DEK 5000 User Manual GENERATOR Manuals And Guides L0606321

DEK Generator Manual L0606321 DEK Generator Owner's Manual, DEK Generator installation guides

User Manual: DEK 5000 5000 DEK GENERATOR - Manuals and Guides View the owners manual for your DEK GENERATOR #5000. Home:Tool Parts:DEK Parts:DEK GENERATOR Manual

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® Heavy Duty Power Equipment

Owner's Manual
This manual contains important safety instructions for gasoline engine
powered electric generator models: 3850, 4000, 5000, 5000EL, 5650, 5650EL, 6500, 6500EL, 1SOW, 180WEL.
READ SAFETY

WARNINGS

AND OPERATING

INSTRUCTIONS

CAREFULLY,

SAVE THESE

INSTRUCTIONS.

Contents:
1.
2.
3.

Tools and Accessories
Warnings & Specifications
Component identification

4.
5.

Wheel Kit Assembly
Controls

Operating

Maintenance

Transporting

Troubleshooting

10.

Warranty

the Generator
and Storage
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] 800-393-0668
or go to www,DEKPowerUSA.com

Have the following

information

ready when

you call us:

Date of Purchase:
Location
Serial

of Purchase:

DEK® is registered trademark of GXi International, LLC Clayton, NC 27520 USA
No part of this publication can be printed or copied without written permission.

Rev:1/2006
..

DEK® is exclusively distributed by GXi International, LLC
1 of 14

Tools

Heavy
Duty
Power
Equipment

Required
1.

tools to assemble

An adjustable

Additional
generator:

and Accessories

Universal

this generator:

required

to safely

operate

this

6500(EL),

Cover:

mon 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

1.
2,

Gas can.
Unleaded

SAE 10W30 motor oil (a little more than 1 quart for DEK
11hp and 13hp engines, a little less than 1 quart is required for DEK's smaller engines).
An oil fill funnel.

5.
6.

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

An adjustable

gasoline.

wrench

Generator

5650(EL),

Heavy duty nylon cover fits over
most models of 40O0W to 7500W
generators. A flexible handle bar
flap accommodates most com-

wrench or a wrench with an 8ram socket.

equipment

3850, 4000, 5000(EL),
180W(EL)

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 genorator.

or a 12mm socket for oil changes.

SAE 10W30

Motor Oil:

A premium high performance
formulation designed for high
RPM small gasoline engines
such as those used on generators. This all provides excellent protection against viscosity
and thermal breakdown that

Converts

often happens under the prolonged severe duty experienced by generator engines.
This eli is approved by the
engine manufacturer and

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 (7500 Watts).
Extension

Cords:

240V, 10/4, heavy duty
extension cords with L1430 connectors
at each
end. Lighted end shows
when power is on, Ideal
for use in combination
with the 240V to 120V

•

;<_;;
.

duces harmful voltage
drops experienced
when
using most 120V extension cords. Available in
25' lengths and can be
combined to reach the

Roy: 1/2006

Fuel Stabilizer:
Use of DEK's fuel stabilizer
keeps your gasoline fresh for
up to !2 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

adapter, eliminating up
to six 120V extension
cords.
This cord re-

desired

specifications
to remain in
meets all the requirements
and
compliance with the terms and
conditions of DEK's generator
warranty. Use of this el! formulation is highly encouraged
by
the manufacturer.
Frequent oil
changes with high quality motor oil will prolong the life of
your DEK generator.

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

length.

DEK® is exclusively

distributed
2 of 14

by GXi International,

LLC

_HeavyDuty

WARNINGS

Power Equipment

3850, 4000,
180W(EL)

5000(EL),

5650(EL),

6500(EL),

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

were in

GXi International,
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.

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

Fire and Burn Hazards
The exhaust

system gets hot enough to ignite some materials,

EMISSION CONTROL SYSTEM INFORMATION
The U.S. and California Clean Air Acts

•

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

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.

•

Do not enclose

the generator

•

Do not smoke

when refueling.

•

Keep flammable

•

The muffÊer 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

•

Refuel in a well ventilated

area with the engine

•

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.

SAFETY

LABEL

LOCATIONS

These labels warn you of potential hazards that can cause serious injury. Read them carefully. If a 1abet comes off or becomes
hard to read, contact your DEK generator dealer for a replacement.
SAFETY

materials

in any structure•

away from the generator.

indoors.
stopped.

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,

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.

and connections.
Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the
generator without parental supervision.

CARBON

MONOXIDEGAS

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.

Electric

Shock Hazards

•

Keep the generator

•

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

dry.

•

DO NOT use when

your hands

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 show the same ground circuit condition as for a home receptacle.
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.

are wet

NEVER START OR STOP THE ENGINE
NECTED TO THE GENERATOR.

Rev: 1/2006

rain or

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.
Consult the utility company
or a qualified electrician.

WITH

DEVICES

CON-

This generator does not meet US Coast Guard regulation
CFR-183 and should not be used on marine applications.

DEK® is exclusively distributed by GX{ International, LLC
3 of 14

_O(_

WARNINGS

Heavy Duty PowerEguipment

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 t_e rated load capacity of the generator has been exceeded.
3.

6500(EL),

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

Substantial
overloading
will open the circuit breaker. Exceeding the time limit for maximum power operation or
may not switch the
OFF, but will shorten

5650(EL),

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.

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 _eveis between rated and maximum may be used for no more than
30 minutes.

slightly overloading
the generator
circuit breaker or circuit protector
service life of the generator.

3850, 4000, 8000(EL),
180W(EL)

•

Carbon monoxide
poisoning
Be sure there is adequate
operate the engine.

•

Burns from hot parts.
Let the engine and exhaust
ing.

•

from engine exhaust.
ventilation whenever you

system cool before touch-

Injury from moving parts.
Do not run the engine unless instructed

to do so.

the
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

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

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.

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 generator, devices attached to the generator,
and may result in bodily injury, Do not adjust or
tamper with the engine speed setting.

Product Specifications
Models
Generator
Rated frequency
Rated voltage
Rated output power
AC output (Max)
DC output

3880_ 4000
60 Hz
120V / 240V / 12V

888018080EL
60 Hz
120V / 24gv / 12V

6500, 68gOEL
60 HZ

180W_ 10OWEL
60 Hz

120V ; 240V / 12V

120V / 24gV ! 12V

4 kW (Max.)

5.6 kW (Max)

6.5 kW (Max)

16A

235A

27.1A

16A

12V, 83A

36V, 2O0A welder and
12V, 83A output

12V. 8.3A

lgv, 8.3A

4.5 kW (Max.)

DJ270

DJ340

DJ390

Engine type

OHV 4-Stroke

O HV 4-Stroke

displacement

270 cc

390 cc

8.2:1

8.01

80:1

6 0:1

3600 RPM

13 Hp

Engine model

Compression ratio
Rated rotation speed
Rated power

8.8 Hp

1! Hp

Recoil

Recoil and optional
electric starter

Rotation direction

Counter clockwise

Fuel type

Unleaded gasoline

Unleaded gasotine

Unleaded gasoline

Yes

594 gallons

5.94 gallons

Optional

Yes

Starting system

Low oil alert
Max. fuel tank volume
integrated voltrnetar

Rev: 1/2006

DEK® is exclusively

distributed
4 of 14

Recoil and optional elec- Recoil and optional electric
tric starter
starter

by GXi International,

LLC

Power Equipment

_HeavyOuty

Fuel Tank

Component

Fuel Gauge

Choke Lever

Identification

3850, 4000, 5000(EL),
180W(EL)

Fuel C_

5650(EL),

6500(EL),

Generator models may
have different features and/
or options than shown in
these diagrams, DEK reserves the right to alter
product features and
specifications,

•

Air Filter

•

Fuel Valve

Battery (electric

Recoil Starter

start option only)

Oil Fill Cap and Dipstick
Oil Drain (on both sides)

Emissions lnformatior
Engine Serial Number

Data Tag

Start Switch (electric start option only)

L14-30 240V/120V Twist Lock Connector
/

ON/OFF Switch

Push Button Breakers

Digital Meter _

(for each outlet) I_--/

_' 120V AC Outlets/
12V DC terminals /

!
Ground Lug

Handle Bars

Choke Lever
(recessed)

Valve Cover

Alternator
Frame Ground Lug _--'--'_
Exhaust

Muffler Guard

Pipe

Rev: 1/2006

DEK® is exclusively distributed by GXi International, LLC
5 of 14

Heavy Duty Power Equipment

Wheel

Kit Assembly

3850, 4000, 5000(EL),
180W(EL)

5650(EL),

Pre-assembled
axle assembly.

(le and tighten
the bolt to secure in place
using an adjustable wrench
or 8 mm socket.

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

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

Commissioning
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.

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

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 OCCL_rring.
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 _ife.

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.

DEK® is exclusively

distributed
6 of 14

See supplemental instructions

the Battery

Rev; 1/2006

wheel f

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

6500(EL),

by GXi International,

LLC

Hoar/Duty

Power Equipment

Controls

3850, 4000, 5O00(EL),
1SOW(EL)

5650(EL),

6500(EL),

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
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 staffer.

Choke Rod
I_OK_

_IOD

The recoil starter is used to start the engine if the generator is
net 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 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.

Fuel Valve

Turn clockwise to turn
fuel valve on.

Lever
Oil Alert System

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

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 ) before troubleshooting
in other areas.

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

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.

Switch

To start and stop the engine.

Off
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,

Start

Engine

ON / OFF Switch

Rev: 1/2006

Electric Starter Switch
(optional feature)

DEK® is exclusively

distributed by GXi International,
7of14

LLC

Duty Power Equipment

Heavy

385O, 4OOO,5000(EL), 5650(EL), 6500(EL),
180W(EL)

Controls

DC Terminals
The DC terminals may ONLY be used for charging 12 volt automotive type batteries. The terminals are colored red to identify
the positive (+) terminal and black to identify the negative (-)
terminal. The battery must be connected to the generator DC
terminals with the proper polahty (battery positive to generator
red terminal and battery negative to the generator black terminal).
Note: Some generators are shipped with optional DC battery
charging cables, have a standard !2V DC receptacle, and have
a 12V cigarette lighter style outlet.

Connecting
the battery cables:
t.
Before connecting the battery charging
that is installed in a vehicle, disconnect
battery cable from the battery negative
2.
Connect the other end of the positive (
the generator positive ( + ) terminal.
3.
Connect the positive ( + ) battery cable
tive ( + ) terminal.
4.
Connect the negative ( - ) battery cable
tive ( - ) terminal
5.
6.

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

at the same

Other DC Outlet
Options,

Heavy Duty Power Equipment

•

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

•

Remove the oil filler cap and
wipe the dipstick clean.

•

Check the oil level by inserting
the dipstick into the filler neck
without screwing it in.

•

If the oil level is low, fill to the
Upper Level Mark with the recommended
proximately

If additional

posi-

to the battery

nega-

( - ) battery cable to

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,

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

3850, 4000, 5000(EL), 5650(EL), 6500(EL),
180W(EL)

30 engine oil is recommended
cations.

for most general

purpose appli-

Step 3.
Make sure there is fuel in the gasoline tank. Look at the fuel
level indicated by the fuel level gage and/or remove 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 tank capacity. 6.6 US gal t25 _l
_J_;LGAUGI_

oil. It w_ll take ap1,1 quart of oil.

oil is need, SAE 10W-

Rev: 1/2008

to the battery

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.

Operating the Generator

Step t.
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 using the dip
stick provided as part of the oil filler
cap.

Connect the other end of the negative
the generator negative ( - ) terminal.
Start the generator,

cables to a battery
the vehicle ground
( - ) terminal.
+ ) battery cable to

DEK® is exclusively distributed by GXi international, LLC
8 of 14

_Heavy

(3neratinn

Duty Power Equipment

the Generator

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.

Continuously
mum output

3850, 4000,

t80W(EL)

5000(EL),

5650(EL),

6500(EL),

loading this generator above 80% of its maxipower will shorten the life of the generator.

Balance the load evenly between
mize the output power.

the A and B outlets to maxi-

Appliances with electric motors require an additional 150%
Dower when they •re st•rtin£ up (indicated by an * and in bold
in the chart below).

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

•

Refuel

•

Wipe

and keep heat, sparks,

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.

and flame away.

only outdoors.
up spills

immediately.

Step 4.
Set the fuel valve lever to the ON position
wise.

2. Calculate the surge power by:
i) Adding up the running power of each appliance with an
* and in bold be_ow.

by rotating it clock-

ii) Multiplying

Step 5.
Pull the choke lever to the CLOSED position. See page 7 for a
diagram of the choke lever.

The surge power requirements
of your appliances
exceed the surge power rating of this generator.

Step 6.
Turn the generator ON/OFF switch to the "ON" position.

Typical

Step 7.
Start the engine
1.

If you have an electdc starter, turn the electdc star,or 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.
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 card.

Step 8.
Once the generator
OPEN position.

is running,

push the choke lever into the

Step 9.
Let the generator warm up for approximately
applying any electrical loads.

3 minutes

before

Step 10.
Apply leads to the generator one •t 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 smeller loads once the generator has stabilized with the
larger loads.

Connecting

a load larger than this
power rating may
the circuit breakers, alter-

hater and sensitive
Rev: !/2006

STOPPING

cannot

Loads
Running Power
75 Watts
1500 Watts
1500 Watts
700 Watts
750 Watts
250 Wails
800 Watts
1500 Watts
1000 Watts
750 Watts
5500 Wat_
1850 Wat_
5000 Wa_,s
5000 Wat_
1200 Watts
750 Watts
2400 Watts
2800 Watts
850 Watts
2000 Watts
1000 Watts
1000 Watts

THE GENERATOR

use:

1.
2,

Turn the AC circuit breaker to the OFF position
Disconnect all loads and extension cords.

3.
4.
5.
6.

Allow the engine to run with no load for 3 minutes.
Turn the engine switch to the OFF position.
Turn the fuel valve lever to the OFF position.
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.

appliances.

DEK® is exclusively

Residential

Appliance
Light bulbs (each)
Stove element (each)
Microwave
Coffee maker
Television
VCR
Computer & monitor
Space heater
Washing machine
NG clothes dryer
Electric clothes dryer
Dishwasher
water heater
Electric furnace
Toaster
BOX fan*
Window A/C - 8000 BTU*
Central A/C (per ton)*
Furnace blower"
2 hp well pump*
Refrigerator*
Freezer*

In normal
ALWAYS UNPLUG APPLIANCES
AND REMOVE ALL ELECTRICAL LOADS BEFORE REFUELING.
THEN FOLLOW
STEPS 2 - 10.

the total by 1.5.

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

distributed
9of14

by GXi International,

LLC

(if applicable).

Duty Power Equiprnent

Heavy

Maintenance

MAINTENANCE

3850, 4000,
180W(EL)

Engine Oil Change
Drain the oil while the engine
plete draining.

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

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

2.
3.

50 hrs or

each use

every 3
month

every 3
months

1OD hrs or
every 6
months

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

Unsnap the air cleaner cover clips, remove the air
cleaner cover, and remove the element.
Wash the air cleaner element in a solution of household

detergent and warm water, then rinse thoroughly, or
wash in nonflammable
or high fiashpoint solvent. Allow
the air cleaner element to dry thoroughly.
Soak the air cleaner element in clean engine oil and

300 hrs
or every
1 year

Engine oil (Check)

Engine Oil (Change)

squeeze out the excess oil. The engine will smoke during initial startup if too much oil is tefi in the air cleaner
element.

Air CJeaner (Check)
Air Cleaner Wash

Service

NOTICE:

20hrs or

is warm to assure rapid and com-

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cteaner regularly.
Service more frequently when operating the generator in extremely dusty areas.

Schedule
Before

6500(EL),

Remove the drain plug and sealing washer, remove the oil
filler cap, and drain the oil.
Reinstall the drain plug and sealing washer. Tighten the
plug securely.
Refill with the recommended oil (SAE 10W-30 ) and check
the oil level.

Air Cleaner

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.

Item

5650(EL),

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 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

5000(EL),

FueE fi_er Cup (Clean)

Reinstall the air cleaner

element

and the cover.

Spark Plug (Clean)

Fuel Filter Cleaning

Spark Plug (Change)
Optiona_ Spark Arrestor (C_ean)
Valve Clearance

(C_ean)

Fue_ Tank and Filter (Clean)
Fuel Tube (Check)
Combust_n

Every 2 yrs (_eplace if necessary)*

Cham_er (Clean)

* Should be performed

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 btow the
debris out of the filter with air pressure.
Spark Plug Service

After every 500 hrs*

by an authorized DEK dealer

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

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
hot, Be careful not to touch the muffler.
1.
2.
3.

Remove the spark plug cap.
Clean any dirt from around the spark plug base.
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 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.

Rev: 1/2006

DEK® is exclusively

distributed
10 of 14

will be very

by GXi International,

LLC

HeavyDuty

Maintenance

Power Equipment

3850, 4000,
180W(EL)

5000(EL),

5650(EL).

6500(EL),

TRANSPORTING
4.

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

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)

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.

Check that the spark plug washer is in good condition, and
thread the spark p)ug in by hand to prevent cross-threading.
After the spark plug is seated, tighten with a spark plug
wrench to compress the washer.

Contact with a hot engine
or exhaust system can
cause serious burns or

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.

fires• Let the engine cool
before transporting
or storing the generator.

NOTICE:

STORING

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,

Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive
2. Service according to the table below:
STORAGE

Optional Spark Arrestor Maintenance
If the generator has been running, the muffter 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
remove the spark arrester.
2.
Use a brush to remove carbon deposits from
rester screen, inspect the screen for breaks
replace it if necessary,
3.
Install the spark attester in the reverse order

TIME

Recom me'r,ded Service

humidity

and dust.

Procedure to prevent hard st_rdng:

1 to 2 months

Fill with fr_J_ g aso_ir_earid _dd gasolir_e _nciff_oner *

2 months Io 1 year

Fill with fresh gaso_ir_eand add gaSOline conditioner"
Drain the carburetor float bow1

Flit with h_h ga_olir_ and add gasoline _ nbitione_"
Drain the _rburetor _3oatbo'_

muffler and

1 year or I_ger

the spark ator tears and
of removal,

Remove the s_rk pl_g. Put a tablespoon of engine oil into the ¢ylinde_
Turn the engine slowly '_th t_e recoil starter to distribute the oil Reins_a_l
the spark plug.
Change the eng=ne oi_
A_I removal from stooge, d_i_ the stored ga_r_e into a s_itab_e con
tainer, and fill with fresh gasoline before $_rting

• Us_ gasol_e conditioners _hal ar_ fotr_ul_ed to extetld Storage life Contact your authorized
DEK g_ne_t_" def_er for conditioner recornmendation_

Storage Preparation
1.
Drain the carburetor by loosening
gasoline into a suitable container.
stabilizer in the fuel tank.
2,
3.

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.

the drain screw. Drain the
Place 4 ounces of fuel

Change the engine oil (page 10 ).
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.
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 wil! help to protect it from internal
corrosion.

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

Rev: 112006

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.

DEK® is exclusively

distributed
11 of 14

by GXi International,

LLC

D( Heavy

Duty Power

Equipment

Symptom:
Potential Causes
Fuel valve off/out of fuel

_1o spark, engine
Check / solution

Spark arrestor doqged
Choke is open
Vacuum check valve has failed
On/Off switch broken
Oi{ level too low
Olt switch

Remove

:il_ tan_Jturn

not

eatchlng_

engine

won_

start

I clean and rel_lace

31ose choke
Replace

by pulling

check

Jse fuel shut-off
The en,_ine

choke wire

out

Open

choke after staring

valve
as ON/OFF

shuts

down

switch

when

vrerify oil s_tch/sensor

unUI switch

If ratchets

oil level low

is tonctioning
Dis-connect

are broken

The

elf switch

Spark plug boot off/loose
Ignition coil failure
Spark plug fouted or failed
Carburetor clogged

_ress

Symptom:

Recoil is hard to pull or not retracting
Check / solution

will clog filter,

not alfavnng

boot

is too low,

¢o_ored

box about

lead out of finger
if engine

3 inches

cennect_Jn

still does

to the

firmly

not start, then

at the specified

Ctean
pressure

or replace

fuel fiIfar

and temperate

and b_o,cks filters

on spark plug

Call
Call
Call
Call

=_emove spark plug, clean or replace
Clean wdh fresh fuel

DEK
DEK
DEK
DEK

for
for
for
for

parts/service
parts/service
parts/service
pads/service

Recommendation

Spark arrestor
Remove, clean and replace
Recoil rubbing on dented housing
Alternator beadng failed
Alternator
beahng needs to be replaced
Camshaft detent has failed

Call DEK tor parts/service
Send

to service

Call DEK for Ports!service
Call DEK for parts/service
Call DEK for parts/service

Head valve timing is off
Symptom:
Potentfal Causes

._nglne starts, but then shuts off before 10 seconds
Check I solution

Remove/Clean spark arrestor
Oil level too low
Fuel valve off/out of fuel

Remove, clean and replace¸
The engine shuts down when the oil level is _ow Check the owners manual for oil capacity
:ill tankJturn fuel verve on

Spark plug fouled or failed
Vacuum check valve f/as failed

Remove spark plug_ clean or replace
RepIace cheek valve, call DEK for replacement procedure¸

Symptom:
Potentfal Causes

Choke Wire broke

Recommendation

Call DEK for parts/service
Call DEK for parts/service

Choke broke

Check I solution
Choke should be closed while starting PUll black cfioke counter clockwise and hold in place with wire.
Release after staffing

Symptom:
Potential Causes

._nglne runs: rough/vlbratlnglosetllattog
Check / sofutlon

Remove/Clean spark arrestor
The choke is not open
Over feuding generator
Air filter is dirty
Fuel filter is clogged
Fuel kscontaminated
Vacuum check valve has failed

Remove_ clean and replace
mush choke lever in.

Recommendation
Call DEK for parts/service

Recommendation

C,isconneet some appliances
Clean air fi_ter

Head valve timing {s 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
Send to service

Symptom:
Potential Causes

Engine runs r but boggs down under load
Check I solution

Remove/Clean spark arrestor
Choke is open
Over loading generater
Air filter is dirty
Fuel fitter is clogged

Remove clean and replace
gush choke lever in

Symptom:
Potential Causes

_'.nglne

Sad extension cord/pewer stnp
Push huron breaker topped
GFCl tdpped
GFCl failed

Fry different

Rev: 1/2006

Call DEK for parls/service

If the

Call DEK for pads/service

fuel to get to engine

in fuel wlt_ not allow combusfion
plug

oil level

brass

black

they will not spin the engine.

3ontaminates

spark

ls the gold,

oil switch by disccnnecgng

Fuel filter is dirty
Fuel is contaminated

Contaminates

Call DEK for paris/service
Call DEK for parts/service

is replaced¸

.=ngine starts, then switch/sensor
is faulty or the
_witch/sensor
is probabty
ok to reassemble

Potential Causes

180W(EL)

Recommendation

fuel valve

eft of the oil fill cap

Recolt is broken

3850, 4000, 5000(EL), 5850(EL), 6500(EL),

Troubleshooting

Call DEK for pads/service
Call DEK for parts/service

Recommendation

Disconnect some appliances / devices
3teen air filter
Contaminates wilt clog filter_ not altowing fuel to get to engine

Check

runsp Volt meter

shows

to outlets
RecommendaSon

/ shorter

extension

Sisconnect

all loads and push

_isconnect

all toads

Replace

120 VAC_ but no power

/ solution

GFC_ with

cord or a d_erent
reset

stnp

button.

Push the red reset fiu_ton
any GFCI

powe_

or fio_sehoifi

DEK® is exclusively

ver_ deep_rmly

outlet

distributed
12 of 14

Call DEK for panstservice

by GXi International,

LLC

Duty Power

Heavy

Equipment

3850,

4000, 5000(EL),
180W(EL)

Troubleshooting

Symptom:
_otential Causes

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

3ad extension cord/power strip
gevice taited

Try different / shorter extension cord or a different power strip
Tr_ a different light bulb or device
Push button breaker tripped
Push the red reset burton very deep/firmly
Replace GFCI with any GFCI or household out{et

_ush burton breaker tripped
3FCL tripped
3FCI failed
3roken yvire

Engine
Check

runs_ volt
/ solution

meter

shows

120VAC

in "f20V mode_

but

Call DEK for parts/service
Call DEK for partsJservice
Call DEK for paff_Jservice

t20VAC

or 0VAC

in 240V

mode

Recommendation
Call DEK for paffstservice
Call DEK tor paffs/service
Call DEK for paffstservice
Call DEK for paffs/service

T'oggleswrtch failed
_,ltemstor phase has failed
_roken wire

Symptom:
Potential Causes

Vottage too high/low
Check I solution

Spark arrestor

Remove, clean and replace

Voltagespeed
screwn°t
measuredbent
correctly

VO age mus be measured between hot and neural,

Symptom:

Voltage is 120 VAC on 1 phase but too hlghllow on other phase

Recommendation

no ho and ground he _round s so a ed

I:,t°to:n°:'t;',
,o,,od
Potential
Oil leaking
ket
Oil leaking

Engine
Causes

Check

from

crankcase

from

shaft

gas

crankcase

Oil seals

Recommendation
bolts

failed

Call DEK for paffs/service

Symptom:

Otl leaking from Valve head cover

IP°tttennot:tlg
Causes

ITC
_htCekn/bSo/Is
uti°n

leak

at tank

[

Symptom:
Potential Causes

Fuel leaking out of carburator
Check / solution

Fuel
drain screw
loosenot seating
Carburstor
float seat

Tighten
fuelclean
drainfuel
screw
Flush with

_ymptom:
=otentlal Causes

Cannot turn end{he with recoil
Check ! solution

shut

off vatve

Recommendation

_ecoil ratchets have broken
Recoil is crushed fn
_,lternstor bearing has fai_ed
_ead valve timing is off

Symptom:

Call
Call
Call
Call

Fuel
e: e _aske,

Rev: 1/2006

Rec°mmendatl°n

shut*off

I;,';_t_n'nu_'_':;_st-o.
valve/replace

IP: ;:an:rest, uC:;:

oll leaking
/ solution

Tighten

Fuel

Call DEK for parts/service

Check t solution

Symptom:

1Check

6500(EL),

Recommendatton

[oggle switch failed

Symptom:
=otentlal Causes
_ ffcuti breaker failed

5650(EL),

gauge

leaks

' s°luti°n

DEK® is exclusively

distributed
13 of 14

by GXi International,

LLC

DEK
DEK
DEK
DEK

for
for
for
for

parts/service
parts/service
paffs/service
parfa/service

Heavy
Duty
F'ower
Equipment
PRODUCTS

Limited Warranty & Service

COVERED BY THIS WARRANTY:

LENGTH OF WARRANTY:*
IFROM THE DATE OF ORIGINAL RETAIL PURCHASE)
NONCOMMERCIAL/NONCOMMERCIAL
RENTAL
RENTAL

Engine

36 months / 300 hours

Centrifugal Pump and Frame Components

24 months

3 months

Diaphram Pump and Frame Components
Generator Engine and Affernator

12 months
36 months / 300 hours

12 months
36 months I 300 hours

12 months
36 months / 300 hours

Generator Electrical and Frame Components

24 months

12 months

"LENGTH

WARRANTY:

(noncommercial
use)
ered by this warranty

Batteries

or 3 months

supplied

with

applicable

(oommer¢ial/renta_

use)

from

products
the date

standard,

of origina4

original

retail

product

equipment
purChase¸

are

covered

Consumable

by this
parts

warranty

for

such as oil, _park

pehod

plL_gs, f]_ers

months

are not cov-

TO QUALIFY FOR THIS WARRANTY:
The product must be purchased in the United States from a dealer authorized by GXi international, LLC to sell those products. This warranty applies to first retail pur=
chaser / owner during the applicable warranty time period.
WHAT DE){ POWER EQUIPMENT WILL REPAIR OR REPLACE UNDER WARRANTY:
DEK will repair or replace, at its option, any pad that is proven to be defective In rnatert al or workmanship ur_der normal use dunng the applicabte warranty time period
sub}ect to the exclusions stated herein This warranty is void ifthe owner fails to fullow the prescribed maintenance and operating p_Oceduresdescribed in this manual
This specificalty refers to er_suringroutine oil changes are made, that fael stabilizer is used when the generator is stored, that the generator is nut overloaded, and that
the generator loads are distributed eventy between the A and B outtsts
DEK has the right

to recover

ship
In particular,
this
to follow proper storage

warranty

administration

costs

from

the owner

if the root cause

of the

malfunction

was

warranty
does t_ct cover: contaminants
in the fuel or dill damage
cauSed by net fullowing
proceduresi
and physical
damage
due to shipping
or handling
or storage¸

found

the

to be other

prescribed

than

warnings

defective

mater_ai

and operating

or workman-

practices;

failure

Damage to the generator that occurs as a resutt 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 a_d grounded as per applicable focal elect rica{ codes, is not covered by this warranty
Warranty repairs will be made without charge for parts and labor for the f_rst year

After the first year, this limited warranty covers the costs of replacement parts oniy.

Anything replaced under warrant_ becomes the property of DEK Pads replaced under warranty will be considered as part of the original produ_ and any warranty on
those parts will expire coincident with the original product warranty¸
TO OBTAIN

WARRANTY

You must

take the

and proof

of purchase,

SERVICE:

DEK

Power Equipment
at your

expense,

location's
normal business
hours¸
contact tee manager
of the se_ice
tomer Sef_dce

product,

accessory

to any DER

Power

If you are unable
center involved_

to obtain
normally

reptscement
Equipment

part, apparel

se_dce

location

or the power
in the

United

equipment
States,

on which

the

who is authorized

accessory
to service

or replacement
that product_

part is installed=
during

the Service

warranty
service, or are dissatisfied
with the warranty
service you receive, take the followfrtg steps¸ First,
this wdl resolve the problem
However,
if you should require further assistance,
write or call the DER Cus-

EXCLUSIONS:
THIS

WARRANTY

DOES

NOT

EXTEND

TO PARTS

AFFECTED

OR DAMAGED

BY ACCIDENT

AND/OR

COLLISION,

NORMAL

WEAR,

FUEL

CONTAMINATION,

IN AN APPLICATION
FOR WHICH
THE PRODUCT
WAS NOT DESIGNED
OR ANY OTHER
MISUSE,
NEGLECT,
INCORPORATtON
OR USE OF UNSUITABLE
TACHMENTS
OR PARTS= UNAUTHORIZED
ALTERATION,
OR ANY CAUSES
OTHER
THAN DEFECTS
IN MATERIAL
OR WORKMANSHIP
OF THE PRODUCT

DISCLAIMER OF CONSEQUENTIAL DAMAGE AND
DEK DISCLAIMS ANY RESPONSIBILITY FOR LOSS
TAL OR CONSEQUENTIAL DAMAGE ANY IMPLIED
This warranty is void if the manufactudng date and the

LIMITATION OF IMPLIED WARRANTIES:
OF TIME OR USE OF THE PRODUCT, TRANSPORTATION, COMMERCIAL LOSS, OR ANY OTHER INCIDENWARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY
serial number on the equipment has been removed or the equipment has been modified,

O,.er,,°e
.ro.uct.
o.ere.

Commercial

Rev: 1/2006

Lawn Mowers

USE
AT-

Heavy

Duty Pressure

DEK® is exclusively

Washers

distributed
14 of 14

Heavy Duty Power Equipment

Rental

Grade Chipper

Shredders

by GXi International,

LLC

Generator Accessories

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File Type Extension             : pdf
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PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 14
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Wed Aug 15 05:33:25 2007
Author                          : 
Title                           : 
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DEK 5000 User Manual GENERATOR Manuals And Guides L0606321

DEK Generator Manual L0606321 DEK Generator Owner's Manual, DEK Generator installation guides

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