lbs. working load or more to raise or suspend generator. Never operate generator while suspended. This could cause property damage, serious injury or death. DO NOT suspend objects other than generator from lifting hook. Make sure all fasteners in frame and lifting hook are tight. Route cable, chain or strap through lifting hook (A) as shown. ALWAYS use lifting hook when raising or suspending generator. Make sure the generator is in a level position before raising or suspending to prevent damage.

Accessories

Recommended accessories for use with your tool are available for purchase from your local dealer or authorized service center. If you need assistance in locating any accessory for your tool, please contact DEWALT Industrial Tool
Co., 701 East Joppa Road, Baltimore, MD 21286, call 1-888-431-6871 or visit our website www.dewalt.com.

Service Information
Please have the following information available for all service calls:
Model Number ____ Serial Number ___
Date and Place of Purchase ____

Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment should be performed by a DEWALT factory service center, a DEWALT authorized service center or other qualified service personnel. Always use identical replacement parts.

Three Year Warranty – U.S.A. and Canada
DEWALT heavy duty generators are warranted for three (3) years from date of purchase in the United States and Canada. We will repair, without charge, any defects due to faulty materials or workmanship. For warranty repair information, call 1-888-431-6871. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces.

One Year Warranty – Mexico
DEWALT heavy duty generators are warranted for one (1) year from date of purchase in Mexico. We will repair, without charge, any defects due to faulty materials or workmanship. For warranty repair information, call 1-888-431-6871. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states.

LATIN AMERICA (EXCEPT MEXICO): This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained either in the packaging, call the local company or see website for warranty information.
FREE WARNING LABEL REPLACEMENT: If your warning labels become illegible or are missing, call 1-888-431-6871 for a free replacement.

FEDERAL EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS
The United States Environmental Protection Agency (EPA) and Pramac America, LLC (herein “Pramac America”) are pleased to explain the Evaporative Emission Control System (EECS) warranty on your 2011 model year and later generator. New equipment that uses small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the federal government. Pramac America must warrant the evaporative emission control system on your generator for the periods of time listed below, provided there has been no abuse, neglect or improper maintenance of your generator. The evaporative emission control system on this generator includes all components whose failure would increase the generator evaporative emissions of any regulated pollutant. These components are listed in the Warranted Parts section of this warranty.

MANUFACTURER’S WARRANTY COVERAGE
This EECS warranty is valid for three years. If, during such warranty period, any evaporative emission-related part on your equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by an authorized Pramac America warranty service center.

OWNER’S WARRANTY RESPONSIBILITIES
As the generator owner, you are responsible for performance of the required maintenance listed in your owner’s manual. Pramac America recommends that you retain all receipts covering maintenance on your generator, but Pramac America cannot deny warranty solely for the lack of receipts. You should, however, be aware that Pramac America may deny you warranty coverage if your generator or a part has failed due to abuse, neglect or improper maintenance or unapproved modifications. You are responsible for presenting your generator to an authorized Pramac America warranty service center or a distribution center as soon as the problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should call Pramac America Product Service at 1-800-445-1805, Email: generatorservices@powermate.com.

DETAILS OF YOUR WARRANTY
Subject to certain conditions and exclusions as stated below, the warranty on emission-related parts is as follows:

1. Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied, is warranted for the EECS period stated above. If the part fails during the period of EECS warranty coverage, the part will be repaired or replaced by Pramac America according to Subsection (4) below. Any such part repaired or replaced under EECS warranty will be warranted for the remainder of the period.
2. Any warranted part that is scheduled only for regular inspection in the written instructions supplied, is warranted for the EECS warranty period stated above. Any such part repaired or replaced under EECS warranty will be warranted for the remaining warranty period.
3. Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied, is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement date, the part will be repaired or replaced by Pramac America according to Subsection (4) below. Any such part repaired or replaced under EECS warranty will be warranted for the remainder of the period prior to the first scheduled replacement date for the part.
4. Repair or replacement of any evaporative emissions warranted part under the EECS warranty provisions herein must be performed at an authorized Pramac America warranty service center at no charge to the owner.
5. The generator owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at an authorized Pramac America warranty service center.
6. Pramac America is liable for damages to other engine or generator components proximately caused by a failure under warranty of any warranted part.
7. Throughout the generator warranty period stated above, Pramac America will maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
8. Any Pramac America authorized replacement parts may be used in the performance of any EECS warranty maintenance or repairs and must be provided without charge to the owner. Such use will not reduce the EECS warranty obligations of Pramac America.
9. No modifications, other than those explicitly approved by Pramac America, may be made to the generator. Unapproved modifications void this EECS warranty and shall be sufficient grounds for disallowing and EECS warranty claim.
10. Pramac America shall not be held liable hereunder for failures of any non-authorized replacement parts, or failures of any authorized parts caused by the use of non-authorized replacement parts.
11. Notwithstanding the provisions herein, warranty services or repairs will be provided at all of our distribution centers franchised to service the subject engines or equipment.

WARRANTED PARTS
The following emission warranty parts list is covered:

• Fuel Tank
• Fuel Cap
• Fuel Hoses
• Carbon Canister (if equipped)
• Vapor Hoses
• Hose Clamps
• Hose Connectors
• Vapor/Fuel Check Valve

EVAPORATIVE EMISSION CONTROL SYSTEM

NOTE: A typical system is shown in this diagram. All emissions related components are covered by the CALIFORNIA EMISSION CONTROL WARRANTY.

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Pramac America, LLC (herein “Pramac America”) are pleased to explain the evaporative emission control system (EECS) warranty on your 2008 model year and later generator. In California, new generators must be designed, built and equipped to meet the State’s stringent anti-smog standards. Pramac America must warrant the EECS on your generator for the periods of time listed below, provided there has been no abuse, neglect or improper maintenance of your generator. Your EECS includes parts such as fuel tank, fuel hoses, fuel cap, carbon canister, vapor hoses, clamps, connectors, and other emission-related components. Where a warrantable condition exists, Pramac America will repair your generator at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE
This evaporative emission control system is warranted for three years. The warranty period begins on the date the generator is delivered to an ultimate purchaser. Pramac America warrants to the ultimate purchaser and any subsequent owner that the generator is (i) designed, built and equipped so as to conform with all applicable regulations; and (ii) free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in Pramac America’s application for certification. If any evaporative emission-related part on your generator is defective, the part will be repaired or replaced by Pramac America.

OWNER’S WARRANTY RESPONSIBILITIES
As the generator owner, you are responsible for performance of the required maintenance listed in your owner’s manual. Pramac America recommends that you retain all receipts covering maintenance on your generator, but Pramac America cannot deny warranty solely for the lack of receipts. You should, however, be aware that Pramac America may deny you warranty coverage if your generator or a part has failed due to abuse, neglect or improper maintenance or unapproved modifications. You are responsible for presenting your generator to an authorized Pramac America warranty service center or a distribution center as soon as the problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should call Pramac America Product Service at 1-800-445-1805.

DETAILS OF YOUR WARRANTY
Subject to certain conditions and exclusions as stated below, the warranty on emission-related parts is as follows:

1.  Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied, is warranted for the period stated above. If the part fails during the period of warranty coverage, the part will be repaired or replaced by Pramac America according to Subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period.
2.  Any warranted part that is scheduled only for regular inspection in the written instructions supplied, is warranted for the warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period.
3. Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied, is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement date, the part will be repaired or replaced by Pramac America according to Subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement date for the part.
4. Repair or replacement of any warranted part under the warranty provisions herein must be performed at an authorized Pramac America warranty service center at no charge to the owner.
5. The generator owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at an authorized Pramac America warranty service center.
6. Pramac America is liable for damages to other engine or generator components proximately caused by a failure under warranty of any warranted part.
7. Throughout the generator warranty period stated above, Pramac America will maintain a supply of warranted parts sufficient to meet the expected demand for such parts.
8. Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use will not reduce the warranty obligations of Pramac America.
9. Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims. Pramac America will not be liable to warrant failures or warranted parts caused by the use of a non-exempted add-on or modified part.
10. The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if the generator has been abused, neglected or improperly maintained, and such abuse, neglect or improper maintenance was the direct cause of the need for repair or replacement of the part.
11. Notwithstanding the provisions herein, warranty services or repairs will be provided at all of our distribution centers franchised to service the subject engines or equipment.

WARRANTED PARTS
The following emission warranty parts list is covered:

• Fuel Tank (except metal fuel tank)
• Fuel Cap
• Fuel Hoses
• Carbon Canister
• Vapor Hoses
• Hose Clamps
• Hose Connectors
• Vapor/Fuel Check Valve

OPERATION GENERAL INFORMATION

This manual has been prepared to acquaint you with the operation and maintenance of this product. Study the information provided carefully to avoid problems associated with improper application or maintenance. Upon receipt of your generator, verify that it is complete and in good condition. The generator is comprised of a 4 stroke, air-cooled engine directly coupled to a 2 pole alternator producing either 125VAC or 125/250VAC depending on model. The no-load speed is approximately 3750rpm with the speed under load going to approximately 3600rpm thus producing a frequency of 60Hz.

INITIAL INSPECTION
Upon receiving your generator set, inspect the product to make sure it is complete and in good condition. Handle with care and place in a suitable site for storage or operation.

GROUND CONNECTION
The generator should be grounded to earth to reduce the risk of electrical shock. To do this you will need a grounding rod and an appropriately sized copper ground wire. Drive the ground rod into the earth, connect one end of the copper wire to the rod and connect the other end to the external ground connection on the generator set. This is a general explanation, consult National and Local electrical codes to ensure compliance.

GENERATOR NEUTRAL BOND
There is a permanent conductor between the generator (stator winding) and the frame.

BEFORE START-UP ENGINE FUEL
Use Unleaded Gasoline with minimum Octane 86. Check the fuel gauge and add as necessary.

• SLOWLY ADD UNLEADED GASOLINE TO FUEL TANK
• DO NOT OVERFILL TANK
• DO NOT FILL ABOVE TOP OF FUEL SCREEN. THIS WILL ALLOW EXPANSION IN HOT WEATHER AND PREVENT OVERFLOW.

ENGINE OIL
The engine manual or other information provided by the engine manufacturer supersedes data provided here. Proper oil grade varies with climate. The grade listed in the table is typically a good grade but consult the engine manual to verify proper grade. The oil fill ports are located on both sides of the engine. The gray filler cap has an integral dipstick. Add the proper amount of oil and check the level using the dipstick.
NOTE: The dipstick should be placed into the filler opening but not screwed in to check the level.

STARTING BATTERY (Electric Start Models Only)
The starting battery should be rated at 12V-18AH (12V-34AH for DXGN14000). The battery is fully charged if a voltage of 13.7VDC is measured across the terminals using a DC Voltmeter.

POSITIONING

• Place the generator set on a flat and solid surface to prevent it from sinking.
• Keep fuel, oil or other flammable or combustible materials at a safe distance from the generator set.
• Select a site that is well ventilated and protected from the weather.
• Place the generator set safely away from people and animals.

TILTING CAN CAUSE FUEL SPILLAGE OPERATION
Check the engine oil before each use. Never operate the generator set with insufficient oil.

GENERATOR SET OVERLOAD
Do not exceed the rated load of the generator set when operating continuously. Before connecting items to the generator set, determine the total electrical requirements of the products to be connected. The requirement of each item is
generally given on the manufacturer’s nameplate. Following is a list of commonly used items and typical requirements. Use this list as a guideline only if no other data is available.

GENERAL WATTAGE GUID

Item Running Watts

GENERAL WATTAGE GUIDE

Item Running Watts

Air Conditioner (12000 Btu) (*)…………………………………….. 1750

Air Compressor (1/2 hp) (*)………………………………………….. 1400

Air Compressor (3/4 hp) (*)………………………………………….. 1800

Air Compressor (1 hp) (*)…………………………………………….. 2000

Battery Charger (25A)…………………………………………………….. 600

Belt Sander (3” belt)……………………………………………………… 1000

Circular Saw (7 1/4”)…………………………………………….. 825-1050

Coffee Maker………………………………………………………… 900-1100

Edger (lawn)………………………………………………………………….. 550

Furnace Fan (1/3 hp) (*)……………………………………………….. 1200

Hot Plate (single)…………………………………………………………… 1500

Impact wrench………………………………………………………………… 600

Light Bulb……………………………………………………………. Bulb rating

Nail Gun……………………………………………………………………….. 1200

Microwave……………………………………………………………………… 750

Paint Sprayer (1/3 hp) (*)……………………………………………….. 650

Paint Sprayer, hand-airless…………………………………………….. 175

Radio………………………………………………………………………… 50-200

Refrigerator (*)………………………………………………………………… 600

Table Saw (10”) (*)………………………………………………………… 2000

Television………………………………………………………………… 250-550

Weed Trimmer………………………………………………………………… 500

Note: (*) Items allow at least 3 times the listed wattage for starting.

NOTE: Many appliances such as saws or drills draw more current than indicated on the manufacturer’s nameplate when under severe load.

STARTING THE GENERATOR SET
Before attempting to start the generator set, ensure that all instructions given in previous sections have been followed completely.

• Check oil and fuel levels.

• Turn the fuel shut-off valve on.

• Move the choke lever on the front of the engine on.
  Note: the choke may not be required when the engine is warm or in high ambient temperatures.

• Turn idle-control On/Off switch OFF.

RECOIL START

• Move engine On/Off switch to On position.
• Slowly pull recoil cord until resistance is felt and then pull firmly. Let the recoil rewind slowly to avoid damage.
• Return the choke to the original position.

ELECTRIC START (DXGN7200)

• Move engine On/Off switch to On position.
• Push and hold the On/Off switch in the Start position until the engine starts and release. Note: If the engine does not start after 5 seconds, stop and wait 10 seconds and repeat this step.
• Return the choke to the original position.

ELECTRIC START (DXGN14000)

• Turn the key switch to “START”. Release key switch after the engine starts.
• Return the choke to the original position.
  CAUTION: This generator is equipped with an oil protection system. When oil levels are too low for safe operation the engine will shut down and/or will not start until the oil level is corrected.

OPERATING THE GENERATOR SET
Once started, allow the engine to stabilize for approximately 3 minutes. Check that the circuit breakers and the GFCI receptacles are not tripped. Turn the idle-control switch to the On position if this feature is to be utilized. Set the voltage
selector switch to the appropriate mode, either 120V or 120/240V. See the guides below for more information on the idle-control and voltage selector features.

IDLE CONTROL GUIDE (applicable models)
The automatic idle control system is available on some generators. This feature allows the engine to automatically idle down when there is no load drawn against the generator thus saving fuel, decreasing wear and lowering the noise level.
There is an on-off switch located on the control panel that activates or deactivates this feature. In the on position the engine will idle down after detection of less than 40 Watts. The engine will return to the correct running speed immediately
when a load of 350 Watts or more is applied. For applications with loads less than 50W or with near constant loads, such as home back up, it is best to turn the idle control feature off. The feature should be turned off before starting or stopping the generator and turned on when there will be extended periods of inactivity for the generator. Model DXGN14000: A 12V battery must be installed in order for the idle control to function.

VOLTAGE SELECTOR GUIDE (applicable models)
The voltage selector switch allows the generator set to produce 120 volts only or to produce 120/240 volts simultaneously. With the switch in the 120V position only the 120V receptacles may be used. All of the power from the generator is available at 120 volts but the 240V output is not available. In the 120/240V position all receptacles are operable however only half of the generator output is available at any one 120V receptacle. Full power may be pulled from the generator from the 240V receptacle. The switch should always be left in the 120V position when 240 volts are not needed. This balances the load on the generator more effectively.

STOPPING THE GENERATOR SET
Unplug all appliances and let the engine run unloaded for a couple of minutes. Turn the engine On/Off switch or key switch to the Off position. Turn the fuel shut-off valve to the Off position. Never use the choke to stop the engine.

WHAT IS A GENERATOR
A generator is basically a prime mover, typically a gasoline or diesel engine, coupled to an alternator to produce electricity. It is very useful as a substitute power source during power outages or as the primary source in remote locations where power is not available. Generators are essential for people such as contractors or farmers who are always in need of portable power. They are also very convenient for recreational use.

SELECTING A GENERATOR
Selecting the proper generator is important. A generator that is too small for your application will not run all of the equipment needed. A generator that is too large will cost more and if never used to its potential the money is wasted. The correct size generator is determined by totaling the wattage requirements of the items to be used simultaneously, determine additional starting wattage requirements and total these numbers. Select a generator with a continuous rating that exceeds this by about 20% to allow for expansion. See the table in the section titled “Generator Set Overload” for some wattage guidelines of common equipment.

RATED vs. SURGE WATTS
Rated, or continuous, watts are the watts an item needs as it is running. Surge, or maximum, watts are the watts an item needs to start. This is typically 2-4 times the rated watts. This information is typically provided on the manufacturer’s nameplate. If watts are not provided, it can be calculated using the formula: Watts=Amps x Volts.

EXTENSION CORDS
An extension cord should always be in good condition with no damage to the wires or sheathing. Never run an extension cord through water. The correct wire size for an extension cord can be determined from the table that follows.

LOADING YOUR GENERATOR SET
With reference to the Receptacle details section, please review the power receptacles fitted to your generator. The circuit breaker rating and the generator rating drive the actual load that may be pulled from each receptacle. The ratings shown in the table are the maximum available from each receptacle.

DO NOT EXCEED THE INDIVIDUAL RECEPTACLE RATINGS AS SHOWN IN THE TABLE BELOW. DO NOT EXCEED THE TOTAL GENERATOR NAMEPLATE RATING. All generator units are equipped with a thermal-magnetic main circuit breaker as well as a “PUSH TO RESET” breaker on branch circuits. AMPERAGE RATE TABLE

Feet

20

25

30

35

40

50

| 12

12

10

10

8

6

| 10

10

8

8

6

4

| 8

6

6

4

2

2

RECEPTACLE DETAILS
The receptacles shown in this section are for reference only. Each receptacle is not available on all generator

ENGINE LIMITATIONS ON GENERATOR PERFORMANCE
Generator ratings assume 60°F (20C) and Sea Level.  Operation of your generator at temperatures above 60°F (20C) or above Sea Level will result in lower electrical output. Electrical output must be derated 1% for each 10°F above 60°F and 3 ½ % for each 1000 feet above mean sea level.

Model| GX270 (DXGN4500)| GX340 (DXGN6000)| GX390 (DXGN7200)| GX630 (DXGN14000)
---|---|---|---|---
Type| 4-stroke, overhead vale single cylinder, inclined 25°| 4-stroke, overhead valve,

V-Twin

Displacement| 270cc (16.5 cu in)| 389cc (23.7 cu in)| 389cc (23.7 cu in)| 688cc (42.0 cu in)
Bore and Stroke| 73 x 58 mm

(2.9 x 2.3 in)

| 88 x 64 mm

(3.5 x 2.5 in)

| 88 x 64 mm

(3.5 x 2.5 in)

| 78 x 72 mm

(3.1 x 2.8 in)

Net HP| 8.5 hp @3600rpm| 10.7 hp @3600rpm| 11.7 hp @3600rpm| 20.2hp @3600rpm
Net Torque| 14.1ft-lb @2500rpm| 19.5ft-lb @2500rpm| 19.5ft-lb @2500rpm| 35.1ft-lb @2500rpm
Compression Ratio| 8.5 : 1| 8.2 : 1| 8.2 : 1| 9.3 : 1
Cooling System| Forced-air
Ignition System| Transistorized magneto
Ignition Timing| | | 25° B.T.D.C. (fixed)|
Spark Plug| BPR6ES (NGK), W20EPR-U (Nippondenso)
Carburetor| Horizontal type, butterfly valve
Air Cleaner| Dual element type
Lubricating System| Splash| Forced Oil
Oil Capacity| 1.1l (1.16 US qt)| 1.1l (1.16 US qt)| 1.1l (1.16 US qt)| 2.0 l (2.1 US qt)
Starting System| Recoil| Recoil| Recoil/Electric| Electric
Stopping System| Ignition primary circuit ground
Fuel Type| Unleaded gasoline (86 pump octane)
PTO Shaft Rotation| Counterclockwise (from PTO side)
Dry Weight| 25.0 kg (55.1 lb)| 31.5 kg (69 lb)| 31.5 kg (69 lb)| 44.0 kg (96.8 lb)

GENERATOR CLEANING ALWAYS SHUT DOWN THE GENERATOR AND ALLOW IT TO COOL COMPLETELY BEFORE PERFORMING CLEANING OPERATIONS. DO NOT USE HIGH PRESSURE WATER OR A GARDEN HOSE TO CLEAN YOUR GENERATOR. WATER INTRODUCED INTO THE GENERATOR CAN CAUSE ELECTRICAL SHORTS, GENERATOR DAMAGE OR PERSONAL INJURY.

• Compressed air (max. 25 psi) may be used to blow loose dirt and dust from your generator. DO NOT DIRECT COMPRESSED AIR DIRECTLY INTO ANY OPENING IN THE GENERATOR OR ENGINE.
• Use a dampened cloth to wipe clean exterior surfaces.
• Use a soft bristle brush to clean/ loosen heavy dirt, oil or grease deposits.
• NEVER insert rags, tools or any device into the generator or engine openings.

GENERAL STORAGE GUIDELINES GASOLINE FUEL FUMES ARE FLAMMABLE. DO NOT STORE YOUR GENSET IN ANY AREA THAT IS INDOOR OR IN POORLY VENTILATED AREAS. GASOLINE FUEL FUMES CAN IGNITE IN THE PRESENCE OF ANY OPEN FLAME, PILOT LIGHT, CLOTHES DRYER, WATER HEATER, ETC.

Your generator should be started and operated for several minutes at least every 30 days. When the generator set is not being operated or is being stored more than one month, follow these instructions:

1. Replenish engine oil to upper level.

2. Run the generator, then close the fuel shut-off valve and allow the unit to run until the engine stops.

3. Move the engine switch to the “OFF” position. (Turn the key switch to “OFF” on the DXGN14000 model).

4. After the unit has cooled, drain gasoline from fuel tank, fuel line and carburetor.

5. Pour about one teaspoon of engine oil through the spark plug hole, pull the recoil starter several times and replace the plug. Then pull the starter until you feel the piston is on its compression stroke and leave it in that position. This
   closes both the intake and exhaust valves to prevent the inside of the cylinder from rusting.

6. Cover the unit and store in a clean, dry place that is well ventilated away from open flame or sparks. We recommend always using a fuel stabilizer.

7. A fuel stabilizer will minimize the formulation of fuel gum deposits during storage. The fuel stabilizer can be added to the gasoline in the fuel tank, or into the gasoline in a storage container.

GENERAL MAINTENANCE

Proper maintenance and service are required to achieve maximum engine life and maintain warranty. The following tables provide engine specifications as well as maintenance schedules for the generator engines. Note that the generator models are referenced with the engine model. An engine owner’s manual is provided with each machine that also provides basic maintenance and troubleshooting information. Defer to the engine manufacturers manual if any discrepancies appear between the data provided in this manual and the engine owner’s manual. Full engine service manuals are available from American Honda Motor Co., 4900 Marconi Drive, Alpharetta, GA 30005-8847, 800-910-1293.

OIL SELECTION

Proper oil selection as well as proper oil level is critical to achieve maximum engine life. Use high detergent, premium quality motor oil certified for service class SJ that should be designated on the container. SAE 10W-30 is recommended for general, all temperature use. Use the table below to select the proper oil for the temperature in your area.

ENGINE MAINTENANCE SCHEDULE

ITEM

| Each Use| First Month

Or 20 Hrs

| 3 Months Or

50 Hrs

| 6 Months Or

100 Hrs

| Every Year

Or 300 Hrs

---|---|---|---|---|---

Oil

| Check| X| | | |
Change| | X| | X|

Air Cleaner

| Check| X| | | |
Clean| | | X (1)| |
Sediment Cup| Clean| | | | X|
Spark Plug| Check-Clean| | | | X|
Spark Arrester| Clean| | | | X|
Valve Clearance| Check-Adjust| | | | | X (2)
Fuel Tank and Strainer| Clean| | | | | X (2)
Fuel Line| Check| Replace as necessary.

Notes

1.  Service more frequently in dusty areas.
2.  Should be serviced by authorized dealer unless owner has proper tools and is mechanicaly proficient. See engine Shop Manual for instructions.

DAILY INSPECTION

1. Recoil Starter Cord
2. Engine Oil Level
3. Check for Engine Oil or Fuel Leaks
4. Inspect Spark Plug Cables
5. Inspect Cooling System for Cleanliness
6. Listen for Abnormal Noise
7. Look for Abnormal Vibration

SPARK ARRESTER
The spark arrester must be serviced every 100 hours to keep it functioning as designed. If the engine has been running, the muffler will be hot. Allow it to cool before servicing the spark arrester.

DXGN4500, DXGN6000, and DXGN7200
Clean and inspect the spark arrester as follows:

1. Remove the four screws (B) and spark arrester screen (A) from the muffler.
2. Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.
3. The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.
4. Attach the spark arresting screen (A) to the muffler by aligning the holes in the screen with the holes pierced in the muffler. Thread the four screws (B) into the holes and tighten securely. DXGN14000
5. See instructions supplied with Spark Arrestor Kit.

FAULT FINDING GUIDE

2.  No fuel or valve(s) turned off.

3.  Start switch turned Off.

4.  Blocked or leaking fuel system.

5.  Clogged air filter.

6.  Genset under load at start-up.

| 1. Add oil.

2. Add fuel and/or turn valve(s) on.

3.  Turn switch On.

4.  Repair fuel system.

5.  Clean or replace air filter.

6.  Disconnect load.

NO POWER OUTPUT| 1.  Circuit breaker tripped.

2.  GFCI receptacle tripped.

3.  Faulty circuit breaker.

4.  Faulty receptacle.

5.  Faulty capacitor in alternator.

6.  Faulty diodes in alternator.

7.  Failure in alternator windings.

| 1.  Reset circuit breaker.

2.  Reset GFCI receptacle.

3.  Replace circuit breaker.

4.  Replace receptacle.

5.  Replace capacitor.

6.  Replace diodes.

7.  Repair or replace alternator.

NOISY MACHINE| 1.  Damaged bearing.

2.  Damaged exhaust system.

3.  Loose or rattling parts.

| 1.  Replace bearing.

2.  Repair or replace.

3.  Repair loose or rattling parts.

OVERHEATING| 1.  Ventilation openings blocked.

2.  Overload.

3. Ambient temperature too high.

| 1.  Clear ventilation openings.

2.  Verify load levels.

3.  Provide better ventilation for cooling.

CIRCUIT BREAKER TRIPS| 1.  Overloaded circuit.

2.  Faulty equipment or cable.

3.  Faulty circuit breaker.

| 1.  Reduce load.

2.  Check, repair or replace.

3.  Replace circuit breaker.

PRAMAC America 1300 Gresham Road Marietta, GA 30062 Copyright © 2012
The following are trademarks for one or more DEWALT power tools: the yellow and black color scheme.
DEWALT®, GUARANTEED TOUGH® and the yellow and black color scheme are trademarks of the
DEWALT Industrial Tool Co., used under license. PRAMAC America 1300 Gresham Road Marietta, GA 30062, a licensee of DEWALT Industrial Tools.

References

• DEWALT® Power Tools Official Site | Guaranteed Tough®
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