Pulsar PG7000DOF User manual

Operator's Manual
6500 Watt

Model
Diesel Generator

PG7000DOF
Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,
actual product may differ slightly from the product described herein.
FOR SERVICE CALL: 1-866-591-8921
A WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL
BEFORE ATTEMPTING TO OPERATE THIS MACHINE. FAILURE TO COMPLY WITH
THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

A
DANGER
CARBON MONOXIDE
Using a generator indoors WILL KILL YOU IN MINUTES.
Generator exhaust contains high levels of carbon monoxide (CO), a poi-
sonous gas you cannot see or smell. If you can smell the generator ex-
haust, you are breathing CO. But even If you cannot smell the exhaust, you
could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other
partly enclosed areas. Deadly levels of carbon monoxide can build up in
these areas. Using a fan or opening windows and doors does NOT supply
enough fresh air.
ONLY use a generator outdoors and far away from open windows, doors,
and vents. These openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home.
ALWAYS use a battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AWAY. See a doctor. You could have carbon mon-
oxide poisoning.

AIR-COOLED DIESEL GENERATOR
TABLE OF CONTENTS
Page number
Chapter 1 Technical Specifications and Data

3
1-1 Technical specifications and data

3
1-2 Basic operating instructions 
5
1-3 General dimensions and overview of generator

5
Chapter 2 Operating the Diesel Generator

7
2-1 Main points of safety during operation of the generator 
7
2-2 Preparation before operation

9
2-3 Checking the operation of the diesel engine 
12
2-4 Starting the generator 
12
2-5 Procedures for starting the generator 
15
2-6 Proper operation of the generator
17
2-7 Loading

17
2-8 Stopping the generator 
19
Chapter 3 Maintenance 
20
3-1 Maintenance schedules 
20
3-2 Storing for a long period of time 
22
Chapter 5 Generator Parts Diagrams and Listings 
23
Limited Warranty 
24
2

AIR-COOLED DIESEL GENERATOR
CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA
1-1 Technical specifications and data
Single-cylinder diesel venerator
PG7000DOF
Rated frequency (Hz) 60
Rated voltage (V)
120/240
Rated output power
(kVA)
5.0
Max  output  power
(kVA)
6.5
Rated rotation speed
(rpm)
3600
Power 
factor  cos_
1
Phase number Single
Pole number 2
Excitation
Transistorized
self-excitation ,
Brush type
ATS type without ATS
Structure type Open-frame
Fuel
consumption(g/kw.h)
340
Fuel tank capacity(L) 12.5
Continuour  running
time(hr)(at 
rated
power)
7.5
Noise  level
[dBA/7m](zero
load_full load)
75-79
Net weight (kg)
L_X95;  E:100
Overall  dimension
(L W H)
29"x19"x26.25"
3

OWNER'S MANUAL
Starter system
C: recoil starter
E: recoil starter/electric starter
Fuel type
0# (summer),_10# (winter),
_35#(chill cold) diesel
Lube oil SAE 15W 40
Engine type
Single-cylinder,4-stroke,air-
cooled,yertical,diesel engine
Bore 
stroke(mm) 86 72
Displacement(crn3) 0.418
Compression ratio 19_1
Rated power [kW/rpm] 6.0/3600
Rotation direction(from
the flywheel)
clockwise
4

OWNER'S MANUAL
1 - 2 Basic
operating instructions
1-2.1 Under the given conditions, the generator will output the specified power in the table
listed below.
Table I.
Height above sea level (ft)
Ambient temperature ( F)
RH
0
+60 (+20
0
C)
60%
1-2.1 Under the given conditions, the generator will output the approximate
power in the table listed below.
Table 2
Height above sea level (ft)
0
Ambient temperature ( F)
RH
<3280.8 (<1000 m)
°
41-104 (5-40 C)
90%
5

OWNER'S MANUAL
CHAPTER 2 OPERATING THE DIESEL GENERATOR
2-1 General
main points
of safety during operation of the generator set.
In order to operate the generator set safely, please follow all the instructions provided
in this manual carefully. Doing so otherwise may lead to accidents and or equipment
damage.
2-1.1 Fire prevention
The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline,
kerosene and or other fuels other than light diesel fuel. Keep all flammable fuels
away from the generator as the generator may spark and ignite these gases. In order
to prevent fires from occurring and to provide enough ventilation for people and the
machine, keep the diesel generator at least 1.5 meters away from buildings and or
other equipment. Always operate your diesel generator on a level site. If the
generator is operated on an incline, the lubricating system within the engine will not
perform well and may lead to failure of the engine.
2-1.2 Prevention from inhaling exhaust gases
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic
carbon monoxide. Never operate your generator in places with poor ventilation. In
order to operate this machinery indoors, a suitable ventilation system for the building
is required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental bums
Never touch the muffler and its cover when the diesel engine is running. Never touch
the muffler and cover after the diesel engine has been used, as the muffler remains hot
for a long period of time.
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet. Also never touch the generator if
your hand is wet. Never operate your generator if the weather conditions call for any
type of precipitation such as rain, snow, or fog. To prevent electrical shocks, the
generator should be grounded. Use a lead to connect the grounding end of the
generator to the grounding surface of choice. Please refer to Fig. 2-1 before
beginning to use the electric generator.
6

OWNER'S MANUAL
Note: When connecting devices to the generator, make sure all other devices are
rated lower than the generators output. Any generator socket should not be
overloaded over its regulated limit
2-1.5
Other safety points
Before operating this generator, all operators should have a good knowledge of how
to break the circuit if any accidents occur. Also, all operators should be familiar with
all the switches and functions of the generator before using this machine. While
operating the generator, wear safe shoes and suitable clothes during operation.
Always keep children and animals away from the generator.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric acid.
In order to protect your eyes, skin, and clothing, wear protective gear when working
with the battery. If you come in contact with the electrolytic liquid, wash it
immediately with clean water. Also, if the electrolytic liquid comes in contact with
your eyes, see a doctor immediately.
7

gearlever
OWNER'S MANUAL
2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Fuel tank
Use only light diesel fuel. The fuel should be filtered clean. Never let dust and
water mix with fuel in the fuel tank. Otherwise it will clog the fuel lines and oil
nozzles. It may also damage your pressure pump.
Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the
filter.
Type
PG7000DOF
The effective volume of fuel
tank:(L)
12.5
(US gal)
3.3
a. After purchasing fuel, put it into a
drum and let it sit for 3-4 days.
b. 3-4 days later, insert half of the fuel
siphon into the drum, (water and
impurities stay in the lower portion
of the drum)
Air filter element
Do not wash the air filter. The element is made of dry material, which does not
permit washing. When the output of the diesel engine is bad or the color of the
exhaust gas is abnormal, replace the air filter element. Never start the diesel engine
without the air filter.
stop
stanfrun
Note:
Never smoke near the opening of the fuel tank.
Do not let sparks get near the fuel or fuel tank
and do not overfill tank. After filling, tighten the
fuel cap.
8

OWNER'S MANUAL
2-2.2 Filling engine oil
Remove the dipstick from the engine
Make sure the generator is on level ground, and fill the engine with 15W40 engine oil.
Put the dipstick back into the hole to check the engine oil level.
ergo
I I
Ctassnicatkin of
maintenance tot A.P.I. damn
engine
Be sins km oil GRADE CO o r Wier, No
CO
Engine oil is the most important factor in determining the life of your generator
engine. If you use poor engine oil or if you don't change the oil regularly, the piston
and cylinder will wear easily or seize up. Also, the life of the other parts in your
engine such as bearings, and other rotating parts will shorten considerably.
FIRST USE
 "P .
doe at
'may 3 mord,. 200hours
Interval of Chan‘inti Madan OE
Although there is an oil sensor that checks for low oil pressure, it is always a good
idea to check the amount of oil inside the engine. If the oil level is low, fill it before
starting the engine. A good time to drain the oil from the engine is when the diesel
engine is warm. If the engine is fully cooled, it is more difficult to drain all the oil out
or some impurities will remain in the engine.
Odstr ~
x
too lo drain  kasng ail
Ott In drain kitinciting cal
Warning: Don't fiN engine oil when diesel is operating.
9

filter core
OWNER'S MANUAL
2-23 Checking the air filter
(1) Loosen the butterfly nut, take the cover of the air
filter off and take the air filter element out.
Do not wash the air filter element.
When the performance of the engine decreases or
when the color of the exhaust gases is bad, exchange
the filter element. Never start the engine without the
air filter as foreign objects may enter the intake and damage the engine.
Use dry compressed air (with pressure about 28 PSI to blow the dust out in
the electric control cabinet and at the surface of the generator. Check to see
how clean the surface of the sliding ring is. Check the pressure of the carbon
brush. Also, check whether the position of the carbon brush at the slide rig is
correct and the fixture is reliable with a good contact.
2-2.5 The fuel and oil in a new engine is drained before sold. Before you start the
engine, please fill the fuel tank and engine oil first.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure oil switch.
CF diesel engines have a low-pressure sensor system where if the oil pressure
drops too low, the sensor will shut the engine off. The purpose of having this
system is to ensure that the engine does not seize up. If there is not enough oil
in the engine, the temperature of the oil will be raised too high. On the
contrary, if there is too much oil in the engine, the engine oil can slow the
engine down considerably.
10

position
OWNER'S MANUAL
2-3.3 Engine break in
When you purchase a brand new engine, the engine must be properly broken
in. The break in period is about 20 hours.
(1)
Avoid overloading the engine when brand new
(2) Change the engine oil according to specifications. An oil change for a
brand new engine is about 20 hours or every month, an older engine, the
oil change is about 100 hours or three months.
2-4 Starting the generator set
2-4.1 Manual starting.
Start the engine in accordance with procedures below:
(1)
Put the fuel switch in the "On" position.
(2) Turn the handle of the engine to the
"RUN" position.
(3) Pull the recoil starter handle out until
you feel resistance. It will reset to its original
automatically. The handle
should be reset into its recoil device slowly to
prolong the life of the engine starter.
(4)
In cold climate, it is difficult to start the engine.
Rubber plug
To remedy this, pull the rubber plug out from the
rocker of the diesel engine and fill 1/2 a cap full of engine
oil. Before starting, put the rubber plug back in
place. If you don't put the rubber plug back in place,
rain, dust and other dirt can enter into the diesel engine. It will cause the parts inside the
diesel engine to wear quickly and lead to engine failure.
2-4.2 Electric starting
The procedures for preparing to start the engine are the same as the manual starting
engine.
2-4.3 Battery
1. Insert key into ignition and put it in the "off' position.
2.
Put the speed handle in the "Run" position.
3.
Turn the start switch clockwise to the "START" position; to set the silent
type, first turn it clockwise to the "RUN" (ON) position for 1-2 seconds.
11

OWNER'S MANUAL
The electromagnetic iron will be triggered, now turn it clockwise to the "START'
position.
4.
After the diesel engine is started, remove your hand from the switch handle; the
switch will automatically reset itself to the "ON" position.
5.
If the engine is not starting after 10 seconds of cranking, wait about 15 seconds
before trying it again. If you crank to long, the voltage of the battery will drop. This
can lead to improper ignition. When the diesel engine is operating, let the ignition
retain on the "ON" position.
Note:
If you crank the starter to long, the battery may be drained too much to provide
enough energy for proper engine ignition. Also, when the diesel engine is
operating, let the key retain in the "ON" position.
Important Notice:
All of our units come with a dry battery for shipping
safety purposes. In order to get your generator started
for the first time; the battery must be filled with
battery acid which can be purchased at a local
automotive supply store and slowly charged (trickle
charged) for a day.
To properly maintain your battery; check the height of the battery acid once a month.
If the level of the liquid drops too low, fill it with distilled water until it reaches the
high mark. If there is not enough battery acid, then the diesel engine cannot be
started. It is important to keep the liquid level between the high and low limits.
If the level in the battery is to high, the liquid may flow out and end up on
surrounding parts resulting in corrosion of these parts.
Note: Avoid too much or too little of battery acid. Check and fill it once a month
if necessary.
12

13
0
Open the fuel valve)
OWNER'S MANUAL
2-5 Procedures for starting the generator
This procedure applies to the CF series recoil starting style models.

OWNER'S MANUAL
14

f uel adjustment It Speed
handle
High-mason lite]. ply nut Fuel adjustment holt
OWNER'S MANUAL
2-6 Proper operation of the generator
2-6.1 Operating the diesel engine
1. Pre-heat the diesel engine for 3
minutes under no load conditions.
2. First check the height of the
lubricating oil level, if it is
low, refill it. Our diesel
engines are equipped with
an oil switch that will
notify you if the oil pressure
is too low. The system will
shut down the engine if the oil
pressures too low.
3. Do not adjust the speed limit
regulation bolt or the fuel adjustment
bolt.These bolts have been set by the
factory already, changing them will affect the properties of the engine
performance.
2-6.2 Checks during engine operation
1. Check to see if there are abnormal noises.
2. Check to see if the performance is good or bad
3. Check the color of the exhaust gases (whether it is too black or too white).
If any of these conditions exist, stop the engine and find the cause of the
problem. If no problems are found, please contact your local dealer or our
nearest company branch.
2-7 Loading
2-7.1 Load conditions
Exert loads in accordance with the specified parameters.
2-7.2 Output of electricity
I. Raise the revolutions per minute (turn the speed handle to the max setting) of the
generator to get the maximum power out of the generator. If not, the
automatic voltage regulator device will excite and doing this for long periods of time
will cause the AVR to burn. For the rated speed of the generator, please refer to
Chapter 1, item 1-1 technical specification and data.
2. Observe the pointer of the voltmeter, it should point to 240 (60Hz). Meanwhile
put the switch in the GEN (generator) position. The AC voltage from the socket of
the power supply can be output.
3. When connecting devices to the generator, make sure to connect these devices in order.
15

OWNER'S MANUAL
Connect the large loads onto the generator first. If everything is functional, smaller loads can then
be added. If the generator shuts off, it may be because the load being drawn by all the various
devices are too high. In this event, decrease the number of small devices until everything is
functional. The total drawn power should not exceed the maximum output power of the generator.
Please see Table 1-1 for technical specifications of what the generator can output. In order to reset
the generator after overdrawn power, let it sit for several minutes. If the indication of the
voltmeter is too high or too low, adjust the speed accordingly. If there are problems, stop the
generator immediately and fix the issue.
4. During operation, the generator should be in a place that has very good ventilation.
Never cover the engine to solve a ventilation problem, as this will damage your
equipment.
Note: Do not start more than two devices simultaneously. Each device should be
started one by one to prevent overloading the generator.
The generator should be running at 3600 revolutions per minute in order to
achieve the (60 Hz) frequency. The speed of the engine can be adjusted from the
speed governor.
2-7.3 Charging the battery
1. For the electric starter on the generator sets, the 12V battery is automatically
charged through the regulator on the side of the engine when it is running.
2. If the generator is not used for long periods of time, the battery should be
disconnected to avoid energy loss from the battery.
3. Do not connect the negative and positive terminals of the battery together at any
time. Doing so will cause the battery to explode and cause serious injuries.
4. Do not reverse the polarities when attaching the battery cables to the battery.
Doing so will damage both the battery and the electric starter.
5. When charging the battery, the battery produces flammable gases. Do only on well
ventilated area.
Do not smoke, let flames, and sparks get near the battery while it is charging as
this may cause a fire.
To avoid sparking while connecting the cables to the battery, first, connect the cables
to the battery then to the motor. To disconnect battery cables, first disconnect the
motor end of the cable.
16

OWNER'S MANUAL
2-8 Stopping the generator
1. Take the electrical load of f the
generator
2.
Put the speed handle in the "RUN"
position and let the engine run for 3
minutes after unloading. Do not stop the
engine immediately let it warm down.
Stopping the diesel engine suddenly may
the temperature of the engine abnormally
lock the nozzle and damage the diesel
engine.
1.
If the speed handle is in the "Stop position and the engine is still running , turn the
fuel switch to the "OFF" position or loosen the high pressure oil pipe nut. The engine
could be stopped more than one-wayother than the speed handle way.
2.
If you cannot stop the engine with a load on it, then remove the load first than
stop
the engine.
3.
Press down on the brake handle
4.
If equipped with an electric starter, turn the key to the "Of f' position
5. Put the fuel handle to the "S" position
6.
Finally, pull slowly on the recoil handle until you feel resistance (this is when the
piston is on the compression stroke, where the intake and exhaust valves are closed).
What this does is prevent the engine from rusting when not in use.
17

OWNER'S MANUAL
CHAPTER 3 MAINTENANCE
3-i Maintenance schedules
Keeping your generator well maintained will prolong the life of your generator. Everything needs to be
checked including the diesel engine, generator, control cabinet, and frame.
Before starting the maintenance, make sure the diesel engine is off.
Please refer to the Table 3-I for the proper maintenance schedule.
it
".*
::
-a
"
--
-----__________
Everyday
After 1 month
or 50hours
Every 3 month or
200 hours
Every 6 mouth or 400
hours
Every

I year

or
1000 hours
Check the fuel level
and
refill
Before
starting
Drain the fuel tank
Check and

fill

enough
engine oil
Clean the fuel filler
Check fuel oil leakage
alter every
operating
Check and

screw each
fostered part
screw

the

bolt

of
cylinder head firmly
Check injector
Check injection pump
Cheek fuel pipe
If necessary exchange
it
Check the lube oil level in
Ile oil pan and refill
before
mailing
Replace the tube oil
the first tune
the second time and
a
-
ficr.d
Clean lab, Oil filter
the first dine
- the sewed tune and
a
fterward
Check

the

air

cleaner
denim
the Iasi time
the second time and
the
Change the core of axe filter
If damaged to

II
wary , change it intime
Check

the

battery

liquid
level and refill
Adjusting the intake and
exhaust valve clearance
the fiist ante
the second liner and
allot want
Grind air intake and an
exhausted gate
Exchange piston ring
Check electric brush and
slide ring
Cheek insulation resistance
The time of slop is over 10 days

OWNER'S MANUAL
Limited Warranty (cont'd)
THIS WARRANTY DOES NOT COVER:
Merchandise sold as reconditioned, used as rental equipment, or floor or
display models.
Merchandise that has become damaged or inoperative because of ordinary
wear, misuse, cold, heat, rain, excessive humidity, freeze damage, use of
improper chemicals, negligence, accident, failure to operate the product
in accordance with the instructions provided in the Owner's Manual(s)
supplied with the product, improper maintenance, the use of accessories
or attachments not recommended by Pulsar Products Inc. or
unauthorized repair or alterations.
Repair and transportation costs of merchandise determined not to be defective.
Costs associated with assembly, required oil, adjustments or other
installation and start-up costs.
Expendable parts or accessories supplied with the product which are
expected to become inoperative or unusable after a reasonable period of
use.
Merchandise sold by Pulsar Products Inc. which has been manufactured by
and identified as the product of another company, such as gasoline
engines. The product manufacturer's Warranty, if any, will apply.
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS,
DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY
DEFECTS, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT
COVERED BY THIS WARRANTY. Some states do not allow the
exclusion, so it may not apply to you.
IMPLIED WARRANTIES, INCLUDING THOSE OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL
PURCHASE. Some states do not allow limitations on how long an implied
warranty lasts, so the above limitations may not apply.
25