Dek Generator User Manual

®
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Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
DEK Product Lines  
Heavy Duty Power Equipment  
Other fine products offered by  
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For more information or where to purchase DEK outdoor power  
Missing Parts Request Form  
Please indicate the part that you are missing:  
Hardware bag  
Name  
Wheel Kit  
Other  
Address  
Date of purchase  
Model #:  
4550Pro  
Phone  
Email  
5650  
6500 or 6500EL  
755EL Pro  
Serial #:  
Comments:  
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.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
WARNINGS  
WARNING  
The engine exhaust from this product contains chemicals  
known to the State of California to cause cancer, birth de-  
fects 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 separately derived sys-  
tem in accordance with the National Electrical Code, NFPA  
70. The generator shall be connected through transfer equip-  
ment that switches all conductors other than the equipment  
grounding conductor. The frame of the generator shall be  
connected to an approved grounding electrode.  
DANGER  
CARBON MONOXIDE GAS  
Exhaust contains poisonous carbon monoxide, a colorless  
and odorless gas. Breathing exhaust can cause loss of con-  
sciousness and may lead to death. To keep exhaust gas  
from accumulating, use in an area with adequate ventila-  
tion. 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.  
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 com-  
pany 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.  
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  
Special Requirements  
 DO NOT use when your hands are wet  
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 hav-  
ing jurisdiction.  
NEVER START OR STOP THE ENGINE WITH DEVICES CON-  
NECTED TO THE GENERATOR.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
WARNINGS  
AC Applications  
WARNING  
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 abnor-  
mally, becomes sluggish or stops suddenly, turn it off imme-  
diately.  
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.  
2. Disconnect the appliance, and determine whether the prob-  
lem is the appliance, or if the rated load capacity of the gen-  
erator 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 be-  
tween rated and maximum may be used for no more than  
30 minutes.  
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 touch-  
ing.  
Substantial overloading will open the circuit breaker. Ex-  
ceeding 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.  
 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.  
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.  
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.  
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.  
Changing the speed of the generator by adjusting the governor can cause damage to the gen-  
erator, devices attached to the generator, and may result in bodily injury. Do not adjust or  
tamper with the engine speed setting.  
DANGER  
Product Specifications  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Component Identification  
Fuel Cap  
Fuel Tank  
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  
Battery (electric start option only)  
Air Filter  
Fuel Valve  
Oil Fill Cap—one one each side of the  
engine.  
Recoil Starter (Assembly)  
Emissions Information  
Oil Drain (one on each side of the engine)  
Engine Serial Number stamped  
on the engine block  
Main  
Breaker  
ON/OFF Switch  
L14-30 240V/120V  
Digital Meter  
Ground  
Lug  
12 V Breaker  
120V AC Outlets  
Start Switch (electric start option)  
12V DC Outlet  
Pull Out Handle  
Bars  
Choke Lever  
(recessed)  
Valve Cover  
Carburetor  
Alternator  
Muffler Guard  
Exhaust Pipe  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Wheel Kit Assembly  
Required Tools (not supplied)  
1. Adjustable wrench or a socket  
wrench with a 8 mm socket.  
Pre-assembled wheel /  
axle assembly.  
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.  
Insert each axle and tighten the  
bolt to secure in place using an  
adjustable wrench or 8 mm  
socket.  
Step  
2
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. Bat-  
tery posts, terminals and related accessories contain lead  
and lead compounds. Avoid spills of electrolyte and wash  
hands thoroughly after handling.  
FOR YOUR SAFETY AND CONVENIENCE, THE  
BATTERY WAS SHIPPED SEALED AND  
PRE-CHARGED.  
The battery is ready to be connected to the generator.  
Use gloves and safety glasses when handling and installing  
lead acid batteries.  
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.  
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.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Controls  
DC Terminals  
Disconnecting the battery cables:  
1. Stop the engine.  
Some generators are shipped with optional DC battery charging  
cables, have a standard 12V DC receptacle, and have a 12V  
cigarette lighter style outlet.  
2. Disconnect the negative ( - ) battery cable from the genera-  
tor negative ( - ) terminal.  
3. Disconnect the other end of the negative ( - ) battery cable  
from the battery negative ( - ) terminal.  
The battery must be connected to the generator DC terminals  
with the proper polarity (battery positive to generator red termi-  
nal and battery negative to the generator black terminal).  
4. Disconnect the positive ( + ) battery cable from the genera-  
tor 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.  
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 posi-  
tive ( + ) terminal.  
4. Connect the negative ( - ) battery cable to the battery nega-  
tive ( - ) 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 charg-  
ing cable is connected and the generator is running. The  
vehicle or the generator may be damaged.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Controls  
WARNING  
Recoil Starter  
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.  
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.  
Choke Rod  
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.  
The choke is used to  
provide an enriched  
fuel mixture when  
starting a cold en-  
gine. It can be  
opened and closed  
by operating the  
choke rod manually.  
Pull the rod out to-  
ward CLOSED to  
enrich the mixture  
for cold starting.  
Open once the en-  
gine is running.  
STARTER GRIP  
RECOIL STARTER  
Turn clock-  
wise to turn  
fuel valve on.  
Fuel Valve Lever  
Oil Alert System  
The fuel valve is  
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.  
located between the  
fuel tank and carbu-  
retor. 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.  
Ground Terminal  
The generator ground terminal is con-  
nected to the frame of the generator, the  
metal non-current-carrying parts of the  
generator, and the ground terminals of  
each receptacle.  
Engine Switch  
To start and stop the engine.  
WARNING  
Before using the ground terminal, consult a qualified elec-  
trician, electrical inspector or local agency having jurisdic-  
tion 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  
Electric Starter Switch  
(optional feature)  
Engine ON / OFF Switch  
Rev. 1/2010  
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.  
9 of 16  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Operating the Generator  
DANGER  
CARBON MONOXIDE GAS  
CARBON MONOXIDE Using a generator indoors CAN KILL  
YOU IN MINUTES.  
Step 3.  
Generator exhaust contains carbon monoxide (CO). This is  
a poison you cannot see or smell. If you can smell the gen-  
erator exhaust, you are breathing CO. But even if you can-  
not smell the exhaust, you could be breathing CO.  
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 com-  
plete.  
NEVER use a generator inside homes, garages, crawl-  
spaces, 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.  
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 en-  
gine and spark plug deposits and  
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 battery-  
backup CO alarm in the home.  
extends exhaust system life. Never  
use stale or contaminated gasoline  
or an oil/gasoline mixture. Avoid  
getting dirt or water in the fuel tank.  
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 compo-  
nents, possibly leading to a generator failure.  
WARNING  
Ethanol 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.  
This portable generator is not for use with  
gasoline/ethanol blends with over 15%  
ethanol.  
Step 2.  
Check the oil level by removing the oil fill cap.  
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.  
 Put the generator on a level surface with the engine  
stopped.  
 Remove the oil filler cap.  
 Stop engine and keep heat, sparks, and flame away.  
 Refuel only outdoors.  
 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.  
 Wipe up spills immediately.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Operating the Generator  
Continuously loading this generator above 80% of its maxi-  
mum output power will shorten the life of the generator.  
Step 4.  
Set the fuel valve lever to the ON position by rotating it clock-  
wise.  
Balance the load evenly between the A and B outlets to maxi-  
mize the output power.  
Step 5.  
Pull the choke lever to the CLOSED position. See page 7 for a  
diagram of the choke lever.  
Appliances with electric motors require an additional 150%  
power when they are starting up (indicated by an * and in bold  
in the chart below).  
Step 6.  
Turn the generator ON/OFF switch to the “ON” position.  
To determine maximum load that you may safely connect  
to this generator:  
Step 7.  
Start the engine  
1. Calculate the maximum continuous power required by add-  
ing up the running power of each appliance. The total run-  
ning power of your appliances cannot exceed the maximum  
output power of this generator.  
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 back-  
pressure building, rapidly pull the cord.  
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.  
Step 8.  
Once the generator is running, push the choke lever into the  
OPEN position.  
The surge power requirements of your appliances cannot  
exceed the surge power rating of this generator.  
Step 9.  
Let the generator warm up for approximately 3 minutes before  
applying any electrical loads.  
Typical Residential Loads  
Appliance  
Running Power  
Step 10.  
Light bulbs (each)  
Stove element (each)  
Microwave  
Coffee maker  
Television  
75 Watts  
Apply loads to the generator one at a time, allowing the genera-  
tor 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.  
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  
VCR  
Computer & monitor  
Space heater  
Washing machine  
NG clothes dryer  
Electric clothes dryer  
Dishwasher  
Water heater  
Electric furnace  
Toaster  
ALWAYS UNPLUG APPLIANCES AND REMOVE ALL ELEC-  
TRICAL LOADS BEFORE REFUELING. THEN FOLLOW  
STEPS 2 - 10.  
Box fan*  
Window A/C - 8000 BTU*  
Central A/C (per ton)*  
Furnace blower*  
2 hp well pump*  
Refrigerator*  
Freezer*  
WARNING  
STOPPING THE GENERATOR  
In an emergency:  
Connecting a load larger than this generator’s power rating may  
damage the circuit breakers, alternator and sensitive appliances.  
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.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Maintenance  
MAINTENANCE  
Engine Oil Change  
Drain the oil while the engine is warm to assure rapid and com-  
plete draining.  
The Importance of Maintenance  
Good maintenance is essential for safe, economical, and trou-  
ble-free operation. It will also help reduce air pollution.  
1. Remove the drain plug and sealing washer, remove the oil  
filler cap, and drain the oil.  
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 re-  
quire special tools, are best handled by professionals and are  
normally performed by a DEK technician or other qualified  
mechanic.  
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.  
The maintenance schedule applies to normal operating condi-  
tions. 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 servic-  
ing dealer for recommendations applicable to your individual  
needs and use.  
Air Cleaner Service  
A dirty air cleaner will restrict air flow to the carburetor. To pre-  
vent carburetor malfunction, service the air cleaner regularly.  
Service more frequently when operating the generator in ex-  
tremely dusty areas.  
Maintenance, replacement, or repair of the emission con-  
trol devices and systems may be performed by any engine  
repair establishment or individual, using parts that are  
‘‘certified’’ to EPA standards.  
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.  
Maintenance Schedule  
Item  
Before  
each use  
20hrs or  
every 3  
month  
50 hrs or  
every 3  
months  
100 hrs or  
every 6  
months  
300 hrs  
or every  
1 year  
3. Soak the air cleaner element in clean engine oil and  
squeeze out the excess oil. The engine will smoke dur-  
ing initial startup if too much oil is left in the air cleaner  
element.  
Engine oil (Check)  
X
X
Engine Oil (Change)  
X
4. Reinstall the air cleaner element and the cover.  
Air Cleaner (Check)  
Fuel Filter Cleaning  
Air Cleaner Wash  
X
X
Fuel filter Cup (Clean)  
Spark Plug (Clean)  
X
X
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 (Change)  
Optional Spark Arrestor (Clean)  
Valve Clearance (Adjust)  
Fuel Tank and Filter (Clean)  
Fuel Tube (Check)  
X
X*  
Spark Plug Service  
X*  
Every 2 yrs (replace if necessary)*  
After every 250 hrs*  
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 depos-  
its.  
Combustion Chamber (Clean)  
* Should be performed by an authorized DEK dealer.  
Replacement Parts  
If the engine has been running, the muffler will be very  
hot. Be careful not to touch the muffler.  
The emission control systems on your DEK engine were designed,  
built, and certified to conform with EPA and California emission regu-  
lations. 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 effec-  
tiveness of your emission control system.  
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.  
A manufacturer of an aftermarket part assumes the responsibility that  
the part will not adversely affect emission performance. The manu-  
facturer 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 regula-  
tions.  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
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.  
4. Visually inspect the spark plug. Dis-  
card 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)  
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 genera-  
tor 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.  
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.  
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.  
STORING  
NOTICE:  
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:  
The spark plug must be securely tightened. An improperly tight-  
ened spark plug can become very hot and could damage the  
engine. Use only the recommended spark plugs or equivalent.  
Optional Spark Arrestor Maintenance  
STORAGE TIME  
1 to 2 months  
Recommended Service Procedure to prevent hard starting:  
Fill with fresh gasoline and add gasoline conditioner*.  
Fill with fresh gasoline and add gasoline conditioner*.  
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.  
2 months to 1 year  
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 ar-  
rester screen. Inspect the screen for breaks or tears and  
replace it if necessary.  
Fill with fresh gasoline and add gasoline conditioner*.  
Drain the carburetor float bowl.  
1 year or longer  
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.  
3. Install the spark arrester in the reverse order of removal.  
Change the engine oil.  
SCREW  
After removal from storage, drain the stored gasoline into a suitable con-  
* 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.  
SPARK ARRESTOR  
2. Change the engine oil (page 10 ).  
Optional Starter Motor Fuse Replacement  
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.  
If the fuse is blown, the starter motor won’t operate. Turn the en-  
gine switch to the OFF position. Remove the fuse holder cover  
and replace the fuse. The specified fuse is 10A.  
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.  
NOTICE:  
Never use a fuse with a  
different rating from that  
specified. Serious dam-  
age to the electrical sys-  
tem or fire may result.  
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.  
Rev. 1/2010  
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.  
13 of 16  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Troubleshooting  
Symptom:  
No spark, engine not catching, engine won't start  
Potential Causes  
Fuel valve off/out of fuel  
Spark arrestor clogged  
Choke is open  
Vacuum check valve has failed  
On/Off switch broken  
Oil level too low  
Check / solution  
Fill tank/turn fuel valve on  
Remove, clean and replace.  
Close choke by pulling choke wire out. Open choke after starting  
Replace check valve  
Recommendation  
Call DEK for parts/service  
Call DEK for parts/service  
Use fuel shut-off as ON/OFF switch until switch is replaced.  
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  
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  
Call DEK for parts/service  
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.  
Contaminates in fuel will not allow combustion at the specified pressure and temperate and blocks filters  
Press spark plug boot firmly on spark plug.  
Fuel is contaminated  
Spark plug boot off/loose  
Ignition coil failure  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Spark plug fouled or failed  
Carburator clogged  
Remove spark plug, clean or replace  
Clean with fresh fuel  
Symptom:  
Potential Causes  
Recoil is hard to pull or not retracting  
Check / solution  
Recommendation  
Spark arrestor  
Remove, clean and replace.  
Recoil rubbing on dented housing  
Alternator bearing failed  
Camshaft detent has failed  
Head valve timing is off  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Alternator bearing needs to be replaced. Send to service.  
Symptom:  
Potential Causes  
Engine starts, but then shuts off before 10 seconds  
Check / solution  
Recommendation  
Remove/Clean spark arrestor  
Oil level too low  
Fuel valve off/out of fuel  
Spark plug fouled or failed  
Remove, clean and replace.  
The engine shuts down when the oil level is low. Check the owners manual for oil capacity  
Fill tank/turn fuel valve on  
Remove spark plug, clean or replace  
Call DEK for parts/service  
Call DEK for parts/service  
Vacuum check valve has failed Replace check valve, call DEK for replacement procedure.  
Symptom:  
Choke wire broke  
Potential Causes  
Choke broke  
Check / solution  
Recommendation  
Call DEK for parts/service  
Choke should be closed while starting. Pull black choke counter-clockwise and hold in place with wire.  
Release after starting.  
Symptom:  
Engine runs: rough/vibrating/oscillating  
Potential Causes  
Check / solution  
Recommendation  
Remove/Clean spark arrestor  
The choke is not open  
Over loading generator  
Air filter is dirty  
Remove, clean and replace.  
Push choke lever in.  
Disconnect some appliances  
Clean air filter  
Fuel filter is clogged  
Fuel is contaminated  
Vacuum check valve has failed  
Head valve timing is off  
Contaminates will clog filter, not allowing fuel to get to engine. Clean filter  
Contaminates in fuel will not allow combustion at the specified pressure and temperate  
Replace check valve.  
Call DEK for parts/service  
Call DEK for parts/service  
Send to service  
Symptom:  
Engine runs, but boggs down under load  
Check / solution  
Remove, clean and replace.  
Potential Causes  
Remove/Clean spark arrestor  
Choke is open  
Recommendation  
Push choke lever in  
Over loading generator  
Air filter is dirty  
Disconnect some appliances / devices  
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  
Check / solution  
Try different / shorter extension cord or a different power strip  
Disconnect all loads and push reset button.  
Disconnect all loads. Push the red reset button very deep/firmly  
Replace GFCI with any GFCI or household outlet  
Potential Causes  
Bad extension cord/power strip  
Push button breaker tripped  
GFCI tripped  
Recommendation  
GFCI failed  
Call DEK for parts/service  
Rev. 1/2010  
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  
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  
Check / solution  
Try different / shorter extension cord or a different power strip  
Try a different light bulb or device  
Potential Causes  
Bad extension cord/power strip  
Device failed  
Recommendation  
Push button breaker tripped  
GFCI tripped  
Push button breaker tripped  
Push the red reset button very deep/firmly  
GFCI failed  
Broken wire  
Toggle switch failed  
Replace GFCI with any GFCI or household outlet  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Symptom:  
Engine runs, volt meter shows 120VAC in 120V mode, but 120VAC or 0VAC in 240V mode  
Check / solution  
Potential Causes  
Circuit breaker failed  
Toggle switch failed  
Alternator phase has failed  
Broken wire  
Recommendation  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Symptom:  
Potential Causes  
Spark arrestor  
Voltage too high/low  
Check / solution  
Remove, clean and replace.  
Recommendation  
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:  
Potential Causes  
Alternator phase has failed  
Voltage is 120 VAC on 1 phase but too high/low on other phase  
Check / solution  
Recommendation  
Call DEK for parts/service  
Symptom:  
Potential Causes  
Engine oil leaking  
Check / solution  
Recommendation  
Oil leaking from crankcase gas- Tighten crankcase bolts  
ket  
Oil leaking from shaft  
Oil seals failed  
Call DEK for parts/service  
Symptom:  
Potential Causes  
Bolt not tight  
Oil leaking from Valve head cover  
Check / solution  
Tighten bolts  
Recommendation  
Symptom:  
Fuel leak at tank shut-off  
Potential Causes  
Shut-off valve loose  
Check / solution  
Tighten nut on shut-off valve/replace shut-off valve  
Recommendation  
Call DEK for parts/service  
Symptom:  
Potential Causes  
Fuel drain screw loose  
Fuel leaking out of carburator  
Check / solution  
Tighten fuel drain screw  
Recommendation  
Carburator float seat not seating Flush with clean fuel  
Symptom:  
Cannot turn engine with recoil  
Potential Causes  
Check / solution  
Recommendation  
Recoil ratchets have broken  
Recoil is crushed in  
Alternator bearing has failed  
Head valve timing is off  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Call DEK for parts/service  
Symptom:  
Potential Causes  
Replace fuel gauge gasket  
Fuel gauge leaks  
Check / solution  
Recommendation  
Call DEK for parts/service  
Rev. 1/2010  
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  
Heavy Duty Power Equipment  
4550 Pro, 5650, 6500(EL), 7550 Pro  
Limited Warranty & Service  
LENGTH OF WARRANTY:*  
(FROM THE DATE OF ORIGINAL RETAIL PURCHASE)  
PRODUCTS COVERED BY THIS WARRANTY:  
NONCOMMERCIAL/ NON-  
COMMERCIAL  
RENTAL  
RENTAL  
Engine  
36 months / 300 hours  
12 months / 300 hours  
3 months  
3 months / 300 hours  
3 months  
Battery  
3 months  
Alternator  
36 months / 300 hours  
24 months / 300 hours  
36 months  
12 months / 300 hours  
12 months /300 hours  
36 months  
3 months / 300 hours  
3 months / 300 hours  
36 months  
Electrical and Frame Components  
Emission Controls  
*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 pur-  
chaser / 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 gen-  
erator 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 workman-  
ship. 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 Cus-  
tomer 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 follow-  
ing 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 manufac-  
turer 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.  
Rev. 1/2010  
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.  
16 of 16  

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