DeWalt DXGNSeries User manual

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Operator'smanual
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Portable Generator
DXGN series
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Copyright © 2017 PR Industrial s.r.l. – Loc. Il Piano – 53031 Casole d’Elsa (SI)
Printed in Italy All rights are reserved, in particular the world-wide applicable copyright, right
of duplication and right of distribution.
This document may only be used by the recipient for the intended purpose. The document
may not be reproduced entirely or partially, or translated into any other language.
Reproduction or translation, even extracts thereof, only with written approval of PR Industrial
s.rl.
Any breach of the statutory provisions, in particular the protection of copyright, will lead to
civil and criminal prosecution. PR Industrial s.r.l. constantly working on the improvement of
its products as part of the technical further development. Therefore, we reserve the right to
make changes to the illustrations and descriptions in this documentation without incurring
any obligation to make changes to machines already delivered.
Errors excepted. The machine on the cover may have special equipment (options).
Supplier
PR Industrial s.rl.
Loc. Il Piano
53031 Casole d’Elsa (SI) - Italy
Tel.: [phone]
E-mail address: [email protected]
Original operator's manual

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1 Foreword 5
2 Introduction 6
2.1 Means of representation for this operator's manual 6
2.2 DEWALT representative 7
2.3 Described machine types 7
2.4 Identification of the machine 7
3 Safety Regulations 8
3.1 Safety information in this operator's manual 8
3.2 Description and purpose of the machine 9
3.3 Operational safety 10
3.4 Operator qualifications 11
3.5 Safety when using combustion engines 13
3.6 Service safety 14
4 Safety and information labels 16
5 Standard package 17
6 Lifting and transporting 18
7 Operation 19
7.1 Prepare the machine for first-time application 19
7.2 Power requirements 20
7.3 Performance loss with high altitude application 21
7.4 Ground 22
7.5 Heavy duty operation 22
7.6 Installation 22
7.7 Use of extension cables 23
7.8 Control Panel 25
7.9 Before starting 26
7.10 Starting 26
7.11 Stopping 27
7.12 Emergency stop procedure 27
8 Maintenance 28
8.1 Period maintenance schedule 28
8.2 Engine oil 29
8.3 Air cleaner maintenance 30
8.4 Spark plug 31
8.5 Setting the engine speed 32
8.6 Long-term storage 33

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9 Basic troubleshooting 34
10 Disposal 35
10.1 Disposal of waste electrical and electronic equipment 35
11 Technical data 36
11.1 DXGN3000E 36
11.2 DXGN4000E 37
11.3 DXGN5000E singlephase 38
11.4 DXGN5000E threephase 39
11.5 DXGN6000E 40
11.6 DXGN8000E singlephase 41
11.7 DXGN8000E threephase 42
12 Glossary 43
13 Diagram 45
EC declaration of conformity 46

1 Foreword
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1. Foreword
This operator's manual contains important information and procedures for the safe,
proper and economic operation of this DEWALT machine. Carefully reading,
understanding and observing is an aid to avoiding hazards, repair costs and
downtime, and therefore to increasing the availability and service life of the
machine.
This operator's manual is not a manual for extensive maintenance or repair work.
Such work should be carried out by DEWALT service or by technically trained
personnel. The DEWALT machine should be operated and maintained in
accordance with this operator's manual. An improper operation or improper
maintenance can pose dangers. Therefore, the operator's manual should be
constantly available at the location of the machine.
Defective machine parts must be exchanged immediately!
If you have any questions concerning the operation or maintenance, a DEWALT
contact person is always available.

2 Introduction
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2. Introduction
2.1 Means of representation for this operator's manual
Warning symbols
This operator's manual contains safety information of the categories:
DANGER, WARNING, CAUTION, NOTICE.
They should be followed to prevent danger to life and limb of the operator or
damage to equipment and exclude improper service.
DANGER
This warning notice indicates immediate hazards that result in serious injury or
even death.
 Danger can be avoided by the following the actions mentioned.
WARNING
This warning notice indicates possible hazards that can result in serious injury or
even death.
 Danger can be avoided by the following the actions mentioned.
CAUTION
This warning notice indicates possible hazards that can result in minor injury.
 Danger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates possible hazards that can result in material
damage.
 Danger can be avoided by the following the actions mentioned.
Notes
Note: Complementary information will be displayed here.
Instructions
 This symbol indicates there is something for you to do.
1. Numbered instructions indicate that you have to carry out something in a
defined sequence.
 This symbol is used for lists.

2 Introduction
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2.2 DEWALT representative
Depending on your country, your DEWALT representative is your DEWALT
service, your DEWALT affiliate or your DEWALT dealer.
You can find the addresses in the Internet at WWW.DEWALT.COM
The address of the manufacturer is located at the beginning of this operator's
manual.
2.3 Described machine types
This operator's manual is valid for different machine types from a product range.
Therefore some figures can differ from the actual appearance of your machine.
It is also possible that the descriptions include components which are not a part of
your machine.
Details for the described machine types can be found in the chapter Technical
data.
2.4 Identification of the machine
Nameplate data
The nameplate lists information that uniquely identifies your machine. This
information is needed to order spare parts and when requesting additional
technical information.
 Enter the information of your machine into the following table:
Designation Your information
Group and type
Construction year
Code no.
Serial no.

3 Safety Regulations
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3. Safety Regulations
3.1 Safety information in this operator's manual
This operator's manual contains safety regulations in the categories: DANGER,
WARNING, CAUTION, NOTE and COMMENT. These are to be followed in order
to reduce the danger of injury, damage to equipment or improper service.
This is a safety warning symbol that warns against possible danger of injury.
 Comply with all safety regulations that follow this warning symbol.
DANGER
DANGER indicates a hazardous situation that leads to serious injury or death if
this warning is not observed.
 In order to avoid fatal accidents and serious injuries, observe all safety
instructions precisely that follow this signal word.
WARNING
WARNING indicates a hazardous situation that can lead to serious injury or death
if this warning is not observed.
 In order to avoid possible fatal accidents and serious injuries, observe all
safety instructions precisely that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation that can lead to minor to moderate injury
if this warning is not observed.
 In order to avoid possible minor or moderate injuries, observe all safety
instructions precisely that follow this signal word.
NOTE: When this word appears without a safety warning symbol, NOTE indicates
a hazardous situation that can lead to damage if not observed.
Comment: A comment contains additional important information about a work
process.

3 Safety Regulations
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3.2 Description and purpose of the machine
This machine is a portable power source. The portable generator from DEWALT
consists of a steel pipe frame, which includes a fuel tank, a gasoline engine, a
control panel and an electrical alternator. The control panel contains controls and
bushings. When the engine is running, the generator converts the mechanical
energy into electrical energy. The operator connects electronic loads to the mains
sockets.
This machine is used for the electric power supply of connected electric loads. See
the product specifications for output voltage and frequency of the generator as well
as the maximum power limitation of this generator.
This machine was designed and built exclusively for the aforementioned purpose.
Use of the machine for any other purpose could permanently damage the machine
or cause serious injury to the operator or other persons in the vicinity. Machine
damage due to misuse is not covered by the warranty.
The following practices are considered misuse:
 Connection to an electric load whose voltage and frequency are not
compatible with the generator output
 Overloading the generator with a load that takes too much power during
continuous operation or when starting
 Operating the generator in a manner that is inconsistent with the national,
statewide and local standards and regulations
 Use of the machine as a ladder, support or working surface
 Operation of the machine to carry or transport people or equipment
 Operation of the machine outside of the plant specifications
 Operation of the machine contrary to warning notices attached to the
machine and contained in the operator's manual.
This machine was designed and built according to the latest global safety
standards. In order to eliminate dangers as much as possible, it was technically
designed with great care and contains protective side plates and warning labels for
an increased safety of the operator. Additional risks may exist despite these
protective measures. These are designated as residual risks. Possible residual
risks with this machine:
 Heat, noise, exhaust and carbon monoxide from the engine
 Risk of fire due to incorrect refueling procedure
 Gasoline or gasoline vapors
 Electric shock and arc discharge
 Injury due to incorrect hoisting technology
For your own protection and the protection of other people, make sure that the
safety instructions in this manual have been closely read and understood before
starting the machine.

3 Safety Regulations
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3.3 Operational safety
DANGER
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES.
The exhaust fumes from the generator contain carbon monoxide (CO). This is an
invisible odorless poison. If the exhaust fumes of the generator can be smelled,
CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be
being inhaled.
 NEVER use the generator in buildings, garages, crawl spaces or other
partially enclosed areas. Carbon monoxide can build up to deadly levels in
these areas. A fan or open window does NOT provide sufficient fresh air.
 ONLY use generators outdoors and far away from windows, doors and
aeration. These openings can draw in generator exhaust fumes.
 CO can penetrate into a home, even if a generator is used properly. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
 IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using
the generator. Consult a physician. It could be carbon monoxide poisoning.
WARNING
Electric shock or risk of fire or explosion. Incorrect connection of the generator to
a building's mains supply can lead to current being lead from the generator back
into the power supply system. This can cause electric shock, serious injury or death
of the worker in the public utility company!
 The following connection prerequisites are to be met.

3 Safety Regulations
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Connection prerequisites
The following prerequisites are to be met to connect the generator to the building's
mains supply.
 The generator must meet the prerequisites with regard to performance,
voltage and frequency of the equipment.
 The generator must be disconnected from the electric power supply.
 Connections from the generator to the power supply system of a building
must be established by a licensed electrician.
 The electrical connections must meet all laws and electrical regulations.
WARNING
Prerequisites for safe operation are familiarity with the machine and proper
training. Machines that are incorrectly operated or that are operated by untrained
personnel may pose a danger. Read through the operating instructions in this
manual and in the engine manual to make yourself familiar with the job and the
proper use of the operator's controls. Inexperienced operators must be instructed
by personnel who are familiar with the machine before they are allowed to operate
the machine.
3.4 Operator qualifications
Only trained personnel may start, operate and switch off the machine. The
personnel must also have the following qualifications:
 be trained in the correct operation of the machine
 be familiar with the necessary safety devices
Access to the machine and operation of the machine is not permitted for:
 Children
 People under the influence of alcohol, drugs or medication
Personal Protective Equipment (PPE)
The following personal protective clothing (PPE) is to be worn when operating this
machine:
 Close-fitting work clothes that do not impede movement
 Safety glasses with protective sides
 Ear protection
 Work shoes or boots with toe protection
 NEVER use generator near open containers of fuel, paint or other flam-mable
liquids.
 NEVER touch the generator or tools connected to it if you have wet hands.
 NEVER use damaged power cables. Electric shock and major machine
damage could occur.
 NEVER place power cable below the generator or on vibrating or hot parts.
 NEVER cover hot or running generator.

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 NEVER overload generator. The total amperage of the parts connected to
the generator may not exceed the output limit.
 NEVER operate the machine in snow, rain or standing water.
 NEVER allow untrained personnel to operate or maintain the generator.
Familiarize yourself with the operation and shutdown before starting the
generator.
 ALWAYS store the machine properly when not in use. Store the machine in
a clean dry place and keep it out of reach of children.
 ALWAYS make sure that the machine is stable and cannot tip, roll, slide or
fall during operation.
 ALWAYS transport the generator in an horizontal position.
 ALWAYS keep at least one meter distance from facilities, buildings or other
machines while operating the machine.
 ALWAYS keep the area immediately around and under the machine clean,
tidy and free of grime and flammable materials. Check that there is also no
grime above the machine that could fall onto or into the machine or the
exhaust area.
 ALWAYS keep all tools, power cables and other loose objects away from the
generator before starting.
 Do NOT ground this generator.
 If more than one electric device is connected to the generator, the additional
connected electric equipment must be connected to the generator via an
isolating transformer or a suitable FI switch (PRCD), whereby each additional
electric device must be operated via a separate isolating transformer or
PRCD.
Generator vibration
Generators vibrate during normal operation. Check during and after use of the
generator whether the generator or the extension cord and power cable show
damage due to vibration.
 Repair any damage as needed or replace the parts affected.
 Do not use any plugs or cables that show signs of damage, such as damaged
or cracked insulation or blades.

3 Safety Regulations
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3.5 Safety when using combustion engines
WARNING
Combustion engines pose a particular danger during operation and when refueling.
Failure to follow the warning notices and safety standards can lead to serious injury
or death.
 Read and always observe the warning notices in the operator's manual of
the engine and the safety instructions below.
DANGER
Carbon monoxide.
Use of the generator in buildings can LEAD TO DEATH WITHIN MINUTES. The
exhaust fumes from the generator contain carbon monoxide (CO). This is an
invisible odorless poison. If the exhaust fumes of the generator can be smelled,
CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be
being inhaled.
Operational safety
When running the engine:
 Keep the area around the exhaust pipe free of flammable materials.
 Inspect the fuel lines and fuel tank for leaks and cracks before starting the
engine. Do not operate the machine if there are leaks or if the fuel lines are
loose.
When running the engine:
 Do not smoke while operating the machine.
 Do not operate the engine near sparks or open flames.
 Do not touch the engine or the muffler while the engine is running or shortly
after switching the engine off.
 Do not operate the machine with a loose or missing fuel cap.
 Do not start the engine if fuel has been spilled or there is an odor of gas.
Move the machine away from the spilled fuel and wipe away the spilled fuel
before starting.

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Safety when refueling
When refueling the machine:
 Immediately wipe away any spilled fuel.
 Fill the fuel tank in a well-ventilated area.
 Reattach the fuel tank cap after refueling.
 Do not smoke.
 Do not refuel hot or running engines.
 Do not refuel the engine near sparks or open flames.
 Do not refuel the machine while it is on plastic-coated surfaces of pick-ups.
Static electricity can ignite the fuel or fuel vapors.
3.6 Service safety
WARNING
Carelessly maintained machines can pose dangers! Regular maintenance and
occasional repairs are necessary to ensure the safe and correct functioning over
longer time periods. If problems should occur with the generator or while the
machine is being maintained, always attach a "DO NOT START" sign to the
control panel in order to alert others of this.
Personal Protective Equipment (PPE)
Wear the following personal protective equipment during maintenance or repair
work:
 Close-fitting work clothes that do not impede movement
 Safety glasses with protective sides
 Ear protection
 Work shoes or boots with toe protection
Additional notes before operating the machine:
 Tie up long hair
 Take off all jewelry (including rings)
 Do NOT use any gasoline or other types of fuel or flammable solvents to
clean the machine parts, especially not in closed areas. The vapors from
fuels and solvents may explode.
 NEVER operate equipment without protective devices or with damaged
protective devices.
 NEVER modify the machine without written approval from the manufacturer.
 NEVER allow water to collect at the bottom of the generator. If water should
collect, remove the generator and allow it to dry thoroughly before
maintaining.
 NEVER maintain the machine with wet clothing or wet skin

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 NEVER have the machine serviced by untrained personnel. Electric
elements of this machine should only be maintained by qualified electricians.
 NEVER allow children to approach the machine. Keep always a safe
distance between children and the generating set.
 ALWAYS keep the machine clean and ensure that the labels are legible.
Replace all missing and hard-to-read labels. The labels contain important
operating instructions and warn against dangers.
 ALWAYS reattach protective devices and safety equipment to the unit after
repair and maintenance.
 ALWAYS allow the engine to cool completely before transport.
 ALWAYS watch out for the rotating parts of the generator and engine and
keep hands, feet and loose clothing parts away from these rotating parts.
 ALWAYS switch the engine off before maintenance. Disconnect the negative
connection of the battery on machines with electric starters.
 ALWAYS keep fuel lines in a good condition and connected correctly.
Leaking fuel and gases are highly explosive.
 If spare parts are required for this machine, only use parts from DEWALT or
parts that match the original exactly in terms of dimensions, model, intensity
and material.

4 Safety and Information labels
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4. Safety and information labels
There are labels on your equipment that contain important information and safety
instructions.
 Keep all labels legible.
 Replace missing or illegible labels.
The item numbers on the labels can be found in the parts book.
Item Label Description
1 Guaranteed sound power level.
2 DANGER!
Danger of suffocation.
 Engines give off carbon monoxide.
 Do not run the machine indoors or in
enclosed areas.
 NEVER operate in houses or garages,
EVEN IF doors and windows are open.
 Only use OUTDOORS and away from
windows, doors and aeration.
 Read through the operator's manual.
 No sparks, flames or burning objects are
permitted near the machine.
 Stop the engine before refueling.
3 Warning against hot surface.
4 Warning against hot surface.
PE = Potential grounding - Connect cable
from grounding rod here (where required).
WARNING!
Electric shock will cause serious injury or
death.
5 Use this kind of fuel.

5 Standard package
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5. Standard package
The standard package includes:
 Equipment.
 Operator's manual.
 Engine’s manual
 Alternator’s manual
 CE declaration

6 Lifting and transporting
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6. Lifting and transporting
Lifting the machine
This compact generator is heavy enough to cause injury in the event of incorrect
hoisting technology. Observe the following instructions to lift the generator:
 Do not try to lift the generator without help. Use suitable lifting bars e.g. loops,
chains, twisting hooks, ramps or car jacks.
 Make sure that the lifting bars are firmly attached and have sufficient carrying
capacity to safely lift or hold the generator.
 Pay attention to surrounding persons when lifting the generator.
Transporting the machine
Observe the following instructions when the generator is transported from and to
the construction site.
 Allow the engine to cool off before refueling the generator.
 Empty the fuel tank.
 Close the fuel cock.
 Firmly fasten the generator to the transport vehicle so that it does not slide
or tip over.
 Do not refuel the generator in or on the transport vehicle. Transport the
generator to the work location first and refuel the fuel tank there.
 Do not operate the genset in / on transport vehicle

7 Operation
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7. Operation
7.1 Prepare the machine for first-time application
Prepare the machine for first-time application:
1. Ensure that all loose packaging material has been removed from the
machine.
2. Check the machine and its components for damage. Do not operate the
machine if you find visible damage! Ask the DEWALT dealer for advice at
once.
3. Check whether all of the parts belonging to the machine have been delivered
and whether all loose parts and fasteners are present.
4. Now attach components that are not yet fastened.
5. Fill fluids as needed, including fuel, engine oil and battery acid.
6. Bring the machine to its site of operation.
DANGER
Carbon monoxide.
The application of a generator in buildings can LEAD TO DEATH WITHIN
MINUTES. The exhaust fumes from the generator contain carbon monoxide (CO).
This is an invisible odorless poison. If the exhaust fumes of the generator can be
smelled, CO is being inhaled. Even if no exhaust fumes can be smelled, CO could
still be being inhaled.
 NEVER use the generator in buildings, garages, crawl spaces or other
partially enclosed areas. Carbon monoxide can build up to deadly levels in
these areas. A fan or open window does NOT provide sufficient fresh air.
 ONLY use generators outdoors and far away from windows, doors and
aeration. These openings can draw in generator exhaust fumes.
 CO can penetrate into a home, even if a generator is used properly. ALWAYS
use a battery-powered or battery-backup CO alarm in the home.
 IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using
the generator. Consult a physician. It could be carbon monoxide poisoning.
Use of gasoline / ethanol mixtures
This portable generator may not be used with gasoline / ethanol mixtures with more
than 10% ethanol content.