DEWALT DG6000 6,000-Watt 11 HP Portable Generator Instruction Manual

1. Introduction

This manual provides essential information for the safe and efficient operation of your DEWALT DG6000 Portable Generator. Please read and understand all instructions before operating the generator.

The DEWALT DG6000 is a heavy-duty, gas-powered portable generator featuring an 11 HP Honda OHV GX engine, designed for reliable power output up to 6,000 watts. It is suitable for both commercial and residential applications.

2. Important Safety Information

Operating a generator can be hazardous if proper safety precautions are not followed. Always prioritize safety to prevent serious injury or death.

• Carbon Monoxide Hazard: Generators produce carbon monoxide, an odorless, colorless, poisonous gas. Operate the generator outdoors only, far away from windows, doors, and vents. Never operate it inside a home, garage, basement, crawlspace, or other enclosed area.
• Electrical Shock Hazard: Never operate the generator in wet conditions. Ensure all electrical connections are dry and properly grounded. Do not touch the generator or electrical cords with wet hands.
• Fire Hazard: Gasoline is highly flammable. Refuel in a well-ventilated area with the engine off and cool. Do not smoke or allow open flames near the generator. Store fuel in approved containers.
• Moving Parts Hazard: Keep hands, feet, hair, and clothing away from moving parts such as the fan, belts, and flywheel.
• Hot Surfaces Hazard: The muffler and other engine parts become extremely hot during operation and remain hot for some time after shutdown. Avoid contact to prevent burns.

3. Product Overview

The DEWALT DG6000 Portable Generator is engineered for durability and performance. Key features include:

• Powerful 11 HP Honda OHV GX Engine
• 6,000-Watt Output for demanding tools and appliances
• Maintenance-free brush-less alternator
• Durable all-metal 5-gallon gas tank
• Super quiet muffler for reduced engine noise
• Low oil shut-off protection for the engine
• Idle control to optimize fuel consumption
• High Amp surge capacity for starting high Amp tools
• Maximum 120-volt power switch for peak performance
• Robust 2-1/8-inch protective steel frame
• Semi-pneumatic tires for easy portability

Image: The DEWALT DG6000 Portable Generator, showcasing its yellow and black design, robust steel frame, and integrated wheels for mobility.

4. Setup and Assembly

4.1 Unpacking

Carefully remove all components from the packaging. The generator comes with the following items:

• DEWALT DG6000 Generator Unit
• Wheel Kit
• Handle Kit
• Lifting Hook
• Spark Plug Wrench

4.2 Wheel and Handle Installation

Attach the wheels and handles to the generator frame using the provided hardware. Refer to the diagrams in the separate assembly guide for detailed steps. Ensure all bolts are securely tightened.

4.3 Adding Engine Oil

Before first use, the engine must be filled with the appropriate amount and type of engine oil. Consult the engine manufacturer's manual for specific oil recommendations (e.g., SAE 10W-30) and fill capacity. Do not overfill.

4.4 Fueling the Generator

The DEWALT DG6000 operates on unleaded gasoline. The fuel tank has a capacity of 5 gallons.

1. Ensure the generator is on a level surface and the engine is off and cool.
2. Remove the fuel cap slowly to release any pressure.
3. Carefully pour unleaded gasoline into the fuel tank, avoiding spills. Do not fill above the maximum fill line.
4. Securely replace the fuel cap.

5. Operating Instructions

5.1 Pre-Start Checklist

• Verify the generator is placed outdoors in a well-ventilated area.
• Check engine oil level.
• Ensure fuel tank is adequately filled.
• Confirm all electrical loads are disconnected from the generator outlets.

5.2 Starting the Engine

The DG6000 features an electric start system.

1. Turn the fuel valve to the 'ON' position.
2. Move the choke lever to the 'CHOKE' position (if the engine is cold).
3. Turn the engine switch to the 'START' position. Release the switch once the engine starts.
4. Gradually move the choke lever to the 'RUN' position as the engine warms up.

5.3 Connecting Electrical Loads

Once the engine is running smoothly, you can connect your electrical devices.

• Connect appliances or tools to the appropriate 120V or 240V outlets.
• Do not exceed the generator's rated running wattage of 6,000 watts.
• The generator's high Amp surge capacity is ideal for starting tools like air compressors.

5.4 Stopping the Engine

1. Disconnect all electrical loads from the generator.
2. Allow the engine to run for a few minutes without load to cool down.
3. Turn the engine switch to the 'OFF' position.
4. Turn the fuel valve to the 'OFF' position.

5.5 Fuel Saving Features

The DG6000 includes features to optimize fuel efficiency:

• Idle Control: This feature helps save fuel by reducing engine speed when no load is detected.
• Low Oil Shut-off: Automatically shuts down the engine if the oil level drops below a safe operating level, preventing engine damage.

6. Maintenance

Regular maintenance ensures the longevity and reliable performance of your generator.

6.1 Regular Checks

• Engine Oil: Check oil level before each use. Change oil according to the engine manufacturer's schedule.
• Air Filter: Inspect and clean the air filter regularly. Replace if damaged.
• Fuel Filter: Check for debris and replace if necessary.
• General Inspection: Check for loose fasteners, fuel leaks, or damaged components.

6.2 Spark Plug Maintenance

Use the provided spark plug wrench to inspect and clean the spark plug periodically. Replace if worn or fouled. Ensure proper gap setting as specified in the engine manual.

6.3 Storage

For extended storage, drain the fuel tank and carburetor, or use a fuel stabilizer to prevent fuel degradation. Store the generator in a clean, dry area.

7. Troubleshooting

This section addresses common issues you might encounter with your generator.

• Engine Will Not Start:
  • Check fuel level.
  • Ensure engine oil level is sufficient (low oil shut-off may be activated).
  • Verify spark plug is clean and properly connected.
  • Check if the engine switch is in the 'ON' position and choke is set correctly for a cold start.
• No Power Output:
  • Check circuit breakers on the generator.
  • Ensure all connections are secure.
  • Verify the total load does not exceed the generator's capacity.
• Engine Runs Rough:
  • Check for stale fuel; drain and refill with fresh gasoline if necessary.
  • Inspect air filter for clogging.
  • Check spark plug condition.

If issues persist, contact DEWALT customer support or a qualified service technician.

8. Specifications

9. Warranty and Support

The DEWALT DG6000 Portable Generator is backed by a comprehensive warranty to ensure your peace of mind.

• Warranty: This product comes with a 1-year free service and a 2-year limited warranty that includes the engine.
• Customer Support: For technical assistance, parts, or warranty claims, please contact DEWALT customer service. Keep your purchase receipt and serial number readily available.