Model: PG7500 Generator OPERATOR’S MANUAL www.pulsar-products.
TABLE OF CONTENTS Introduction..............................................................................................................................................................................3 Product Specifications..................................................................................................................................................3 Parts Ordering / Customer Service.......................................................................................................
INTRODUCTION Thank you for purchasing this superior quality portable generator from Pulsar Products Inc. When operating and maintaining this product as instructed in this manual, your generator will give you many years of reliable service. Product Specifications: This generator is an engine-driven, revolving field, alternating current (AC) portable generator.
SAFETY RULES Safety Symbols WARNING! Indicates a potentially hazardous situation which could result in serious injury or death if not avoided. CAUTION! Indicates a potentially hazardous situation which could result in damage to equipment or property. Toxic Fumes Risk of electric shock Risk of fire Risk of explosion Hot surface Lifting hazard Safety Instructions The manufacturer cannot anticipate every possible hazardous circumstance that the user may encounter.
SAFETY RULES WARNING! Never exceed generator’s wattage / amperage capacity. This could damage the generator and / or connected electrical devices. • Check operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator. • • Never start or stop engine with electrical devices plugged in to the receptacles. Failure to do so could damage the generator and / or connected electrical devices.
SAFETY RULES This generator produces a very high voltage which could result in burns or electrocution causing serious injury or death. Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands or feet are wet. Always keep the generator dry. Never operate generator in rain or under wet conditions. Use a ground fault circuit interrupter (GFCI) in a damp or highly conductive area, such as metal decking or steel work.
FEATURES B A D C E F G E-START ON OFF PG7500 H I A - ON/OFF Start Switch B - Hour Meter C - 4-120V Receptacles D - Circuit Protectors E - 120V 30 Amp Twist Lock (L5 -30) F - 120V / 240V 30 Amp Twist Lock (L14-30) G - Grounding Connection H - Oil Alert I- 12V DC Output (For Charging Batteries Only) 7
FEATURES Q J K L M N R S T O P J - Fuel Tank Vapor Vent K - Choke Lever L - Fuel Valve (ON/OFF) M - Handle N - Recoil Starter Grip O - Air Filter P - Support Foot Q - Fuel Tank R - No Flat Tires S - Battery T - Oil Fill and Dipstick 8
ASSEMBLY Unpacking 1. Place box on a level surface. 2. Remove all items from box except the generator. Make sure all items listed on the packing list are included and not damaged. 3. Cut down the sides of the box being careful to avoid hitting the generator. 4. Leave generator on box to install wheel assembly. Packing List Check all loose parts to the following list. Contact your dealer if any loose parts are not included.
ASSEMBLY Attaching Wheels (See fig 1) • • • • Parts needed - 2 wheels, 2 axles, 2 hair pins, and 2 washers. Raise or tilt generator so you can slide the wheel axle pin into the wheel, the washer, the wheel mounting hole located on the side of the frame. Secure the wheel assembly by reinserting a hair pin through hole at the end of the wheel axle and pressing until it locks into place. Repeat process on the other side of the generator to install the second wheel.
ASSEMBLY Attaching Battery Cable (See fig 3) • • • • • • Parts needed - Black and Red battery cable The Red (+) Connector should be attached to the battery first. Remove the screw from the battery terminal. Place the screw through the eyelet and tighten the screw and make sure the terminal will not touch any part of the frame. Install the Red protection boot. Repeat these steps for the Black (-) Terminal. CAUTION! Be careful not to short across the terminals when installing.
ASSEMBLY Antidotes for battery acid CONTACT TREATMENT External Internal Flush with water. Drink large quantities of milk or water, followed by milk of magnesia, vegetable oil or beaten eggs. Get immediate medical attention. Eyes Flush with water. Get immediate medical attention. Adding / Checking Engine Oil (See fig 4) • • • • • Place generator on a level surface. Remove the crankcase dipstick to ensure you do not overfill the engine.
ASSEMBLY Adding Fuel (See fig 5) • • • Set generator on a clean and level surface in an area that is well ventilated. Remove fuel cap. Insert a funnel into the fuel tank and carefully pour gasoline into the tank until fuel level reaches 1 ½ inches below the top of the neck. Be careful not to overfill the tank to provide space for fuel expansion.
OPERATION Grounding the Generator (See fig 6) The ground terminal located on the front panel of the generator must always be used to connect generator to a driven ground rod. Connect the ground terminal to the driven ground rod with a No 8 AWG (American Wire Gauge) copper wire. The wire connects to the terminal between the lock washer and nut. Tighten the nut securely to ensure proper connection.
OPERATION CHOKE RUN CHOKE LEVER Fig 7 Fig 8 E-START E-START ON OFF 1 ON OFF PG7500 OR START ON PG7500 1 START ON OFF OFF 2 Fig 10 Recoil Start Fig 9 Electric Start WAIT 5sec CHOKE RUN CHOKE LEVER Fig 11 Battery Charger for Electric Starter Keep the generator battery fully charged and ready to use to avoid the need to use the recoil starter to start the generator manually.
OPERATION How to Stop Engine (See fig 12-14) • All loads MUST be disconnected from the generator. Never start or stop the engine with electrical devices plugged in to the receptacles. Turn the fuel valve to the “OFF” position. • Turn the engine START/ON/OFF switch to the “OFF” position. • E-START ON OFF 2 PG7500 START ON OFF Fig 12 Fig 13 Fig 14 Receptacles and Extension Cords Only use high quality, well-insulated, grounded extension cords in good condition with generator receptacles.
OPERATION Extension Cord Selection Refer to the below table to ensure the extension cord used has the capacity to carry the required load. If the size of the cable is inadequate it can cause a voltage drop, which can damage the electrical device and cord. Current (Amps) 2.5 5 7.5 10 15 20 25 30 Load (Watts) 120V 300 600 900 1200 1800 2400 3000 3600 240V 600 1200 1800 2400 3800 4800 6000 7200 Maximum Cord Length #8 Wire #10 Wire X 1000 ft. X 500 ft. X 350 ft. X 250 ft. X 150 ft. 175 ft. 125 ft. 150 ft.
OPERATION Operating voltage and frequency requirement of all electronic equipment should be checked prior to plugging them into this generator. Damage may result if the equipment is not designed to operate within a +/- 10% voltage variation, and +/- 3 Hz frequency variation from the generator name plate ratings. To reduce the risk of damage, always have an additional load plugged into the generator if solid state equipment (such as television set) is used.
OPERATION Hour Meter (See Fig 15) The digital hour meter operates whenever the engine is running and keeps track of how many hours the unit has been used. Use this meter along with the manual to determine when and what type of service on the unit is needed. The display will show the word “LUBE” at the first 25 hours of operation and again at every 100 hours of operation after. Power Management • • • Start engine without anything connected to generator.
MAINTENANCE Regular maintenance will extend the life of this generator and improve its performance. The warranty does not cover items that result from operator negligence, misuse, or abuse. To receive full value from the warranty, operator must maintain the generator as instructed in this manual, including proper storage. Before inspecting or servicing this machine, make sure the engine is off and no parts are WARNING! moving. Disconnect the spark plug wire and move it away from the spark plug.
MAINTENANCE Changing Oil (See Fig 17) Oil drainage plug Fig 17 104 86 68 50 * 32 14 -4 40 * * 30 20 10 0 5W-30 Do not use special additives. Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity for the outdoor temperature range expected. Synthetic 5W-30 • • C F Oil Recommendations 10W-30 • Run the Generator until the Engine is warm. Place generator on a level surface. Remove the crankcase dipstick.
MAINTENANCE Spark Arrestor (See Fig 20 If Applicable) • • • Inspect the spark arrestor for breaks or holes. Replace if necessary. To purchase a replacement spark arrestor contact PULSAR customer service. Use a brush to remove carbon deposits from the spark arrestor screen as needed. To remove the spark arrestor: While the muffler is cool, loosen the locking clamp and slide the spark arrestor out of the muffler. Reverse this process to install it.
MAINTENANCE Draining the fuel tank • Turn the engine OFF. • Turn the fuel valve to the OFF position. • Push the fuel valve knob through the valve holder bracket allowing you to access the petcock. • Remove the fuel line that leads to the carburetor from the petcock by squeezing the ends of the hose clamps and sliding the fuel line off. • If needed, install a fuel hose that will extend to a suitable fuel container large enough to catch the fuel being drained from the tank.
TROUBLESHOOTING Problem Engine is running, but AC output is not available Cause 1. Open circuit breaker 2. Poor connection 3. Defective cord set 4. Connected device is faulty 5. Fault in generator Engine runs well without load but bogs 1. Short circuit in connected device down when loads are connected 2. Generator is overloaded 3. Clogged fuel filter 4. Engine speed is too slow 5. Short circuit in generator Engine will not start, shuts down during 1.
DIAGRAMS + M 25
WARRANTY Pulsar Products Inc. Limited 2 Year Warranty: From the date of original purchase, Pulsar Products Inc. warrants to the original purchaser that each portable generator sold, shall be free from defect in material and workmanship for the items and time period set forth below. Pulsar Products Inc., at its discretion, agrees to repair or replace any defective part that upon examination, inspection, and testing by a Pulsar Products Inc.
WARRANTY What this Warranty Does Not Cover: • Normal wear: This warranty excludes normal wear items such as filters, spark plugs, gaskets, O-rings, adapter cord sets, wheels, and starting batteries. • Maintenance: This warranty does not apply to tune-ups or routine maintenance and does not cover any adjustments or repairs not performed by an authorized repair facility.
