Pulsar PG10000B User manual

10000B
10000

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10000W Generator
Topic
Safety Guidelines
General Precautions
General Parts
Battery
Operation
Inspection, Cleaning and
Maintenance Installation
Troubleshooting
Specifications
Wiring Diagram
Table of Contents
28

Safety Guidelines - Definitions
This manual contains important information that you need to know and
understand in order to protect YOUR SAFETY and to PREVENT
EQUIPMENT PROBLEMS. The following symbols help you recognize this
information. Please read the manual and pay attention to these sections.
Save These Important Safety Instructions!
Read and understand all of these safety instructions. Be
sure to retain them for future use.
WARNING! WARNINGS INDICATE A CERTAINTY OR STRONG
POSSIBILITY OF PERSONAL INJURY OR DEATH IF
INSTRUCTIONS ARE NOT FOLLOWED.
CAUTION: CAUTIONS INDICATE A POSSIBILITY OF
EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT
FOLLOWED.
NOTE: NOTES GIVE HELPFUL INFORMATION
WARNING! IMPROPER OPERATION OR MAINTENANCE
OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY
AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL
WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING
THIS EQUIPMENT. WHEN USING AIR TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE
THE RISK OF PERSONAL INJURY.
3

7500W Generator
Carbon Monoxide
When this tool is running, ensure that the area is well ventilated. Never run the
engine in an enclosed area. Run the engine in an open area or with an exhaust
evacuation system in an enclosed area.
WARNING! THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE
GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS AND MAY LEAD TO
DEATH.
Gasoline and Oil
This product requires oil and fuel. Attempting to start the engine without oil will ruin
the engine and void the warranty. Work in a well ventilated area. Keep cigarettes,
flames or sparks away from the work area or where gasoline is stored.
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE
UNDER CERTAIN CONDITIONS. KEEP OUT OF REACH OF CHILDREN.
• Gasoline fuel and fumes are flammable and potentially explosive. Use proper fuel storage and
handling procedures. Always have multiple ABC class fire extinguishers nearby.
• Keep the generator and surrounding area clean at all times.
• Fuel or oil spills must be cleaned up immediately. Dispose of fluids and cleaning materials as per
any local, state, or federal codes and regulations. Store oily rags in a covered metal container.
• Never store fuel or other flammable materials near the generator.
General Precautions
WARNING! FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN
SEVERE INJURY OR DEATH.
CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO
RESULT IN DAMAGE TO THE TOOL AND/OR THE ITEM YOU ARE WORKING
ON. 4

Owner’s Manual
General Precautions
Gasoline and Oil
• Do not smoke, or allow sparks, flames or other sources of ignition around the engine and fuel
tank. Fuel vapors are explosive.
• Keep grounded conductive objects, such as tools, away from exposed, live electrical parts and
connections to avoid sparking or arcing. These events could ignite fumes or vapors.
• Do not refill the fuel tank while the engine is running or while the engine is still hot. Do not
operate the generator with known leaks in the fuel system
• Excessive buildup of unburned fuel gases in the exhaust system can create a potentially
explosive condition. This buildup can occur after repeated failed start attempts, valve testing, or
hot engine shutdown. If this occurs, open exhaust system drain plugs, if equipped, and allow the
gases to dissipate before attempting to restart the generator.
Hot Components
Power Output
This generator is not designed to power sensitive electronic equipment (including computers
and medical devices) without the addition of an approved line conditioner, which is sold separately.
CAUTION: ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT
WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE
DAMAGE TO THE EQUIPMENT.
FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN
APPROVED LINE CONDITIONER.
5PULSAR PRODUCTS INC.IS NOT RESPONSIBLE
• nly use engine oil and fuel recommended by manufacturer.
o
WARNING! ENGINE AND EXHAUST SYSTEM PARTS BECOME VERY
HOT AND REMAIN HOT FOR SOME TIME AFTER THE ENGINE
INSULATED GLOVES OR WAIT UNTIL THE ENGINE AND EXHAUST SYSTEM
HAVE COOLED BEFORE HANDLING THESE PARTS.
HAS STOPPED

7500W Generator
General Precautions
Work Area
• Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases, or dust. Generators create sparks which may ignite the dust or fumes.
• Keep bystanders, children, and visitors away while operating a generator. Provide barriers or
shields as needed.
Electrical Safety
• Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adapter
plugs.
• Grounding provides a low-resistance path to carry electricity away from the
user in the event of an electrical malfunction.
• Double insulated tools are equipped with a polarized plug, where one blade is wider than the
other. This plug fits in a polarized outlet only one way. If the plug does not fit fully in the outlet,
reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet.
Do not change the plug in any way. Double insulation eliminates the need for the three-wire
grounded power cord and grounded power supply system.
• Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators.
There is an increased risk of electric shock if your body is grounded.
• Do not expose generator to rain or wet conditions. Water entering a generator will increase the
risk of electric shock.
• Do not abuse the power cord. Keep power cords away from heat, oil, sharp edges, or moving
parts. Replace damaged power cords immediately. Damaged power cords increase the risk of
electric shock.
• When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”.
These extension cords are rated for outdoor use, and reduce the risk of electric shock.
6

Owner’s Manual
General Precautions
Electrical Safety
• All connections and conduits from the generator to the load must only be installed by trained and
licensed electricians, and in compliance with all relevant local, state, and federal electrical
codes and standards, and other regulations where applicable.
• The generator must be earth-grounded for fixed installations in accordance with all relevant
electrical codes and standards before operation.
• Do not attempt to connect or disconnect load connections while standing in water, or on wet or
soggy ground.
• Do not touch electrically energized parts of the generator and interconnecting cables or
conductors with any part of the body, or with any non-insulated conductive object.
• Connect the generator only to a load or electrical system (120 volt) that is compatible with the
electrical characteristics and rated capacities of the generator.
• Before servicing equipment powered by the generator, disconnect the equipment from its power
input.
• Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked,
cut abraded or otherwise degraded. Replace terminals that are worn, discolored, or corroded.
Keep terminals clean and tight.
• Insulate all connections and disconnected wires.
• Guard against electric shock. Prevent body contact with grounded surfaces such as pipes,
radiators, ranges, and refrigerator enclosures.
฀฀฀฀Personal Safety
• Stay alert. Watch what you are doing, and use common sense when operating a generator. Do
not use generator while tired or under the influence of drugs, alcohol, or medication. A moment
of inattention while operating generators may result in serious personal injury.
• Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing,
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in
moving parts. 7

7500W Generator
General Precautions
Personal Safety
• Avoid accidental starting. Make sure the power switch is in its “OFF” position and disconnect
the spark plug wire when not in use.
• Remove adjusting keys or wrenches before turning the generator on. A wrench or a key that is
left attached to a rotating part of the generator may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times.
• Use safety equipment. Always wear eye protection. Wear ANSI approved safety impact eye
goggles. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for
appropriate conditions.
• Do not force the generator. Use the correct generator for your application. The correct generator
will do the job better and safer at the rate for which it is designed.
• Do not use the generator if the power switch does not turn it on or off. Any generator that cannot
be controlled with the power switch is dangerous and must be replaced.
Generator Use and Care
Make sure the power switch is in its “OFF” position and disconnect the spark plug wire before
making any adjustment, changing accessories, or storing the generator. Such preventative safety
measures reduce the risk of starting the generator accidentally.
Store idle generators out of reach of children and other untrained persons. Generators are
dangerous in the hands of untrained users.
Maintain generators with care. Do not use a damaged generator. Tag damaged generators “Do not
use” until repaired.
Check for misalignment or binding of moving parts, breakage of parts, and any other condition that
may affect the generator’s operation. If damaged, have the generator serviced before using. Many
accidents are caused by poorly maintained generators.
Use only accessories that are recommended by the manufacturer for your model. Accessories that
may be suitable for one generator may become hazardous when used on another generator.
8

Owner’s Manual
General Precautions
Servicing
Generator service must be performed only by qualified repair personnel. Service or maintenance
performed by unqualified personnel could result in a risk of injury.
When servicing a generator, use only identical replacement parts. Follow all appropriate
instructions in this manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of electric shock or injury.
Heart Pacemakers
WARNING! PEOPLE WITH PACEMAKERS SHOULD CONSULT THEIR
PHYSICIAN(S) BEFORE USING THIS PRODUCT. ELECTROMAGNETIC
FIELDS IN CLOSE PROXIMITY TO A HEART PACEMAKER COULD CAUSE
INTERFERENCE TO OR FAILURE OF THE PACEMAKER.
Installation
• Ensure installation meets all applicable safety, local and national electrical codes. Have
installation performed by a qualified, licensed electrician and building contractor.
• All electrical work, including the earth-ground connection, should be completed by a licensed
electrician.
• Any separate fuel storage or generator supply facility must be built or installed in full compliance
with all relevant local, state, and federal regulations.
• It is recommended to use the generator only in well ventilated, outdoor areas. A running
gasoline engine will generate carbon monoxide, a colorless, odorless gas that, if inhaled, can
cause serious injury or death. If the generator is installed indoors, exhaust fumes must be piped
out of the building using leak-free, heat resistant piping. Pipes and silencer should not use any
flammable materials, nor should they be installed near the same. Generator exhaust fumes
must be within legal limits and installation must always meet local building codes.
฀฀9Maintain labels and name plates on the generator and engine. These carry important information.
If unreadable or missing, contact Pulsar Products Inc. Immediately for a replacement.

10
7500W Generator
General Precautions
Installation
• If the generator is installed outdoors, it must be weatherproofed and should be soundproofed. It
should not be run outdoors without protection to the generator and wiring conduit.
• Before lifting the generator, ensure the lift rigging and supporting structure are in good
condition, and are rated to lift such a load.
• Keep all personnel away from the suspended generator during relocating.
• The supporting oor/ground surface should be level and strong enough to safely hold the weight
of the generator. If the floor/grounded surface is not level, strong cross members should be
placed under the full length of the generator frame at its low side.
• For trailer installation, the generator should be mounted on the center point of the trailer, over
the wheels. The trailer must be capable of supporting the weight of the generator and all
contents (tools, etc.)
• Install sound-and weather-proofing only when it is not raining or snowing to avoid trapping
moisture within the generator’s area.
Mechanical
• Always make sure the power switch is in its “OFF” position. Disconnect the spark plug wire, and
allow the engine to completely cool before carrying out maintenance.
• Check for damaged parts. Before using the generator, any part that appears damaged should
be carefully checked to determine that it will operate properly and perform its intended function.
Check for alignment and binding of moving parts, any broken parts or mounting fixtures, and any
other condition that may affect proper operation.
fl
• The generator weighs lbs (approximately) . Two or more people should assist
when moving or lifting this
product. Never lift the generator using the engine or alternator
lifting lugs. Connect lifting
equipment to the frame of the generator
212
• The generator is designed with guards for protection from moving parts. Care must
still be taken
to protect personnel and equipment from other mechanical hazards when working
around the
generator.

Owner’s Manual
General Precautions
Mechanical
• Do not operate the generator with safety guards removed. While the generator is running, do not
attempt to reach around the safety guard for maintenance or any other reason.
• Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts. Be aware that
when engine parts are moving fast they cannot be seen clearly.
• Keep access doors on enclosures closed and locked when access is not required.
• When working on or around the generator, always wear protective clothing, including ANSI
approved safety gloves, safety eye goggles, and safety hat.
• Do not alter or adjust any part of the generator that is assembled and supplied by the
manufacturer.
• Always follow and complete scheduled engine and generator maintenance.
Chemicals
• Avoid contact with hot fuel, oil, exhaust fumes, and hot solid surfaces.
• Avoid body contact with fuels, oils, and lubricants used in the generator. If swallowed, seek
medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact,
immediately wash with soap and water. For eye contact, immediately flush eyes with clean water
and seek medical attention.
Noise
• Prolonged exposure to noise levels above 68 DBA is hazardous to hearing. Always wear ANSI
approved ear protection when operating or working around the generator when it is running.
11

Owner’s Manual
t
er
GenralPa s 12Fuel tank cap
Fuel tank
Frame
Control Panel
Wheel
Recoil starter
Fuel valve
Voltage frequency
hour meter Thermal protector
Twist-lock outlet
120V/240V outlet
Battery
Handle
Air filter
Choke lever
120V Duplex outlet
DC terminal
120V/240V
Oil dipstick
Engine Switch
Fuel gauge
One way valve
Fuel Selector Switch

13
AC electrical
7500W Generator
Battery
To start generator with electric start you will need a battery (included) .
Also this generator can also be started with the pull start.
Photos below demonstrate battery plate attachment.
Put the battery on the frame, have the battery assembled with the provided accessories
as shown.
Note: Using a battery not designed for
this unit may void warranty.

Operation
NOTE: THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE
CONTROLS MENTIONED BELOW.
Before Starting the Generator
1. Check that the engine power switch is in the
“OFF” position.
2. Before the first use, remove the fuel
tank cap and fill the fuel tank with unleaded
gasoline. When fueling, be sure that the
fuel strainer is in place. Replace the fuel
tank cap. Thereafter, check the engine’s
fuel gauge for the amount of unleaded
gasoline in the fuel tank. If necessary,
refill the fuel tank with unleaded gasoline;
the generator must be turned off and
cooled down before refilling the fuel tank. 14Fuel Tank Cap
CAUTION: PRIOR TO FIRST USING THE GENERATOR, THE ENGINE MUST BE
FILLED WITH A HIGH QUALITY SAE 10W30 GRADE ENGINE OIL.
TO DO SO, UNSCREW AND REMOVE THE ENGINE’S OIL DIPSTICK LOCATED
AT THE BOTTOM OF THE ENGINE CRANKCASE. FILL THE ENGINE’S
CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED
LINE ON THE DIPSTICK. THEN SCREW THE DIPSTICK BACK INTO
THE OIL FILL HOLE.

Operation
15
Connecting to LPG Fuel Source
1.Locate the LPG converter on the backside of the generator
2.Attach small end of the Gas Hose to the LPG converter.
3.Connect gas hose to propane fuel source. Do not turn on propane source prior to following the
steps outlined.
Batteries produce explosive gases. Keep sparks, flames and cigarettes away from battery. To
prevent the possibility of creating a spark near the battery, connect charging cables to battery
terminals first, then to the generator. When disconnecting, disconnect the cables at the generator
first.
1. Connect the red cable with the positive terminal of the battery. Ensure the connection is
secured by using the fastener at the battery terminal.
2. Connect the black cable with the negative terminal of the battery. Ensure
the connection is secured by using the fastener at the battery terminal.
Be sure to connect the Electric Start Battery to the Dual fuel Generator set before operation.
Improper connection will cause malfunction.
Do not reverse the polarity of the terminals when charging the battery. Serious damage to the
generator and/or battery may occur. Do not attempt to connect the battery while the generator
engine is running. Disconnect the cables from the battery while the generator is in storage.
3. When using gasoline to start the engine, the battery must be properly connected to the
generator and check the battery voltage is normal.
Electric Start Battery Connection

Operation
16
Starting the Generator Set
Ground Terminal
Before using generator, a ground wire must be connected to the ground terminal.
The Ground terminal is located on the Front Panel. Before using the ground terminal consult a
qualified electrician.
Ground Terminal Symbol:
The 7750Watt dual fuel generator can be started using the following method. Recoil Start
Method,
Electronic Start Method
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Operation
17
Do not allow the recoil starter to snap back. Return it slowly by hand
4. Push the choke lever to the OPEN position as the engine warms up. The choke is used to
provide the proper mixture when the engine is cold.
It can be opened and closed by operating the choke lever manually by starting.
ELECTRIC STARTING METHOD
RECOIL START METHOD
1. Disconnect all devices from the outlets on the generator panel.
2. Press the engine switch to the "ON" position.
3. Grasp the recoil starter handle and pull it until the engine starts.
Batteries produce explosive gases. Keep sparks, flames and cigarettes away
from the battery. To prevent the possibility creating sparks near the battery, connect the charging
cables to the battery terminals first, then to the generator. When disconnecting, remove cables at
generator first.
1. Follow fuel source selection steps.
2. Push the engine ignition button until the generator starts. Do not push the ignition button for more
than 5 seconds. Doing so may damage the alternator.

Operation
18
1. Turn off the switches of the device before connecting to the generator.
2. Start the generator.
3. Insert the plug of the device into the receptacle based on the voltage
requirement of the device.
To stop the engine in an emergency, turn the engine switch "OFF".
In order to maintain generator's performance:
Using the Generator Set
Always connect the generator to the ground terminal to prevent
electrical shock.
If electric start does not turn on the generator after three attempts, contact customer
support. Repeated attempts could damage the ignition mechanism.
3. Follow steps 6-7 from the Recoil Start Method
Add the watt ratings of all the loads that the generator set will be
powering at the same time. Make sure that total wattage will not exceed
the generator rating.
Using DC Output Terminals
You can use 12V 8.3A DC output to charge automotive batteries. Be sure to monitor the battery
charge time.
Over-charge may cause explosion and injury
1. Connect the positive (red) terminal of the battery to the red (positive)
terminal the 12V 8.3A DC Output Terminal on the front panel
2. Connect negative(black) terminal of the battery to the black (negative)
terminal of the 12V 8.3A DC Output terminal on the front panel (DO NOT REVERSE
POLARITY OF CONNECTIONS)
3. Start the generator.

Operation
19
Stopping the Generator Set
When using gasoline
1.Turn off all the connected devices.
2.Allow the generator set run for a few minutes to cool down.
3.Stop the generator set by pressing and holding the engine switch in the
OFF position until the generator set stops.
4.Rotate the fuel valve lever back to the OFF position.
When using LPG
1.Turn off all the connected devices.
2.Allow the generator set run for a few minutes to cool down.
3.Turn off the LPG valve.
4.Push the engine switch to “OFF” position.

Operation
Powering 120 Volt AC Tools a nd Equipment:
1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage
capacity (120VAC @ 27 AMPs) is adequate to supply all electrical loads that the unit will
power. If powering exceeds the generator’s capacity, it may be necessary to group one or more
of the tools and/or equipment for connection to a separate generator.
CAUTION: ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT
WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE
DAMAGE TO THE EQUIPMENT.
FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN
APPROVED LINE CONDITIONER.
2. Once the generator is running, simply connect the power cords of 120 volt AC powered
tools and equipment into the 120 volt AC dual outlets.
NOTE: THE GENERATOR FEATURES AN AC NON-FUSE CIRCUIT BREAKER
TO PROTECT THE AC CIRCUIT IN CASE OF AN OVERLOAD. SHOULD
AN OVERLOAD OCCUR, THE BREAKER WILL “TRIP” TO ITS “OFF” POSITION,
CAUSING THE GENERATOR TO AUTOMATICALLY SHUT DOWN. IN THIS CASE,
REFER TO ABOVE IN THIS POSITION. THEN, RESET THE CIRCUITRY
SYSTEM BY TURNING THE CIRCUIT BREAKER TO ITS “ON” POSITION.
RESTART THE GENERATOR AND CONTINUE POWERING THE REMAINING
TOOLS AND EQUIPMENT.
20
IS NOT RESPONSIBLE
PULSAR PRODUCTS INC.
3.
4.
Disconnect all electrical powered tools and equipment from the generator s 120 volt Duplex
outlets.
,
After the engine and generator have completely cooled,store generator in safe,chean,dry
location (if not already installed).