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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®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. Tools and Accessories
2. Warnings & Specifications
3. Component identification
4. Wheel Kit Assembly
5. Controls
6. Operating the Generator
7. Maintenance
8. Transporting and Storage
9. Troubleshooting
10. Warranty and Service
DO NOT RETURN THIS GENERATOR
TO THE STORE!
HAVE QUESTIONS OR NEED HELP?
call 24 hrs /7-days a week help-line: [1] 800-393-0668
or go to www,DEKPowerUSA.com
Have the following information ready when you call us:
Date of Purchase:
Location of Purchase:
Serial #:
DEK® is registered trademark of GXi 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
.. 1of 14
HeavyDutyPowerEquipment Accessories 3850, 4000, 5000(EL), 5650(EL), 6500(EL),
Tools and 180W(EL)
Required tools to assemble this generator:
1. An adjustable wrench or a wrench with an 8ram socket.
Additional equipment required to safely operate this
generator:
1. Gas can.
2, Unleaded gasoline.
3, SAE 10W30 motor oil (a little more than 1quart for DEK
11hp and 13hp engines, alittle less than 1 quart is re-
quired for DEK's smaller engines).
4. An oil fill funnel.
5. Gasoline fuel stabilizer (for storing your generator),
6. 120V and/or 240V extension cords.
7. An adjustable wrench or a12mm socket for oil changes.
Universal Generator Cover:
Heavy duty nylon cover fits over
most models of 40O0W to 7500W
generators. A flexible handle bar
flap accommodates most com-
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
to protect the generator when
stored outdoors. The cover can-
not 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 gen-
orator.
SAE 10W30 Motor Oil:
A premium high performance
formulation designed for high
RPM small gasoline engines
such as those used on genera-
tors. This all provides excel-
lent protection against viscosity
and thermal breakdown that
often happens under the pro-
longed severe duty experi-
enced by generator engines.
This eli is approved by the
engine manufacturer and
t_ meets all the requirements and
specifications to remain in
compliance with the terms and
conditions of DEK's generator
warranty. Use of this el! formu-
lation is highly encouraged by
the manufacturer. Frequent oil
changes with high quality mo-
tor oil will prolong the life of
your DEK generator.
Converts 240V twist lock
(L14-30) to six (6) 120V
outlets. Lighted ends
show when power is on,
ideal for use in combina-
tion with a 240V extension
cord. Can handle up to 30
Amps (7500 Watts).
Extension Cords:
240V, 10/4, heavy duty
extension cords with L14- • ;<_;;
30 connectors at each .
end. Lighted end shows
when power is on, Ideal
for use in combination
with the 240V to 120V
adapter, eliminating up
to six 120V extension
cords. This cord re-
duces harmful voltage
drops experienced when
using most 120V exten-
sion cords. Available in
25' lengths and can be
combined to reach the
desired length.
Fuel Stabilizer:
Use of DEK's fuel stabilizer
keeps your gasoline fresh for
up to !2 months. Gasoline
breaks down in 60 days_ po-
tentially causing damage to
your engine. DEK recom-
mends storing your generator
with the fuel tank full and with
fuel stabilizer added. This
protects the engine and fuel
system from the effects of hu-
midity and ensures your gen-
erator is ready for use at all
times.
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2 of 14
_HeavyDuty Power Equipment 3850, 4000, 5000(EL), 5650(EL),
WARNINGS 6500(EL),
180W(EL)
This owner's manual is considered a permanent part of the gen-
erator and should remain with the generator if resold. The infor-
mation and specifications inciuded in this publication were in
effect at the time of approval for printing.
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.
EMISSION CONTROL SYSTEM INFORMATION
The U.S. and California Clean Air Acts
EPA and California regulations require all manufacturers to fur-
nish written instructions describing the operation and mainte-
nance 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.
SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause seri-
ous injury. Read them carefully. If a 1abet comes off or becomes
hard to read, contact your DEK generator dealer for a replace-
ment.
SAFETY INFORMATION
DEK generators are designed to give safe and dependable ser-
vice if operated according to instructions. Read and understand
this owner's manual before operating your generator.
OPERATOR RESPONSIBILITY
Know how to stop the generator quickly in case of emergency.
Understand the use of all generator controls, output receptacles,
and connections. Be sure that anyone who operates the genera-
tor 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 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.
Electric Shock Hazards
• Keep the generator dry.
•DO NOT use the generator in wet conditions, rain or
snow, or near a pool or sprinkler system
•DO NOT use when your hands are wet
NEVER START OR STOP THE ENGINE WITH DEVICES CON-
NECTED TO THE GENERATOR.
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,
• 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 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 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 aBuilding 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. Atransfer switch,
which isolates generator power from utility power, is available
through any of GXi's authorized dealers of DEK generators.
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. Consult the utility company
or a qualified electrician.
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 areceptacle tester, it
will show the same ground circuit condition as for ahome recep-
tacle.
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 hav-
ing jurisdiction.
This generator does not meet US Coast Guard regulation 33
CFR-183 and should not be used on marine applications.
Rev: 1/2006 DEK® is exclusively distributed by GX{ International, LLC
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_O(_ Heavy Duty PowerEguipment 3850, 4000, 8000(EL), 5650(EL), 6500(EL),
WARNINGS 180W(EL)
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 apotential for
electrical shock. If an appliance begins to operate abnor-
mally, becomes sluggish or stops suddenly, turn it off imme-
diately.
2. Disconnect the appliance, and determine whether the prob-
lem is the appliance, or if t_e 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 _eveis be-
tween rated and maximum may be used for no more than
30 minutes.
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.
Limit operation requiring maximum power to 30 minutes. For
continuous operation (longer than 30 minutes), do not exceed
the rated power.
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.
Failure to properly follow main-
tenance instructions and precautions can cause serious
injuries or death. Always follow the inspection and mainte-
nance recommendations and schedules in this owner's
manual.
Safety Precautions:
Make sure the engine is off before you begin any maintenance
or repairs. This will eliminate several potential hazards:
•Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you
operate the engine.
•Burns from hot parts.
Let the engine and exhaust system cool before touch-
ing.
•Injury from moving parts.
Do not run the engine unless instructed to do so.
In the State of California a spark arrestor is required by law.
Other states may have similar laws. Federal laws apply on all
federal lands. If you equip the muffler with a spark arrestor, it
must be maintained in effective working order. See page 11.
Rapid retraction of the recoil starter cord can pull the
starter cord back faster than you can let go. When starting
the engine, pull the cord slowly until resistance is felt then
pull rapidly to avoid kickback.
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.
Generator
Rated frequency
Rated voltage
Rated output power
AC output (Max)
Product Specifications
3880_ 4000
60 Hz
120V /240V /12V
4 kW (Max.)
16A
DC output lgv, 8.3A
Engine model DJ270
Engine type OHV 4-Stroke
displacement 270 cc
Compression ratio 8.2:1
Rated rotation speed 3600 RPM
Rated power 8.8 Hp
Starting system Recoil
Rotation direction Counter clockwise
Fuel type Unleaded gasoline
Low oil alert Yes
Max. fuel tank volume 594 gallons
integrated voltrnetar Optional
888018080EL
60 Hz
120V /24gv /12V
5.6 kW (Max)
235A
12V. 8.3A
DJ340
OHV 4-Stroke
390 cc
8.01
3600 RPM
1! Hp
Recoil and optional
electric starter
Counter clockwise
Unleaded gasotine
Yes
5.94 gallons
Yes
Models
6500, 68gOEL
60 HZ
120V ; 240V /12V
6.5 kW (Max)
27.1A
12V, 83A
DJ390
OHV 4-Stroke
390 cc
80:1
3600 RPM
13 Hp
Recoil and optional elec-
tric starter
Counter clockwise
Unleaded gasoline
Yes
5.94 gallons
Yes
180W_ 10OWEL
60 Hz
120V /24gV !12V
4.5 kW (Max.)
16A
36V, 2O0A welder and
12V, 83A output
DJ390
O HV 4-Stroke
390 cc
6 0:1
3600 RPM
13 Hp
Recoil and optional electric
starter
Counter clockwise
Unleaded gasoline
Yes
5.94 gallons
Yes
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
4of 14
_HeavyOuty Component Identification 3850, 4000, 5000(EL), 5650(EL), 6500(EL),
Power Equipment
180W(EL)
Fuel Tank Fuel Gauge Fuel C_ Generator models may
have different features and/
or options than shown in
these diagrams, DEK re-
serves the right to alter
product features and
specifications,
Choke Lever •
Air Filter •
Fuel Valve Battery (electric start option only)
Recoil Starter
Emissions lnformatior
Engine Serial Number
Oil Fill Cap and Dipstick
Oil Drain (on both sides)
Data Tag
L14-30 240V/120V Twist Lock Connector
/ON/OFF Switch X
Start Switch (electric start option only)
Digital Meter _
Push Button Breakers (for each outlet) I_--/
Handle Bars
(recessed)
_' 120V AC Outlets/ !
12V DC terminals /Ground Lug
Choke Lever
S Valve Cover
Alternator
Frame Ground Lug _--'--'_ Muffler Guard
Exhaust 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), 5650(EL), 6500(EL),
180W(EL)
Pre-assembled wheel f
axle assembly.
Two pro-assembled, retractable, handle bars,
one on each side of the generator frame.
Twist to lock /unlock. Pull or push to ex-
tend /retract.
GInsert each foot assembly
through holes in the frame.
Tighten nut with adjustable
wrench or 8 mm socket.
i
(le and tighten
the bolt to secure in place
using an 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. 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 ver-
ify with your retailer if you believe the battery is miss-
ing.
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.
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 _ife.
Use gloves and safety glasses when handling and in-
stalling 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.
Rev; 1/2006 DEK® is exclusively distributed by GXi International, LLC
6 of 14
Hoar/ Controls 3850, 4000, 5O00(EL), 5650(EL), 6500(EL),
Duty Power Equipment
1SOW(EL)
The engine was shipped without engine oil, DO NOT START
THE ENGINE WITHOUT FILLING THE ENGINE WITH OIL.
Use SAE 10W-30 for normal conditions and SAE 5W-30
when the ambient temperature is below 32 °F.
Choke Rod
The choke is used to
provide an enriched
fuel mixture when
starting a cold 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.
Fuel Valve Lever
The fuel valve is
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.
I_OK_ _IOD
Turn clock-
wise to turn
fuel valve on.
Engine Switch
To start and stop the engine.
Recoil Starter
To start the engine, pull the starter grip lightly until resistance is
felt, then pull briskly.
NOTICE:
Do not allow the starter grip to snap back against the engine.
Return it gently to prevent damage to the staffer.
The recoil starter is used to start the engine if the generator is
net equipped with a12 volt battery to operate the starter motor,
or if the battery does not contain adequate charge to operate the
starter motor.
Oil Alert System
The Oil Alert system is designed to prevent engine damage
caused by an insufficient amount of oil in the crankcase. Before
the oil level in the crankcase can fall below a safe limit, the Oil
Alert system will automatically stop the engine (the engine
switch will remain in the ON position). The Oil Alert system
should not take the place of checking the oil level before each
use. If the engine stops and will not restart, check the engine oil
level (see page ) before troubleshooting in other areas.
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.
Off
On
Start
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,
Engine ON /OFF Switch Electric Starter Switch
(optional feature)
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
7of14
Heavy Controls 5000(EL), 5650(EL), 6500(EL),
Duty Power Equipment 385O, 4OOO,
180W(EL)
DC Terminals
The DC terminals may ONLY be used for charging 12 volt auto-
motive 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 termi-
nal).
Note: Some generators are shipped with optional DC battery
charging cables, have astandard !2V DC receptacle, and have
a12V cigarette lighter style outlet.
Do not use the 12V DC and the AC receptacles at the same
time.
Connecting the battery cables:
t. Before connecting the battery charging cables to abattery
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.
Other DC Outlet
Options,
Disconnecting the battery cables:
1. Stop the engine,
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,
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.
_Heavy Duty Power Equipment Operating the Generator 3850, 4000, 5000(EL), 5650(EL), 6500(EL),
180W(EL)
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.
• Put the generator on alevel
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 rec-
ommended oil. It w_ll take ap-
proximately 1,1 quart of oil.
If additional oil is need, SAE 10W-
30 engine oil is recommended for most general purpose appli-
cations.
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_
Rev: 1/2008 DEK® is exclusively distributed by GXi international, LLC
8 of 14
_Heavy Duty Power Equipment (3neratinn 3850, 4000, 5000(EL), 5650(EL),
the Generator 6500(EL),
t80W(EL)
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 apump
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 extends exhaust system life.
Never use stale or contaminated gasoline or an oil/gasoline mix-
ture. Avoid getting dirt or water in the fuel tank.
Continuously loading this generator above 80% of its maxi-
mum output power will shorten the life of the generator.
Balance the load evenly between the A and Boutlets to maxi-
mize the output power.
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).
DO NOT overfill the tank. Leave a 1 inch air gap in the tank.
Gasoline is highly flammable and explosive. You can be
burned or seriously injured when refueling.
•Stop engine and keep heat, sparks, and flame away.
•Refuel only outdoors.
•Wipe up spills immediately.
Step 4.
Set the fuel valve lever to the ON position by rotating it clock-
wise.
Step 5.
Pull the choke lever to the CLOSED position. See page 7 for a
diagram of the choke lever.
Step 6.
Turn the generator ON/OFF switchto the "ON" position.
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.
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 card.
Step 8.
Once the generator is running, push the choke lever into the
OPEN position.
Step 9.
Let the generator warm up for approximately 3 minutes before
applying any electrical loads.
Step 10.
Apply leads to the generator one •t 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 smeller loads once the generator has stabilized with the
larger loads.
ALWAYS UNPLUG APPLIANCES AND REMOVE ALL ELEC-
TRICAL LOADS BEFORE REFUELING. THEN FOLLOW
STEPS 2 -10.
Connecting aload larger than this
power rating may
the circuit breakers, alter-
hater and sensitive appliances.
To determine maximum load that you may safely connect
to this generator:
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.
2. Calculate the surge power by:
i) Adding up the running power of each appliance with an
* and in bold be_ow.
ii) Multiplying the total by 1.5.
iii) Adding this to the total running power calculated in
step 1 above,
The surge power requirements of your appliances cannot
exceed the surge power rating of this generator.
Typical Residential Loads
Appliance Running Power
Light bulbs (each) 75 Watts
Stove element (each) 1500 Watts
Microwave 1500 Watts
Coffee maker 700 Watts
Television 750 Watts
VCR 250 Wails
Computer & monitor 800 Watts
Space heater 1500 Watts
Washing machine 1000 Watts
NG clothes dryer 750 Watts
Electric clothes dryer 5500 Wat_
Dishwasher 1850 Wat_
water heater 5000 Wa_,s
Electric furnace 5000 Wat_
Toaster 1200 Watts
BOX fan* 750 Watts
Window A/C - 8000 BTU* 2400 Watts
Central A/C (per ton)* 2800 Watts
Furnace blower" 850 Watts
2 hp well pump* 2000 Watts
Refrigerator* 1000 Watts
Freezer* 1000 Watts
STOPPING THE GENERATOR
In 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 3minutes.
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: !/2006 DEK® is exclusively distributed by GXi International, LLC
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Heavy Maintenance 3850, 4000, 5000(EL), 5650(EL), 6500(EL),
Duty Power Equiprnent
180W(EL)
MAINTENANCE
The Importance of Maintenance
Good maintenance is essential for safe, economical, and trou-
ble-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 re-
quire special tools, are best handled by professionals and are
normally performed by a DEK technician or other qualified
mechanic.
The maintenance schedule applies to normal operating 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.
Engine Oil Change
Drain the oil while the engine is warm to assure rapid and com-
plete draining.
1. Remove the drain plug and sealing washer, remove the oil
filler cap, and drain the oil.
2. Reinstall the drain plug and sealing washer. Tighten the
plug securely.
3. Refill with the recommended oil (SAE 10W-30 )and check
the oil level.
Dispose of used motor oil in a manner that is compatible with
the environment. Do not throw it in the trash, pour it on the
ground, or down a drain.
Air Cleaner Service
A dirty air cleaner will restrict air flow to the carburetor. To pre-
vent carburetor malfunction, service the air cteaner 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.
Maintenance Schedule
Item Before 20hrs or 50 hrs or
each use every 3 every 3
month months
X
X
X
X
Engine oil (Check)
Engine Oil (Change)
Air CJeaner (Check)
Air Cleaner Wash
FueEfi_er Cup (Clean)
Spark Plug (Clean)
Spark Plug (Change)
Optiona_ Spark Arrestor (C_ean) X
Valve Clearance (C_ean)
Fue_ Tank and Filter (Clean)
Fuel Tube (Check) Every 2 yrs (_eplace if necessary)*
Combust_n Cham_er (Clean) After every 500 hrs*
*Should be performed by an authorized DEK dealer
1ODhrs or 300 hrs
every 6 or every
months 1 year
X*
X,
Replacement Parts
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.
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.
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 fiashpoint solvent. Allow
the air cleaner element to dry thoroughly.
3. Soak the air cleaner element in clean engine oil and
squeeze out the excess oil. The engine will smoke dur-
ing initial startup if too much oil is tefi in the air cleaner
element.
4. Reinstall the air cleaner element and the cover.
Fuel Filter Cleaning
The fuel filter cup /screen prevents dirt which may be in the
fuel from entering the carburetor. The fuel filter should be
inspected and cleaned on a regular basis. For best results,
clean the filter with gasoline and a toothbrush or btow the
debris out of the filter with air pressure.
Spark Plug Service
In order to service the spark plug, you will need a spark plug
wrench. Recommended spark plugs: BPR5ES (NGK) and
W16EPR-U (DENSO). To ensure proper engine operation,
the spark plug must be properly gapped and free of deposits.
If the engine has been running, the muffler will be very
hot, Be careful not to touch the muffler.
1. Remove the spark plug cap.
2. Clean any dirt from around the spark plug base.
3. Use a spark plug wrench to remove the spark plug.
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
10 of 14
HeavyDuty Power Equipment Maintenance 3850, 4000, 5000(EL), 5650(EL). 6500(EL),
180W(EL)
4.
5.
6.
7.
Visually inspect the spark plug. Dis-
card 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)
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.
If installing anew spark plug, tighten 1/2 turn after the spark
plug seats to compress the washer. If reinstalling a used spark
plug, tighten 1/8 1/4 turn after the spark plug seats to compress
the washer.
NOTICE:
The spark plug must be securely tightened. An improperly 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
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 muffler and
remove the spark arrester.
2. Use a brush to remove carbon deposits from the spark at-
rester screen, inspect the screen for breaks or tears and
replace it if necessary,
3. Install the spark attester in the reverse order of removal,
W
Optional Starter Motor Fuse Replacement
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.
NOTICE:
Never use a fuse with a
different rating from that
specified. Serious dam-
age to the electrical
system or fire may re-
sult.
TRANSPORTING
When transporting the generator, turn the engine switch and the
fuel valve OFF. Keep the generator level to prevent fuel spillage.
Fuel vapor or spilled fuel may ignite.
Take care not to drop or strike the generator when transporting.
Do not place heavy objects on the generator. When transporting
the generator by loading it on to avehicle, secure to the genera-
tor frame as shown.
Contact with a hot engine
or exhaust system can
cause serious burns or
fires• Let the engine cool
before transporting or stor-
ing the generator.
STORING
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Service according to the table below:
STORAGE TIME Recom me'r,ded Service 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'_
1 year or I_ger Remove the s_rk pl_g. Put atablespoon 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 the drain screw. Drain the
gasoline into asuitable container. Place 4 ounces of fuel
stabilizer in the fuel tank.
2, Change the engine oil (page 10 ).
3. Remove the spark plug, and pour about atablespoon of
clean engine oil into the cylinder. Turn the engine several
revolutions slowly with the recoil starter to distribute the oil,
then reinstall the spark plug.
4, Slowly pull the starter grip until resistance is felt. At this
point, the piston is coming up on its compression stroke and
both the intake and exhaust valves are closed, Storing the
engine in this position wil! help to protect it from internal
corrosion.
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: 112006 DEK® is exclusively distributed by GXi International, LLC
11 of 14
Duty Power Equipment 3850, 4000, 5000(EL), 5850(EL), 6500(EL),
D( Heavy Troubleshooting 180W(EL)
Symptom:
Potential Causes
Fuel valve off/out of fuel
Spark arrestor doqged
Choke is open
Vacuum check valve has failed
On/Off switch broken
Oi{ level too low
Olt switch
Recolt is broken
Fuel filter is dirty
Fuel is contaminated
Spark plug boot off/loose
Ignition coil failure
Spark plug fouted or failed
Carburetor clogged
Symptom:
Potential Causes
Spark arrestor
Recoil rubbing on dented housing
Alternator beadng failed
Camshaft detent has failed
Head valve timing is off
Symptom:
Potentfal Causes
Remove/Clean spark arrestor
Oil level too low
Fuel valve off/out of fuel
Spark plug fouled or failed
Vacuum check valve f/as failed
Symptom:
Potentfal Causes
Choke broke
Symptom:
Potential Causes
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
Head valve timing {s off
Symptom:
Potential Causes
Remove/Clean spark arrestor
Choke is open
Over loading generater
Air filter is dirty
Fuel fitter is clogged
Symptom:
Potential Causes
Sad extension cord/pewer stnp
Push huron breaker topped
GFCl tdpped
GFCl failed
_1ospark, engine not eatchlng_ engine won_ start
Check /solution
:il_ tan_Jturn fuel valve on
Remove I clean and rel_lace
31ose choke by pulling choke wire out Open choke after staring
Replace check valve
Jse fuel shut-off as ON/OFF switch unUI switch is replaced¸
The en,_ine shuts down when oil level low
vrerify oil s_tch/sensor is tonctioning The elf switch ls the gold, brass ¢o_ored box about 3 inches to the
eft of the oil fill cap Dis-connect oil switch by disccnnecgng black lead out of finger cennect_Jn If the
.=ngine starts, then switch/sensor is faulty or the oil level is too low, if engine still does not start, then
_witch/sensor is probabty ok to reassemble
If ratchets are broken they will not spin the engine.
3ontaminates will clog filter, not alfavnng fuel to get to engine Ctean or replace fuel fiIfar
Contaminates in fuel wlt_ not allow combusfion at the specified pressure and temperate and b_o,cks filters
_ress spark plug boot firmly on spark plug
=_emove spark plug, clean or replace
Clean wdh fresh fuel
Recommendation
Call DEK for paris/service
Call DEK for parts/service
Call DEK for parls/service
Call DEK for pads/service
Call DEK for parts/service
Call DEK for parts/service
Call DEK for parts/service
Call DEK for pads/service
Recoil is hard to pull or not retracting
Check /solution
Remove, clean and replace
Alternator beahng needs to be replaced Send to service
Recommendation
Call DEK tor parts/service
Call DEK for Ports!service
Call DEK for parts/service
Call DEK for parts/service
._nglne starts, but then shuts off before 10 seconds
Check Isolution
Remove, clean and replace¸
The engine shuts down when the oil level is _ow Check the owners manual for oil capacity
:ill tankJturnfuel verve on
Remove spark plug_ clean or replace
RepIace cheek valve, call DEK for replacement procedure¸
Recommendation
Call DEK for parts/service
Call DEK for parts/service
Choke Wire broke
Check Isolution Recommendation
Release after staffing Call DEK for parts/service
Choke should be closed while starting PUll black cfioke counter clockwise and hold in place with wire.
._nglne runs: rough/vlbratlnglosetllattog
Check /sofutlon
Remove_ clean and replace
mush choke lever in.
C,isconneet some appliances
Clean air fi_ter
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
Recommendation
Call DEK for pads/service
Call DEK for parts/service
Engine runs r but boggs down under load
Check Isolution
Remove clean and replace
gush choke lever in
Disconnect some appliances /devices
3teen air filter
Contaminates wilt clog filter_ not altowing fuel to get to engine
Recommendation
_'.nglne runsp Volt meter shows 120 VAC_ but no power to outlets
Check /solution
Fry different /shorter extension cord or a d_erent powe_ stnp
Sisconnect all loads and push reset button.
_isconnect all toads Push the red reset fiu_ton ver_ deep_rmly
Replace GFC_ with any GFCI or fio_sehoifi outlet
RecommendaSon
Call DEK for panstservice
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
12 of 14
Duty Power Equipment 3850, 4000, 5000(EL), 5650(EL), 6500(EL),
Heavy Troubleshooting 180W(EL)
Symptom:
_otential Causes
3ad extension cord/power strip
gevice taited
_ush burton breaker tripped
3FCL tripped
3FCI failed
3roken yvire
[oggle switch failed
Engine runs and volt meter shows 240VAC and 120VAC, but no power goes to connected devices
Check /solution
Try different /shorter extension cord or adifferent power strip
Tr_ adifferent 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
Recommendatton
Call DEK for parts/service
Call DEK for partsJservice
Call DEK for paff_Jservice
Symptom:
=otentlal Causes
_ffcuti breaker failed
T'oggleswrtch failed
_,ltemstor phase has failed
_roken wire
Engine runs_ volt meter shows 120VAC in "f20V mode_ but t20VAC or 0VAC in 240V mode
Check /solution Recommendation
Call DEK for paffstservice
Call DEK tor paffs/service
Call DEK for paffstservice
Call DEK for paffs/service
Symptom: Vottage too high/low
Potential Causes Check Isolution Recommendation
Spark arrestor Remove, clean and replace
Voltagespeedscrewn°tmeasuredbentcorrectly VO age mus be measured between hot and neural, no ho and ground he _round sso a ed Call DEK for parts/service
Symptom:
I:,t°to:n°:'t;',,o,,od
Voltage is 120 VAC on 1 phase but too hlghllow on other phase
Check tsolution I I
Symptom: Engine oll leaking
Potential Causes Check /solution
Oil leaking from crankcase gas Tighten crankcase bolts
ket
Oil leaking from shaft Oil seals failed
Recommendation
Call DEK for paffs/service
Symptom: Otl leaking from Valve head cover
IP°tttennot:tlgCauses ITC_htCekn/bSo/Isuti°n [Rec°mmendatl°n I
Fuel leak at tank shut*off
I;,';_t_n'nu_'_':;_st-o.valve/replace shut off vatve
Symptom: Fuel leaking out of carburator
Potential Causes Check /solution
Carburstor float seat not seating Flush with clean fuel
Fuel drain screw loose Tighten fuel drain screw
Recommendation
_ymptom: Cannot turn end{he with recoil
=otentlal Causes Check !solution Recommendation
_ecoil ratchets have broken Call DEK for parts/service
Recoil is crushed fn Call DEK for parts/service
_,lternstor bearing has fai_ed Call DEK for paffs/service
_ead valve timing is off Call DEK for parfa/service
Symptom: Fuel gauge leaks
IP: ;:an:rest,uC:;: e: e _aske, 1Check 's°luti°n
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
13 of 14
HeavyDutyF'owerEquipment Limited Warranty & Service
PRODUCTS COVERED BY THIS WARRANTY: LENGTH OF WARRANTY:*
IFROM THE DATE OF ORIGINAL RETAIL PURCHASE)
NONCOMMERCIAL/NON- COMMERCIAL RENTAL
RENTAL
Engine 36 months / 300 hours 36 months /300 hours 36 months /300 hours
Centrifugal Pump and Frame Components 24 months 3 months 3 months
Diaphram Pump and Frame Components 12 months 12 months 12 months
Generator Engine and Affernator 36 months /300 hours 36 months I300 hours 36 months / 300 hours
Generator Electrical and Frame Components 24 months 12 months 12 months
"LENGTH OF WARRANTY: Batteries supplied with applicable products as standard, original equipment are covered by this warranty for a pehod of 12 months
(noncommercial use) or 3 months (oommer¢ial/renta_ use) from the date of origina4 retail product purChase¸ Consumable parts such as oil, _park plL_gs, f]_ers are not cov-
ered by this warranty
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 inthis 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 Aand Bouttsts
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 mater_ai or workman-
ship In particular, this warranty does t_ct cover: contaminants in the fuel or dill damage cauSed by net fullowing the prescribed warnings and operating practices; failure
to follow proper storage proceduresi and physical damage due to shipping or handling or storage¸
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 con-
nected 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 SERVICE:
You must take the DEK Power Equipment product, accessory reptscement part, apparel or the power equipment on which the accessory or replacement part is installed=
and proof of purchase, at your expense, to any DER Power Equipment se_dce 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 followfrtg steps¸ First,
contact tee manager of the se_ice center involved_ normally this wdl resolve the problem However, if you should require further assistance, write or call the DER Cus-
tomer Sef_dce
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, INCORPORATtON OR USE OF UNSUITABLE AT-
TACHMENTS OR PARTS= UNAUTHORIZED ALTERATION, OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE PRODUCT
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 manufactudng date and the serial number on the equipment has been removed or the equipment has been modified,
O,.er,,°e.ro.uct.o.ere. Heavy Duty Power Equipment
Commercial Lawn Mowers Heavy Duty Pressure Washers Rental Grade Chipper Shredders Generator Accessories
Rev: 1/2006 DEK® is exclusively distributed by GXi International, LLC
14 of 14

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