Page 1
®
®
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] 919-550-3259
or go to www.DEKPowerUSA.com
Have the following information ready when you call us:
Date of Purchase: _______________________
Location of Purchase: _______________________
Serial #: _______________________
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.
1 of 16 Rev. 1/2010
Page 2
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.
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.
2 of 16 Rev. 1/2010
Page 3
Heavy Duty Power Equipment
DEK Product Lines
4550 Pro, 5650, 6500(EL), 7550 Pro
Other fine products offered by
Heavy Duty Power Equipment
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
IMPORTANT: Please include your receipt. Without a receipt, your
order will be delayed. You may also email us at:
customerservice@gxioutdoorpower.com 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.
No part of this publication can be printed or copied without written permission.
3 of 16 Rev. 1/2010
Page 4
Heavy Duty Power Equipment
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.
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.
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 CONNECTED TO 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.
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 separatel y 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.
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.
4 of 16 Rev. 1/2010
Page 5
Heavy Duty Power Equipment
WARNINGS
4550 Pro, 5650, 6500(EL), 7550 Pro
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.
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.
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.
Do not run the engine unless instructed to do so.
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
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.
5 of 16 Rev. 1/2010
Page 6
Heavy Duty Power Equipment
Fuel Tank
Choke Lever
Air Filter
Recoil Starter (Assembly)
Emissions Information
Engine Serial Number stamped
on the engine block
Fuel Valve
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.
Battery (electric start option only)
Oil Fill Cap—one one each side of the
engine.
Oil Drain (one on each side of the engine)
ON/OFF Switch
Start Switch (electric start option)
Pull Out Handle
Bars
(recessed)
Breaker
Main
12 V Breaker
L14-30 240V/120V
120V AC Outlets
Digital Meter
Ground
Lug
12V DC Outlet
Choke Lever
Valve Cover
Alternator
Exhaust Pipe
Carburetor
Muffler Guard
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.
6 of 16 Rev. 1/2010
Page 7
Heavy Duty Power Equipment
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.
Wheel Kit Assembly
4550 Pro, 5650, 6500(EL), 7550 Pro
Pre-assembled wheel /
axle assembly.
Step
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.
Insert each foot assembly through
1
holes in the frame. Tighten nut with
adjustable wrench or 8 mm socket.
Step
2
Insert each axle and tighten the
bolt to secure in place using an
adjustable wrench or 8 mm
socket.
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.
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 batter ie s. 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.
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.
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.
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.
7 of 16 Rev. 1/2010
Page 8
Heavy Duty Power Equipment
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.
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.
8 of 16 Rev. 1/2010
Page 9
Heavy Duty Power Equipment
Heavy Duty Power Equipment
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.
Turn clockwise to turn
fuel valve on.
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.
RECOIL STARTER
STARTER GRIP
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.
Engine Switch
To start and stop the engine.
Oil Alert System
N
O
F
F
O
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.
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.
Engine ON / OFF Switch
NOTE: SYSTEM GROUND IS NOT CONNECTED TO THE AC
NEUTRAL ON THIS GENERATOR. CONSULT AN ELECTRICIAN WHEN CONNECTING THIS GENERATOR TO YOUR
Electric Starter Switch
(optional feature)
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.
HOME OR BUSINESS ELECTRICAL PANEL TO ENSURE
GROUNDING MEETS THE LOCAL ELECTRICAL CODE
9 of 16 Rev. 1/2010
Page 10
Heavy Duty Power Equipment
Heavy Duty Power Equipment
DANGER
Operating the Generator
4550 Pro, 5650, 6500(EL), 7550 Pro
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 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
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.
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.
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.
10 of 16 Rev. 1/2010
Page 11
Heavy Duty Power Equipment
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 ELECTRICAL 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.
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 Running Power
Light bulbs (each) 75 Watts
Stove element (each) 1000 Watts
Microwave 1500 Watts
Coffee maker 700 Watts
Television 750 Watts
VCR 250 Watts
Computer & monitor 800 Watts
Space heater 1500 Watts
Washing machine 1000 Watts
NG clothes dryer 750 Watts
Electric clothes dryer 5500 Watts
Dishwasher 1850 Watts
Water heater 5000 Watts
Electric furnace 5000 Watts
Toaster 1200 Watts
Box fan* 750 Watts
Window A/C - 8000 BTU* 2400 Watts
Central A/C (per ton)* 2800 Watts
Furnace blower* 850 Watts
2 hp well pump* 2000 Watts
Refrigerator* 1000 Watts
Freezer* 1000 Watts
STOPPING THE GENERATOR
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. T urn 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.
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.
11 of 16 Rev. 1/2010
Page 12
Heavy Duty Power Equipment
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.
Engine Oil Change
Drain the oil while the engine is warm to assure rapid and complete draining.
1. Remov e the drain plug and sealing washer, remove the oil
To help you properly care for your generator, the following
2. Reinstall the drain plug and sealing washer. Tighten the
pages include a maintenance schedule, routine inspection
procedures, and simple maintenance procedures using basic
3. Refill with the recommended oil (SAE 10W-30 ) and check
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
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.
‘‘certified’’ to EPA standards.
Maintenance Schedule
Item Before
Engine oil (Check) X
Engine Oil (Change) X
Air Cleaner (Check) X
Air Cleaner Wash X
Fuel filter Cup (Clean) X
Spark Plug (Clean) X
Spark Plug (Change) X
Optional Spark Arrestor (Clean) X
Valve Clearance (Adjust) X*
Fuel Tank and Filter (Clean) X*
Fuel Tube (Check)
Combustion Chamber (Clean)
* Should be performed by an authorized DEK dealer.
each use
Every 2 yrs (replace if necessary)*
After every 250 hrs*
20hrs or
every 3
month
50 hrs or
every 3
months
100 hrs or
every 6
months
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 replacemen t 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.
filler cap, and drain the oil.
plug securely.
the oil level.
1. Unsnap the a ir cleaner cover clips, remove the air
cleaner cover, and remove the element.
2. Wash the air cl eaner 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. Reinst all 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 sp ark plug cap.
2. Clean an y dirt from around the spark plug base.
3. Use a spark plug wrench to remove the spark plug.
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.
12 of 16 Rev. 1/2010
Page 13
Heavy Duty Power Equipment
4. Visuall y ins pect the spark plug. Discard it if the insulator is cracked,
chipped or fouled.
5. Measur e 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)
Maintenance
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.
4550 Pro, 5650, 6500(EL), 7550 Pro
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 brus h 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 th e reverse order of removal.
SCREW
DANGER
Contact with a hot engine
or exhaust system can
cause serious burns or
fires. Let the engine cool
before transporting or storing 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 Recommended Service Procedure to prevent hard starting:
1 to 2 months Fill with fresh gasoline and add gasoline conditioner*.
2 months to 1 year Fill with fresh gasoline and add gasoline conditioner*.
1 year or longer
Fill with fresh gasoline and add gasoline conditioner*.
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 con-
SPARK AR RESTOR
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.
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.
* Use gasoline conditioners that are formulated to extend storage life. Contact your authorized
DEK generator dealer for conditioner recommendations.
Storage Preparation
1. Drain the carb uretor 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 Rev. 1/2010
Page 14
Heavy Duty Power Equipment
Heavy Duty Power Equipment
4550 Pro, 5650, 6500(EL), 7550 Pro
Troubleshooting
Symptom: No spark, engine not catching, engine won't start
Potential Causes Check / solution Recommendation
Fuel valve off/out of fuel Fill tank/turn fuel valve on
Spark arrestor clogged 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 Call DEK for parts/service
On/Off switch broken Use fuel shut-off as ON/OFF switch until switch is replaced. Call DEK for parts/service
Oil level too low The engine shuts down when oil level low
Oil switch Verify oil switch/sensor is functioning . The oil switch is the gold, brass colored box about 3 inches to the
Recoil is broken If ratchets are broken they will not spin the engine. Call DEK for parts/service
Fuel filter is dirty Contaminates will clog filter, not allowing fuel to get to engine. Clean or replace fuel filter.
Fuel is contaminated Contaminates in fuel will not allow combustion at the specified pressure and temperate and blocks filters
Spark plug boot off/loose Press spark plug boot firmly on spark plug. Call DEK for parts/service
Ignition coil failure Call DEK for parts/service
Spark plug fouled or failed Remove spark plug, clean or replace Call DEK for parts/service
Carburator clogged Clean with fresh fuel Call DEK for parts/service
Symptom: Recoil is hard to pull or not retracting
Potential Causes Check / solution Recommendation
Spark arrestor Remove, clean and replace.
Recoil rubbing on dented housing Call DEK for parts/service
Alternator bearing failed Alternator bearing needs to be replaced. Send to service. Call DEK for parts/service
Camshaft detent has failed Call DEK for parts/service
Head valve timing is off Call DEK for parts/service
Symptom: Engine starts, but then shuts off before 10 seconds
Potential Causes Check / solution Recommendation
Remove/Clean spark arrestor Remove, clean and replace.
Oil level too low The engine shuts down when the oil level is low. Check the owners manual for oil capacity
Fuel valve off/out of fuel Fill tank/turn fuel valve on
Spark plug fouled or failed Remove spark plug, clean or replace Call DEK for parts/service
Vacuum check valve has failed Replace check valve, call DEK for replacement procedure. Call DEK for parts/service
Symptom: Choke wire broke
Potential Causes Check / solution Recommendation
Choke broke Choke should be closed while starting. Pull black choke counter-clockwise and hold in place with wire.
Symptom: Engine runs: rough/vibrating/oscillating
Potential Causes Check / solution Recommendation
Remove/Clean spark arrestor Remove, clean and replace.
The choke is not open Push choke lever in.
Over loading generator Disconnect some appliances
Air filter is dirty 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. Call DEK for parts/service
Head valve timing is off Send to service Call DEK for parts/service
Symptom: Engine runs, but boggs down under load
Potential Causes Check / solution Recommendation
Remove/Clean spark arrestor Remove, clean and replace.
Choke is open Push choke lever in
Over loading generator Disconnect some appliances / devices
Air filter is dirty Clean air filter
Fuel filter is clogged Contaminates will clog filter, not allowing fuel to get to engine
Symptom: Engine runs, Volt meter shows 120 VAC, but no power to outlets
Potential Causes Check / solution Recommendation
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 Disconnect all loads. Push the red reset button very deep/firmly
GFCI failed Replace GFCI with any GFCI or household outlet Call DEK for parts/service
left of the oil fill cap. Dis-connect oil switch by disconnecting black lead out of finger connection. If the
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
Release after starting.
Call DEK for parts/service
Call DEK for parts/service
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.
14 of 16 Rev. 1/2010
Page 15
Heavy Duty Power Equipment
Heavy Duty Power Equipment
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
Potential Causes Check / solution Recommendation
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 Push button breaker tripped
GFCI tripped Push the red reset button very deep/firmly
GFCI failed Replace GFCI with any GFCI or household outlet Call DEK for parts/service
Broken wire Call DEK for parts/service
Toggle switch failed Call DEK for parts/service
Symptom: Engine runs, volt meter shows 120VAC in 120V mode, but 120VAC or 0VAC in 240V mode
Potential Causes Check / solution Recommendation
Circuit breaker failed Call DEK for parts/service
Toggle switch failed Call DEK for parts/service
Alternator phase has failed Call DEK for parts/service
Broken wire Call DEK for parts/service
Symptom: Voltage too high/low
Potential Causes Check / solution Recommendation
Spark arrestor Remove, clean and replace.
Voltage not measured correctly Voltage must be measured between hot and neutral, not hot and ground, the ground is isolated
Speed screw bent Call DEK for parts/service
Symptom: Voltage is 120 VAC on 1 phase but too high/low on other phase
Potential Causes Check / solution Recommendation
Alternator phase has failed Call DEK for parts/service
Symptom: Engine oil leaking
Potential Causes Check / solution Recommendation
Oil leaking from cr ankcase gasket
Oil leaking from shaft Oil seals failed Call DEK for parts/service
Symptom: Oil leaking from Valve head cover
Potential Causes Check / solution Recommendation
Bolt not tight Tighten bolts
Symptom: Fuel leak at tank shut-off
Potential Causes Check / solution Recommendation
Shut-off valve loose Tighten nut on shut-off valve/replace shut-off valve Call DEK for parts/service
Symptom: Fuel leaking out of carburator
Potential Causes Check / solution Recommendation
Fuel drain screw loose Tighten fuel drain screw
Carburator float seat not seating Flush with clean fuel
Symptom: Cannot turn engine with recoil
Potential Causes Check / solution Recommendation
Recoil ratchets have broken Call DEK for parts/service
Recoil is crushed in Call DEK for parts/service
Alternator bearing has failed Call DEK for parts/service
Head valve timing is off Call DEK for parts/service
Symptom: Fuel gauge leaks
Potential Causes Check / solution Recommendation
Replace fuel gauge gasket Call DEK for parts/service
Tighten crankcase bolts
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.
15 of 16 Rev. 1/2010
Page 16
Heavy Duty Power Equipment
Heavy Duty Power Equipment
Limited Warranty & Service
4550 Pro, 5650, 6500(EL), 7550 Pro
PRODUCTS COVERED BY THIS WARRANTY:
Engine 36 months / 300 hours 12 months / 300 hours 3 months / 300 hours
Battery 3 months 3 months 3 months
Alternator 36 months / 300 hours 12 months / 300 hours 3 months / 300 hours
Electrical and Frame Components 24 months / 300 hours 12 months /300 hours 3 months / 300 hours
Emission Controls 36 months 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
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 generat or 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.
NONCOMMERCIAL/ NON-
(FROM THE DATE OF ORIGINAL RETAIL PURCHASE)
RENTAL
LENGTH OF WARRANTY:*
COMMERCIAL RENTAL
under normal use during the applicable warranty time period
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 ATTACHMENTS 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 INCIDENTAL 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.
DEK® is registered trademark of GXi Outdoor Power, LLC Clayton, NC 27520 USA.
16 of 16 Rev. 1/2010
No part of this publication can be printed or copied without written permission.
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