DEK DEK4550PRO Pro 6000-Watt Gasoline Portable Generator Use and care guide

Heavy Duty Power Equipment

Owner’s Manual

This manual contains important safety instructions for gasoline

generator models: 4550Pro, 5650, 6500, 6500EL, 7550EL Pro that should be followed during installation and

maintenance of the generator and batteries

READ SAFETY WARNINGS AND OPERATING INSTRUCTIONS CAREFULLY, SAVE THESE INSTRUCTIONS.

Contents:

1. Tools and Accessories

2. DEK Product Lines

3. Missing Parts Request Form

4. Warnings

5. Warnings and Specifications

6. Component Identification

7. Wheel Kit Assembly & Commissioning the Battery

8. Commissioning the Battery

9. Controls

10. Operating the Generator

11. Operating the Generator

12. Maintenance

13. Maintenance

14. Transporting and Storage

15. Troubleshooting

16. Warranty and Service

DO NOT RETURN THIS GENERATOR

TO THE STORE!

HAVE QUESTIONS OR NEED HELP? call 24 hrs / 7-days a week help-line: [1] 919-550-3221 or go to www.DEKPowerUSA.com

Have the following information ready when you call us:

Date of Purchase: _______________________

Location of Purchase: _______________________

Serial #: _______________________

Rev. 9/2011 DEK® is registered trademark of GXi Outdoor Power, LLC Clayton, NC 27520 USA.

No part of this publication can be printed or copied without written permission.

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Heavy Duty Power Equipment

DEK Product Lines

4550 Pro, 5650, 6500(EL), 7550 Pro

For your convenience, DEK offers a complete range of generator accessories. Please ask your local retailer for more details or call

[1] 919-550-3221.

Universal Generator Cover:

Heavy duty nylon cover fits over most models of

4000W to 7500W generators. A flexible handle bar flap accommodates most common handle bar designs. The cover keeps water, ice, snow, dust and dirt from damaging your generator when it is in storage.

It can also be used as a rain cover to protect the generator when stored outdoors. The cover cannot be used while the generator is in operation. The generator should be allowed to cool down for approximately 15 minutes after being shut down, prior to placing the cover over the generator.

Adapters:

Converts 240V twist lock (L14-30) to six (6) 120V outlets. Lighted ends show when power is on.

Ideal for use in combination with a

240V extension cord. Can handle up to 30 Amps (7200 Watts).

Extension Cords:

240V, 10/4, heavy duty extension cords with L14-30 connectors at each end. Lighted end shows when power is on. Ideal for use in com- bination with the 240V to 120V adapter, eliminating up to six

120V extension cords. This cord reduces harmful voltage drops experienced when using most

120V extension cords. Available in 25‟ lengths and can be combined to reach the desired length.

SAE 10W30 Motor Oil:

A premium high performance formulation designed for high

RPM small gasoline engines such as those used on generators. This oil provides excellent protection against viscosity and thermal breakdown that often happens under the prolonged severe duty experienced by generator engines. Use of this oil formulation is highly encouraged by the manufacturer. Frequent oil changes with high quality motor oil will prolong the life of your

DEK generator.

Fuel Stabilizer:

Use of DEK‟s fuel stabilizer keeps your gasoline fresh for up to 12 months. Gasoline breaks down in 60 days, potentially causing damage to your engine.

DEK recommends storing your generator with the fuel tank full and with fuel stabilizer added.

This protects the engine and fuel system from the effects of humidity and ensures your generator is ready for use at all times.



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DEK Product Lines

Other fine products offered by

4550 Pro, 5650, 6500(EL), 7550 Pro


Commercial Lawn Mowers Heavy Duty Pressure Washers Rental Grade Chipper Shredders

For more information or where to purchase DEK outdoor power equipment, visit us at: www.DEKPowerUSA.com

Missing Parts Request Form

Please indicate the part that you are missing:

Hardware bag

Wheel Kit

Other

Date of purchase

Model #:

4550Pro

5650

6500 or 6500EL

755EL Pro

Serial #:

Comments:

Name

Address

Phone

Email

Rev. 1/2010

IMPORTANT: Please include your receipt. Without a receipt, your order will be delayed. You may also email us at: [email protected] or fax at 919-550-3277. If emailing, please scan in your proof of purchase.

DEK® is registered trademark of GXi Outdoor Power, LLC Clayton, NC 27520 USA.


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WARNINGS

4550 Pro, 5650, 6500(EL), 7550 Pro

This owner‟s manual is considered a permanent part of the generator and should remain with the generator if resold. The information and specifications included in this publication were in effect at the time of approval for printing.

GXi Outdoor Power, LLC, exclusive marketer of DEK Heavy

Duty Power Equipment, reserves the right to discontinue or change specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.

EMISSION CONTROL SYSTEM INFORMATION

The U.S. and California Clean Air Acts

EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must be followed in order to keep the emissions from your DEK engine within the emission standards. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are „„certified‟‟ to EPA standards.

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a label comes off or becomes hard to read, contact your DEK generator dealer for a replacement.

SAFETY INFORMATION

DEK generators are designed to give safe and dependable service if operated according to instructions. Read and understand this owner‟s manual before operating your generator.

OPERATOR RESPONSIBILITY

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles, and connections. Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the generator.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

DANGER

Fire and Burn Hazards

The exhaust system gets hot enough to ignite some materials.

 Keep the generator at least 3 feet (1 meter) away from buildings and other equipment during operation.

 Do not enclose the generator in any structure.

 Do not smoke when refueling.

 Keep flammable materials away from the generator.

 The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot.

 Let the engine cool before storing the generator indoors.

 Refuel in a well ventilated area with the engine stopped.

 Fuel vapors are extremely flammable and may ignite after the engine has started. Make sure that any spilled fuel has been wiped up before starting the generator.

DANGER

Electrocution Hazard

 Keep the generator dry.

 DO NOT use the generator in wet conditions, rain or snow, or near a pool or sprinkler system

 DO NOT use when your hands are wet

NEVER START OR STOP THE ENGINE WITH DEVICES CON-

NECTED TO THE GENERATOR.

Rev. 1/2010

DANGER

CARBON MONOXIDE GAS

Exhaust contains poisonous carbon monoxide, a colorless and odorless gas. Breathing exhaust can cause loss of consciousness and may lead to death. To keep exhaust gas from accumulating, use in an area with adequate ventilation. DO NOT use this generator in a garage, basement, crawlspace, enclosed shed, or any other area that does not have adequate ventilation. DO NOT use this generator near ventilation ducts or open windows that may allow exhaust gasses to enter your home or business. ONLY operate this generator outdoors.

Connections to a Building Electrical System

Connections for standby power to a building electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power, and must comply with all applicable laws and electrical codes. A transfer switch, which isolates generator power from utility power, is available through any of GXi‟s authorized dealers of DEK generators.

WARNING

Generator must be installed by a qualified electrician and connected to transfer equipment as a separately derived system in accordance with the National Electrical Code, NFPA

70. The generator shall be connected through transfer equipment that switches all conductors other than the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode.

Improper connections to a building electrical system can allow electrical current from the generator to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored.

Ground System

DEK portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is not connected to the

AC neutral wire. If the generator is tested by a receptacle tester, it will not show the same ground circuit condition as for a home receptacle where the ground and neutral are connected.

Special Requirements

There may be Federal or State Occupational Safety and Health

Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.



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WARNINGS

AC Applications

Before connecting an appliance or power cord to the generator:

1. Make sure that appliances are in good working order.

Faulty appliances or power cords can create a potential for electrical shock. If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.

2. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded.

3. Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than

30 minutes.

Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker or circuit protector OFF, but will shorten the service life of the generator.

Limit operation requiring maximum power to 30 minutes. For continuous operation (longer than 30 minutes), do not exceed

80% of the rated power balanced equally on the A&B sides of the Alternator.

The total power requirements (VA) of all appliances connected must be considered. Appliance and power tool manufacturers usually list rating information near the model number or serial number.

4550 Pro, 5650, 6500(EL), 7550 Pro

WARNING

Failure to properly follow maintenance instructions and precautions can cause serious injuries or death. Always follow the inspection and maintenance recommendations and schedules in this owner’s manual.

Safety Precautions:

Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

 Carbon monoxide poisoning from engine exhaust.

Be sure there is adequate ventilation whenever you operate the engine.

 Burns from hot parts.

Let the engine and exhaust system cool before touching.

 Injury from moving parts.

Do not run the engine unless instructed to do so.

In the State of California a spark arrestor is required by law.

Other states may have similar laws. Federal laws apply on all federal lands. If you equip the muffler with a spark arrestor, it must be maintained in effective working order. See page 11.

Rapid retraction of the recoil starter cord can pull the starter cord back faster than you can let go. When starting the engine, pull the cord slowly until resistance is felt then pull rapidly to avoid kickback.

DANGER

Changing the speed of the generator by adjusting the governor can cause damage to the generator, devices attached to the generator, and may result in bodily injury. Do not adjust or tamper with the engine speed setting.

Product Specifications



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Fuel Tank

Component Identification

Fuel Cap

4550 Pro, 5650, 6500(EL), 7550 Pro

Generator models may have different features and/or options

than shown in these diagrams.

DEK reserves the right to alter product features and specifications.

Choke Lever

Air Filter

Fuel Valve

Recoil Starter (Assembly)

Emissions Information

Engine Serial Number stamped on the engine block

ON/OFF Switch

Main

Breaker

L14-30 240V/120V

Battery (electric start option only)

Oil Fill Cap—one one each side of the engine.

Oil Drain (one on each side of the engine)

Digital Meter

Ground

Lug

Start Switch (electric start option)

Pull Out Handle

Bars

(recessed)

12 V Breaker

120V AC Outlets

12V DC Outlet

Choke Lever

Valve Cover

Carburetor

Alternator

Muffler Guard

Rev. 1/2010

Exhaust Pipe



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Wheel Kit Assembly

Required Tools (not supplied)

1. Adjustable wrench or a socket wrench with a 8 mm socket.

Approximate assembly time is 5 minutes.

Supplied with your generator:

1. Two(2) foot assemblies with two

(2) 8 mm nuts.

2. Two (2) wheel axle assemblies.

Two pre-assembled, retractable, handle bars, one on each side of the generator frame. Twist to lock / unlock. Pull or push to extend / retract.

Step

1

Insert each foot assembly through holes in the frame. Tighten nut with adjustable wrench or 8 mm socket.

4550 Pro, 5650, 6500(EL), 7550 Pro

Pre-assembled wheel / axle assembly.

Step

2

Insert each axle and tighten the bolt to secure in place using an adjustable wrench or 8 mm socket.

Additional equipment required to safely operate this generator:

1. Gas can.

2. Unleaded gasoline.

3. SAE 10W30 & 14HP oil (a little more than 1 quart for DEK 11hp, 13hp and 14hp engines, a little less than 1 quart is required for DEK‟s smaller engines).

4. An oil fill funnel.

5. Gasoline fuel stabilizer (for storing your generator). 120V and/or 240V extension cords.

6. An adjustable wrench or a 12mm socket for oil changes.

Note: A spark arrestor was supplied with your generator and must be installed for use within the State of California. See supplemental instructions.

Commissioning the Battery

The battery is an optional feature. The battery is used to start a generator equipped with an electric starter. Not all generators are sold with batteries. Please verify with your retailer if you believe the battery is missing.

Battery Maintenance:

Routine maintenance is essential to keep the battery in good condition and maximize its service life.

1. Keep the terminals and connections free from corrosion and coat with petroleum jelly or grease to reduce corrosion from occurring.

2. If the generator sits idle for more than two (2) months, it is best to recharge the battery to ensure it is fully charged when you need it and to increase battery life.

WARNING

Lead acid storage batteries contain sulfuric acid which can cause serious injuries. The battery also gives off explosive gases. Keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using batteries. Battery posts, terminals and related accessories contain lead and lead compounds. Avoid spills of electrolyte and wash hands thoroughly after handling.

Use gloves and safety glasses when handling and installing lead acid batteries.

If you get electrolyte in your eyes, flush your eyes with clean water for 15 minutes and seek medical attention. Keep out of reach of children.

FOR YOUR SAFETY AND CONVENIENCE, THE

BATTERY WAS SHIPPED SEALED AND

PRE-CHARGED.

The battery is ready to be connected to the generator.

To connect the battery, use an adjustable wrench or 8 mm socket to secure the black wire to the positive terminal and the negative terminal.



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Controls

4550 Pro, 5650, 6500(EL), 7550 Pro

DC Terminals

Some generators are shipped with optional DC battery charging cables, have a standard 12V DC receptacle, and have a 12V cigarette lighter style outlet.

The battery must be connected to the generator DC terminals with the proper polarity (battery positive to generator red terminal and battery negative to the generator black terminal).

WARNING

Do not use the 12V DC and the AC receptacles at the same time.

Connecting the battery cables:

1. Before connecting the battery charging cables to a battery that is installed in a vehicle, disconnect the vehicle ground battery cable from the battery negative ( - ) terminal.

2. Connect the other end of the positive ( + ) battery cable to the generator positive ( + ) terminal.

3. Connect the positive ( + ) battery cable to the battery positive ( + ) terminal.

4. Connect the negative ( - ) battery cable to the battery negative ( - ) terminal.

5. Connect the other end of the negative ( - ) battery cable to the generator negative ( - ) terminal.

6. Start the generator.

CAUTION: Do not start the vehicle while the battery charging cable is connected and the generator is running. The vehicle or the generator may be damaged.

Disconnecting the battery cables:

1. Stop the engine.

2. Disconnect the negative ( - ) battery cable from the generator negative ( - ) terminal.

3. Disconnect the other end of the negative ( - ) battery cable from the battery negative ( - ) terminal.

4. Disconnect the positive ( + ) battery cable from the generator positive (+ ) terminal.

5. Disconnect the other end of the positive ( + ) battery cable from the battery positive ( + ) terminal.

6. Reconnect the vehicle ground battery cable to the battery negative ( - )terminal.



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Controls

4550 Pro, 5650, 6500(EL), 7550 Pro

WARNING

The engine was shipped without engine oil. DO NOT START

THE ENGINE WITHOUT FILLING THE ENGINE WITH OIL.

Use SAE 10W-30 for normal conditions and SAE 5W-30 when the ambient temperature is below 32° F.

Choke Rod

The choke is used to provide an enriched fuel mixture when starting a cold engine. It can be opened and closed by operating the choke rod manually.

Pull the rod out toward CLOSED to enrich the mixture for cold starting.

Open once the engine is running.

Recoil Starter

To start the engine, pull the starter grip lightly until resistance is felt, then pull briskly.

NOTICE:

Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter.

The recoil starter is used to start the engine if the generator is not equipped with a 12 volt battery to operate the starter motor, or if the battery does not contain adequate charge to operate the starter motor.

STARTER GRIP

RECOIL STARTER

Turn clockwise to turn fuel valve on.

Fuel Valve Lever

The fuel valve is located between the fuel tank and carburetor. When the valve lever is in the

ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to return the fuel valve lever to the

OFF position after stopping the engine.

OFF

ON

Oil Alert System

The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil

Alert system will automatically stop the engine (the engine switch will remain in the ON position). The Oil Alert system should not take the place of checking the oil level before each use. If the engine stops and will not restart, check the engine oil level (see page 14) before troubleshooting in other areas.

Engine Switch

To start and stop the engine.

Engine ON / OFF Switch

Rev. 1/2010

Electric Starter Switch

(optional feature)

Ground Terminal

The generator ground terminal is connected to the frame of the generator, the metal non-current-carrying parts of the generator, and the ground terminals of each receptacle.

WARNING

Before using the ground terminal, consult a qualified electrician, electrical inspector or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator.

NOTE: SYSTEM GROUND IS NOT CONNECTED TO THE AC

NEUTRAL ON THIS GENERATOR. CONSULT AN ELECTRI-

CIAN WHEN CONNECTING THIS GENERATOR TO YOUR

HOME OR BUSINESS ELECTRICAL PANEL TO ENSURE

GROUNDING MEETS THE LOCAL ELECTRICAL CODE



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Operating the Generator

4550 Pro, 5650, 6500(EL), 7550 Pro

DANGER

CARBON MONOXIDE GAS

CARBON MONOXIDE Using a generator indoors CAN KILL

YOU IN MINUTES.

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.

NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air.

ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust.

Even when you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or batterybackup CO alarm in the home.

If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.”

WARNING

For power outages, permanently installed stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded.

This may result in overheating or stressing the generator components, possibly leading to a generator failure.

Step 1.

Ensure all electrical loads are removed from the generator.

Disconnect all the extension cords and ensure the main breaker is in the OFF position. Remove all flammable materials and debris from the area. Make sure the generator is level.

Step 2.

Check the oil level by removing the oil fill cap.

 Put the generator on a level surface with the engine stopped.

 Remove the oil filler cap.

 Check the oil level. If the oil level is low, fill it until the oil is overflowing. It will take approximately 1.1 - 1.5 quarts of oil.

If additional oil is need, SAE 10W-30 engine oil is recommended for most general purpose applications. In cold weather climate, use SAE 5W-30.

Step 3.

Make sure there is fuel in the gasoline tank. Look at the fuel level indicated by removing the fuel cap to inspect the contents of the fuel tank. The fuel filter can also be inspected once the fuel cap is removed. Ensure the fuel filter is clean of dirt and debris. Tightly secure the fuel cap after your inspection is complete.

Fuel can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilling fuel is not covered under warranty. Use unleaded gasoline with a pump octane rating of 86 or higher. This engine is certified to operate on unleaded gasoline. Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.

WARNING

Ethanol warning

This portable generator is not for use with gasoline/ethanol blends with over 15% ethanol.

DO NOT overfill the tank. Leave a 1 inch air gap in the tank.

Gasoline is highly flammable and explosive. You can be burned or seriously injured when refueling.

 Stop engine and keep heat, sparks, and flame away.

 Refuel only outdoors.

 Wipe up spills immediately.



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Operating the Generator

4550 Pro, 5650, 6500(EL), 7550 Pro

Step 4.

Set the fuel valve lever to the ON position by rotating it clockwise.

Step 5.

Pull the choke lever to the CLOSED position. See page 7 for a diagram of the choke lever.

Step 6.

Turn the generator ON/OFF switch to the “ON” position.

Step 7.

Start the engine

1. If you have an electric starter, press the electric starter switch to the START position, hold it there for 5 seconds and let it come to rest in the ON position once the engine has started.

2. If you are using the recoil starter, pull slightly on the cord until you feel some pressure. Once you feel the backpressure building, rapidly pull the cord.

Step 8.

Once the generator is running, push the choke lever into the

OPEN position.

Step 9.

Let the generator warm up for approximately 3 minutes before applying any electrical loads.

Step 10.

Apply loads to the generator one at a time, allowing the generator to stabilize after you add each incremental load. Add the loads with the largest surge power requirement first. This would include refrigerators, air-conditioners, large motors, and pumps.

Add smaller loads once the generator has stabilized with the larger loads.

ALWAYS UNPLUG APPLIANCES AND REMOVE ALL ELEC-

TRICAL LOADS BEFORE REFUELING. THEN FOLLOW

STEPS 2 - 10.

WARNING

Connecting a load larger than this generator‟s power rating may damage the circuit breakers, alternator and sensitive appliances.

STOPPING THE GENERATOR

Continuously loading this generator above 80% of its maximum output power will shorten the life of the generator.

Balance the load evenly between the A and B outlets to maximize the output power.

Appliances with electric motors require an additional 150% power when they are starting up (indicated by an * and in bold in the chart below).

To determine maximum load that you may safely connect to this generator:

1. Calculate the maximum continuous power required by adding up the running power of each appliance. The total running power of your appliances cannot exceed the maximum output power of this generator.

2. Calculate the surge power by:

i) Adding up the running power of each appliance with an

* and in bold below.

ii) Multiplying the total by 1.5.

iii) Adding this to the total running power calculated in step 1 above.

The surge power requirements of your appliances cannot exceed the surge power rating of this generator.

Typical Residential Loads

Appliance

Light bulbs (each)

Stove element (each)

Microwave

Coffee maker

Television

VCR

Space heater

Washing machine

Computer & monitor

NG clothes dryer

Electric clothes dryer

Dishwasher

Water heater

Electric furnace

Toaster

2 hp well pump*

Refrigerator*

Freezer*

Box fan*

Window A/C - 8000 BTU*

Central A/C (per ton)*

Furnace blower*

Running Power

75 Watts

1000 Watts

1500 Watts

700 Watts

750 Watts

250 Watts

800 Watts

1500 Watts

1000 Watts

750 Watts

5500 Watts

1850 Watts

5000 Watts

5000 Watts

1200 Watts

750 Watts

2400 Watts

2800 Watts

850 Watts

2000 Watts

1000 Watts

1000 Watts

In an emergency:

To stop the engine in an emergency, move the engine switch to the OFF position and turn the fuel valve OFF.

In normal use:

1. Turn the AC circuit breaker to the OFF position (if applicable).

2. Disconnect all loads and extension cords.

3. Allow the engine to run with no load for 3 minutes.

4. Turn the engine switch to the OFF position.

5. Turn the fuel valve lever to the OFF position.

6. Allow the generator to cool off before touching any engine or alternator components. It may take as long as 30 minutes before the generator is cool enough to touch safely.



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Maintenance

4550 Pro, 5650, 6500(EL), 7550 Pro

MAINTENANCE

The Importance of Maintenance

Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.

To help you properly care for your generator, the following pages include a maintenance schedule, routine inspection procedures, and simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best handled by professionals and are normally performed by a DEK technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If you operate your generator under severe conditions, such as sustained high-load or high-temperature operation, or use it in unusually wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are

‘‘certified’’ to EPA standards.

Maintenance Schedule

Item

Engine oil (Check)

Engine Oil (Change)

Air Cleaner (Check)

Air Cleaner Wash

Fuel filter Cup (Clean)

Spark Plug (Clean)

Spark Plug (Change)

Optional Spark Arrestor (Clean)

Valve Clearance (Adjust)

Before each use

X

X

20hrs or every 3 month

X

50 hrs or every 3 months

X

X

Fuel Tank and Filter (Clean)

Fuel Tube (Check)

Combustion Chamber (Clean)

Every 2 yrs (replace if necessary)*

After every 250 hrs*

* Should be performed by an authorized DEK dealer.

X

X*

100 hrs or every 6 months

X

X

X*

300 hrs or every

1 year

Replacement Parts

The emission control systems on your DEK engine were designed, built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine DEK parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system.

A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Engine Oil Change

Drain the oil while the engine is warm to assure rapid and complete draining.

1. Remove the drain plug and sealing washer, remove the oil filler cap, and drain the oil.

2. Reinstall the drain plug and sealing washer. Tighten the plug securely.

3. Refill with the recommended oil (SAE 10W-30 ) and check the oil level.

Dispose of used motor oil in a manner that is compatible with the environment. Do not throw it in the trash, pour it on the ground, or down a drain.

Air Cleaner Service

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly.

Service more frequently when operating the generator in extremely dusty areas.

NOTICE:

Never run the generator without the air filter. Rapid engine wear will result.

1. Unsnap the air cleaner cover clips, remove the air cleaner cover, and remove the element.

2. Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly, or wash in nonflammable or high flashpoint solvent. Allow the air cleaner element to dry thoroughly.

3. Soak the air cleaner element in clean engine oil and squeeze out the excess oil. The engine will smoke during initial startup if too much oil is left in the air cleaner element.

4. Reinstall the air cleaner element and the cover.

Fuel Filter Cleaning

The fuel filter cup / screen prevents dirt which may be in the fuel from entering the carburetor. The fuel filter should be inspected and cleaned on a regular basis. For best results, clean the filter with gasoline and a toothbrush or blow the debris out of the filter with air pressure.

Spark Plug Service

In order to service the spark plug, you will need a spark plug wrench. Recommended spark plugs: BPR5ES (NGK) and

W16EPR-U (DENSO). To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

If the engine has been running, the muffler will be very

hot. Be careful not to touch the muffler.

1. Remove the spark plug cap.

2. Clean any dirt from around the spark plug base.

3. Use a spark plug wrench to remove the spark plug.



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Maintenance

4550 Pro, 5650, 6500(EL), 7550 Pro

4. Visually inspect the spark plug. Discard it if the insulator is cracked, chipped or fouled.

5. Measure the plug gap with a feeler gauge. Correct as necessary by carefully bending the side electrode.

The gap should be: 0.028 0.031 in

(0.70 0.80 mm)

TRANSPORTING

When transporting the generator, turn the engine switch and the fuel valve OFF. Keep the generator level to prevent fuel spillage.

Fuel vapor or spilled fuel may ignite.

Take care not to drop or strike the generator when transporting.

Do not place heavy objects on the generator. When transporting the generator by loading it on to a vehicle, secure to the generator frame as shown.

6. Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent cross-threading.

7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer.

If installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten 1/8 1/4 turn after the spark plug seats to compress the washer.

NOTICE:

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and could damage the engine. Use only the recommended spark plugs or equivalent.

Optional Spark Arrestor Maintenance

If the generator has been running, the muffler will be very hot.

Allow it to cool before proceeding. The spark arrester must be serviced every 50 hours to keep it functioning as designed.

Clean the spark arrester as follows:

1. Loosen the screw by the exhaust port of the muffler and remove the spark arrester.

2. Use a brush to remove carbon deposits from the spark arrester screen. Inspect the screen for breaks or tears and replace it if necessary.

3. Install the spark arrester in the reverse order of removal.

SCREW

SPARK ARRESTOR

Optional Starter Motor Fuse Replacement

If the fuse is blown, the starter motor won‟t operate. Turn the engine switch to the OFF position. Remove the fuse holder cover and replace the fuse. The specified fuse is 10A.

NOTICE:

Never use a fuse with a different rating from that specified. Serious damage to the electrical system or fire may result.

DANGER

Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or stor-

ing the generator.

STORING

Before storing the unit for an extended period:

1. Be sure the storage area is free of excessive humidity and dust.

2. Service according to the table below:

STORAGE TIME

1 to 2 months

Recommended Service Procedure to prevent hard starting:

Fill with fresh gasoline and add gasoline conditioner*.

2 months to 1 year Fill with fresh gasoline and add gasoline conditioner*.

Drain the carburetor float bowl.

Fill with fresh gasoline and add gasoline conditioner*.

1 year or longer

Drain the carburetor float bowl.

Remove the spark plug. Put a tablespoon of engine oil into the cylinder.

Turn the engine slowly with the recoil starter to distribute the oil. Reinstall the spark plug.

Change the engine oil.

After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting.

* Use gasoline conditioners that are formulated to extend storage life. Contact your authorized

DEK generator dealer for conditioner recommendations.

Storage Preparation

1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Place 4 ounces of fuel stabilizer in the fuel tank.

2. Change the engine oil (page 10 ).

3. Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder. Turn the engine several revolutions slowly with the recoil starter to distribute the oil, then reinstall the spark plug.

4. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion.

WARNING

Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well-ventilated area with the engine stopped. Do not smoke or allow flames

or sparks in the area during this procedure.



13 of 16

4550 Pro, 5650, 6500(EL), 7550 Pro

Troubleshooting

Symptom:

Potential Causes

Fuel valve off/out of fuel

Spark arrestor clogged

No spark, engine not catching, engine won't start

Check / solution

Fill tank/turn fuel valve on

Remove, clean and replace.

Choke is open Close choke by pulling choke wire out. Open choke after starting

Vacuum check valve has failed Replace check valve

On/Off switch broken

Oil level too low

Oil switch

Use fuel shut-off as ON/OFF switch until switch is replaced.

The engine shuts down when oil level low

Verify oil switch/sensor is functioning . The oil switch is the gold, brass colored box about 3 inches to the left of the oil fill cap. Dis-connect oil switch by disconnecting black lead out of finger connection. If the

Recoil is broken

Fuel filter is dirty

Fuel is contaminated engine starts, then switch/sensor is faulty or the oil level is too low, if engine still does not start, then switch/sensor is probably ok to reassemble

If ratchets are broken they will not spin the engine.

Contaminates will clog filter, not allowing fuel to get to engine. Clean or replace fuel filter.

Contaminates in fuel will not allow combustion at the specified pressure and temperate and blocks filters

Spark plug boot off/loose

Ignition coil failure

Spark plug fouled or failed

Carburator clogged

Press spark plug boot firmly on spark plug.

Remove spark plug, clean or replace

Clean with fresh fuel

Symptom:


Recoil is hard to pull or not retracting


Spark arrestor Remove, clean and replace.

Recoil rubbing on dented housing

Alternator bearing failed

Camshaft detent has failed

Alternator bearing needs to be replaced. Send to service.

Head valve timing is off

Symptom:

Potential Causes Check / solution

Remove/Clean spark arrestor Remove, clean and replace.

Engine starts, but then shuts off before 10 seconds

Oil level too low

Fuel valve off/out of fuel

Spark plug fouled or failed Remove spark plug, clean or replace

Vacuum check valve has failed Replace check valve, call DEK for replacement procedure.

The engine shuts down when the oil level is low. Check the owners manual for oil capacity

Fill tank/turn fuel valve on

Symptom:


Choke broke

Choke wire broke


Choke should be closed while starting. Pull black choke counter-clockwise and hold in place with wire.

Recommendation

Call DEK for parts/service








Recommendation





Recommendation



Recommendation


Symptom:


Engine runs: rough/vibrating/oscillating



The choke is not open Push choke lever in.

Over loading generator

Air filter is dirty

Disconnect some appliances

Clean air filter

Fuel filter is clogged


Contaminates will clog filter, not allowing fuel to get to engine. Clean filter

Fuel is contaminated Contaminates in fuel will not allow combustion at the specified pressure and temperate

Vacuum check valve has failed Replace check valve.

Send to service

Symptom:


Engine runs, but boggs down under load



Choke is open Push choke lever in

Over loading generator

Air filter is dirty

Fuel filter is clogged

Disconnect some appliances / devices

Clean air filter

Contaminates will clog filter, not allowing fuel to get to engine

Symptom:


Engine runs, Volt meter shows 120 VAC, but no power to outlets


Bad extension cord/power strip Try different / shorter extension cord or a different power strip

Push button breaker tripped Disconnect all loads and push reset button.

GFCI tripped

GFCI failed

Disconnect all loads. Push the red reset button very deep/firmly

Replace GFCI with any GFCI or household outlet

Recommendation



Recommendation

Recommendation




14 of 16

4550 Pro, 5650, 6500(EL), 7550 Pro

Troubleshooting

Symptom:


Engine runs and volt meter shows 240VAC and 120VAC, but no power goes to connected devices


Bad extension cord/power strip Try different / shorter extension cord or a different power strip

Device failed Try a different light bulb or device

Push button breaker tripped

GFCI tripped

GFCI failed

Broken wire

Toggle switch failed

Push button breaker tripped

Push the red reset button very deep/firmly

Replace GFCI with any GFCI or household outlet

Symptom:


Circuit breaker failed

Toggle switch failed

Alternator phase has failed

Broken wire

Symptom:


Spark arrestor

Engine runs, volt meter shows 120VAC in 120V mode, but 120VAC or 0VAC in 240V mode


Voltage too high/low


Remove, clean and replace.

Speed screw bent

Symptom:


Alternator phase has failed

Voltage is 120 VAC on 1 phase but too high/low on other phase


Symptom:


Engine oil leaking


Oil leaking from crankcase gasTighten crankcase bolts

Recommendation




Recommendation





Recommendation


Recommendation


Recommendation

Oil leaking from shaft

Symptom:


Bolt not tight

Symptom:


Shut-off valve loose

Oil seals failed

Oil leaking from Valve head cover


Tighten bolts

Fuel leak at tank shut-off


Tighten nut on shut-off valve/replace shut-off valve

Symptom:


Fuel drain screw loose

Fuel leaking out of carburator


Tighten fuel drain screw

Carburator float seat not seating Flush with clean fuel

Symptom:


Recoil ratchets have broken

Recoil is crushed in

Alternator bearing has failed


Symptom:


Replace fuel gauge gasket

Cannot turn engine with recoil


Fuel gauge leaks



Recommendation

Recommendation


Recommendation

Recommendation





Recommendation




15 of 16

Limited Warranty & Service

4550 Pro, 5650, 6500(EL), 7550 Pro

PRODUCTS COVERED BY THIS WARRANTY:

Engine

Battery

Alternator

Electrical and Frame Components

Emission Controls

LENGTH OF WARRANTY:*

(FROM THE DATE OF ORIGINAL RETAIL PURCHASE)

NONCOMMERCIAL/ NON-

RENTAL

COMMERCIAL RENTAL

36 months / 300 hours 12 months / 300 hours 3 months / 300 hours

3 months

36 months / 300 hours

3 months


3 months



36 months

12 months /300 hours

36 months


36 months

*LENGTH OF WARRANTY: All warranty coverage expires when the operating hours exceed 300 hours.

TO QUALIFY FOR THIS WARRANTY:

The product must be purchased in the United States from a dealer authorized by GXi Outdoor Power, LLC to sell those products. This warranty applies to first retail purchaser / owner during the applicable warranty time period. SAVE YOUR PROOF OF PURCHASE RECEIPT.

WHAT DEK POWER EQUIPMENT WILL REPAIR OR REPLACE UNDER WARRANTY:

DEK will repair or replace, at its option, any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period subject to the exclusions stated herein. This warranty is void if the owner fails to follow the prescribed maintenance and operating procedures described in this manual.

This specifically refers to ensuring routine oil changes are made, that fuel stabilizer is used for long-term storage, that the generator is not overloaded, and that the generator loads are distributed evenly between the A and B outlets. Dirty carburetors, spark plugs, air filters, fuel filters, and freight or handling damage are not covered under warranty.

DEK has the right to recover warranty administration costs from the owner if the root cause of the malfunction was found to be other than defective material or workmanship. In particular, this warranty does not cover: contaminants in the fuel or oil; damage caused by not following the prescribed warnings and operating practices; failure to follow proper maintenance and storage procedures; and physical damage due to shipping or handling or storage. Damage to the generator that occurs as a result of connecting a DEK generator to household wiring without the use of a UL approved transfer switch device that is connected to the home or business and grounded as per applicable local electrical codes, is not covered by this warranty.

Warranty repairs will be made without charge for parts and labor for the first year. After the first year, this limited warranty covers the costs of replacement parts only.

Anything replaced under warranty becomes the property of DEK. Parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincident with the original product warranty.

TO OBTAIN WARRANTY SERVICE:

You must take the DEK Power Equipment product, accessory, replacement part, apparel or the power equipment on which the accessory or replacement part is installed, and proof of purchase, at your expense, to any DEK Power Equipment service location in the United States, who is authorized to service that product, during the service location‟s normal business hours. If you are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the following steps: First, contact the manager of the service center involved; normally this will resolve the problem. However, if you should require further assistance, write or call the DEK Customer Service.

EXCLUSIONS:

THIS WARRANTY DOES NOT EXTEND TO PARTS AFFECTED OR DAMAGED BY ACCIDENT AND/OR COLLISION, NORMAL WEAR, FUEL CONTAMINATION, USE

IN AN APPLICATION FOR WHICH THE PRODUCT WAS NOT DESIGNED OR ANY OTHER MISUSE, NEGLECT, INCORPORATION OR USE OF UNSUITABLE AT-

TACHMENTS OR PARTS, UNAUTHORIZED ALTERATION, OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE PRODUCT.

Consumable parts such as oil, spark plugs, filters, carburetors, are not covered by this warranty.

DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES:

DEK DISCLAIMS ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE PRODUCT, TRANSPORTATION, COMMERCIAL LOSS, OR ANY OTHER INCIDEN-

TAL OR CONSEQUENTIAL DAMAGE. ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY.

This warranty is void if the manufacturing date and the serial number on the equipment has been removed or the equipment has been modified.

EMISSION CONTROL SYSTEM INFORMATION

The U.S. and California Clean Air Acts

EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must be followed in order to keep the emissions from your DEK engine within the emission standards. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are „„certified‟‟ to EPA standards.

The emission control systems on your DEK engine were designed, built, and certified to conform with EPA regulations. We recommend the use of genuine DEK parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or re-builder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

Emission controls are covered by this warranty for all uses for a period of 3 years from original retail purchase date, this coverage extends to subsequent owners of the product with proof of original purchase.



16 of 16

DEK DEK4550PRO Pro 6000-Watt Gasoline Portable Generator Use and care guide

Heavy Duty Power Equipment

Owner’s Manual

This manual contains important safety instructions for gasoline

generator models: 4550Pro, 5650, 6500, 6500EL, 7550EL Pro that should be followed during installation and

maintenance of the generator and batteries

Contents:

DO NOT RETURN THIS GENERATOR

TO THE STORE!

DEK Product Lines

For your convenience, DEK offers a complete range of generator accessories. Please ask your local retailer for more details or call

[1] 919-550-3221.

DEK Product Lines

Other fine products offered by

For more information or where to purchase DEK outdoor power equipment, visit us at: www.DEKPowerUSA.com

Missing Parts Request Form

IMPORTANT: Please include your receipt. Without a receipt, your order will be delayed. You may also email us at: [email protected] or fax at 919-550-3277. If emailing, please scan in your proof of purchase.

WARNINGS

WARNINGS

Product Specifications

Component Identification

Wheel Kit Assembly

Commissioning the Battery

Controls

Controls

Operating the Generator

Ethanol warning

This portable generator is not for use with gasoline/ethanol blends with over 15% ethanol.

Operating the Generator

Maintenance

Maintenance

Troubleshooting

Troubleshooting

Limited Warranty & Service

Related manuals

DEK DEK4550PRO Pro 6000-Watt Gasoline Portable Generator Use and care guide

Heavy Duty Power Equipment

Owner’s Manual

This manual contains important safety instructions for gasoline

generator models: 4550Pro, 5650, 6500, 6500EL, 7550EL Pro that should be followed during installation and

maintenance of the generator and batteries

Contents:

DO NOT RETURN THIS GENERATOR

TO THE STORE!

DEK Product Lines

For your convenience, DEK offers a complete range of generator accessories. Please ask your local retailer for more details or call

[1] 919-550-3221.

DEK Product Lines

Other fine products offered by

For more information or where to purchase DEK outdoor power equipment, visit us at: www.DEKPowerUSA.com

Missing Parts Request Form

IMPORTANT: Please include your receipt. Without a receipt, your order will be delayed. You may also email us at: [email protected] or fax at 919-550-3277. If emailing, please scan in your proof of purchase.

WARNINGS

WARNINGS

Product Specifications

Component Identification

Wheel Kit Assembly

Commissioning the Battery

Controls

Controls

Operating the Generator

Ethanol warning

This portable generator is not for use with gasoline/ethanol blends with over 15% ethanol.

Operating the Generator

Maintenance

Maintenance

Troubleshooting

Troubleshooting

Limited Warranty & Service

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