Pulsar PG4500B Owner's Manual
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Pulsar PG4500B Owner's Manual

4500 watt generator
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Summary of Contents for Pulsar PG4500B

  • Page 1 4500 4500B...

  • Page 2: Table Of Contents

    Topic Page Safety Guidelines General a al Precautions elines General Parts Operation Inspection, Cleaning and Maintenance Installation roubles ooting tenance Specifications Wiring iagram General Parts Listing...

  • Page 3: Safety Guidelines

    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.

  • Page 4: General A Al Precautions Gui Elines D

    7500W 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 Carbon Monoxide When this tool is running, ensure that the area is well ventilated. Never run the engine in an enclosed area.
  • Page 5 CAUTION: ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO THE EQUIPMENT. PULSAR PRODUCTS INC.IS NOT RESPONSIBLE FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN APPROVED LINE CONDITIONER.
  • Page 6 7500W Generator General Precautions (cont’d) 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. •...
  • Page 7 Owner’s Manual General Precautions (cont’d) Electrical Safety (cont’d) • 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. •...
  • Page 8 7500W Generator General Precautions (cont’d) Personal Safety (cont’d) • 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.
  • Page 9 Servicing Maintain 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. Generator service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.
  • Page 10 7500W Generator General Precautions (cont’d) Installation (cont’d) • 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. • The generator weighs lbs (approximately) .
  • Page 11 Owner’s Manual General Precautions (cont’d) Mechanical (cont’d) • 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.

  • Page 12: General Parts

    Owner’s Manual Gen ra l Pa s Fuel tank cap Frame One way valve Fuel tank Choke lever Control Panel Air filter Wheel Fuel valve Recoil starter On/off switch Oil dipstick Drain plug Voltage frequency 120V Duplex outlet hour meter Thermal protector 120V/240V Twist-lock outlet...

  • Page 13: Operation

    Owner’s Manual Operation Fuel tank Choke lever Control panel Fuel valve Pull start NOTE: THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE CONTROLS MENTIONED BELOW. CAUTION: PRIOR TO FIRST USING THE GENERATOR, THE ENGINE MUST BE FILLED WITH A HIGH QUALITY SAE 10W-30 GRADE ENGINE OIL. TO DO SO, UNSCREW AND REMOVE THE ENGINE’S OIL DIPSTICK LOCATED AT THE BOTTOM OF THE ENGINE CRANKCASE.
  • Page 14 Operation (cont’d) Connecting to LPG Fuel Source When using the fuel as LPG, make sure that there is no gasoline in the engine. 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.
  • Page 15 Operation (cont’d) 4. Push LPG Converter button 2-3 times to bleed air in the LPG path. 5. Push the choke lever in OPEN position. 6. Continue to desired start-up method. IF USING GASOLINE FUEL SOURCE 1. Ensure that there is no propane in the engine. If LPG was used in the most recent operation, start engine by following the steps outlined in the Propane Fuel Source section on previous page.
  • Page 16 Operation (cont’d) 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.
  • Page 17 Operation (cont’d) Stopping the Generator Set 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.
  • Page 18 CAUTION: ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO THE EQUIPMENT. PULSAR PRODUCTS INC. IS NOT RESPONSIBLE FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN APPROVED LINE CONDITIONER.
  • Page 19 7500W Generator Operation (cont’d) Powering 12 Volt DC tools and Equipment: 1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage capacity (12VDC) 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.
  • Page 20 Owner’s Manual Operation (cont’d) Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: NHSP LD F7TC. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1.

  • Page 21: Inspection, Cleaning And Maintenance

    Owner’s Manual Inspection, Cleaning, and Maintenance WARNING! ALWAYS MAKE SURE THE ENGINE POWER SWITCH (2) IS IN ITS “OFF” POSITION. DISCONNECT THE SPARK PLUG WIRE FROM THE ENGINE. AND ALLOW SUFFICIENT TIME FOR THE ENGINE AND GENERATOR TO COMPLETELY COOL BEFORE PERFORMING ANY INSPECTIONS, MAINTENANCE, OR CLEANING.

  • Page 22: Installation

    7500W Generator Installation NOTE: PRIOR TO POWERING TOOLS AND EQUIPMENT MAKE SURE THE GENERATOR’S RATED VOLTAGE, WATTAGE AND AMPERAGE CAPACITY IS ADEQUATE TO SUPPLY ALL ELECTRICAL LOADS THAT THE UNIT WILL POWER. IF POWERING EXCEEDS THE GENERATOR’S CAPACITY, IT MAY BE NECCESSARY TO GROUP ONE OR MORE OF THE TOOLS AND/OR EQUIPMENT FOR CONNECTION TO A SEPERATE GENERATOR.
  • Page 23 Owner’s Manual Installation (cont’d) Supporting and Mounting Mount the generator on a concrete slab capable of supporting the weight of the generator. The slab must extend on all sides beyond the frame by at least one foot. Contact a cement contractor for slab specifications if necessary.

  • Page 24: T Roubles Ooting H Tenance

    Troubleshooting Note: Troubleshooting problems may have similar causes and solutions. PROBLEM POSSIBLE CAUSE SOLUTION Is there fuel in the tank? Refill the fuel tank. Is there enough oil in the The engine Add the recommended oil. engine? will not start Is the spark plug in good Readjust gap and dry the spark plug.

  • Page 25: Specifications

    7500 W Ge n erato r Specifications AC electrical Current Output 120V/240V 60Hz, 50A/25A Continuous/rated Wattage 6,000 Peak Wattage 7,500 Outlet 4 AC 120V, 2 AC 120V/240V twist-lock outlet DC electrical none none Gasoline engine Horsepower Type 4-cycle OHV air-cooled recoil start Displacement 389cc Oil capacity...

  • Page 26: Wiring D Iagram

    Wiring Diagra Breaker Breaker L14-30R GNAJ TT-30R 5-20R 3in1 DigitalMeter BlQVR0.5mm Ÿ IgnitionSwitch Ÿ GrQVR1.5mm Ÿ DCcoil1 LBQVR1.5mm Ÿ BlQVR1.5mm Ÿ LBQVR1.5mm 2510 Ÿ Ÿ QVR0.5mm QVR0.5mm ControlBoxDiagram Ÿ WQVR0.5mm Ÿ QVR0.5mm Ÿ RQVR0.5mm Ÿ BuQVR0.5mm Ÿ BuQVR0.5mm Ÿ QVR0.5mm OilAlert Unit Generator...

  • Page 27: General Parts Listing

    PG4500B ENGINE PARTS LISTING This This This This list list list list is is is is provided provided provided provided for for reference reference reference reference purposes purposes purposes purposes only.All only.All only.All only.All repairs repairs repairs repairs and and part...
  • Page 28 PART NO..DESCRIPTION Q'TY REMARK PART PART PART NO DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY REMARK REMARK REMARK DJ168FD-11001-A CRANKCASE COVER ASSEMBLY GB276-89-6205 BEARING RADIAL BALL 6205 DJ168F-11002-A PIN Φ8×14 DJ168F-11014-A OIL SEAL Φ35×Φ52×8 CRANKCASE GASKET DJ168F-11003-B DJ168F-11007-D DIPSTICK GBT16674-B8-30...
  • Page 29 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK GBT16674-B6-12 FLANGE BOLT M6*12 DJ168F-11300-C CYCLINDER HEAD COVER ASSEMBLY DJ168F-11011-A GASKET, CYCLINDER HEAD COVER DJ168F-18500-A SPARK PLUG F7TC GBT5789-B8-60 FLANGE BOLT M8*60 DJ168FD-14001-B BOLT STUD M6*96...
  • Page 30 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK DJ168F-12003-A PISTON PIN CIR-CLIP DJ170FB-12001-B PISTON DJ170F-12002-A PISTON PIN DJ170F-12200-BE CONNECTING ROD ASSEMBLY DJ170F-12300-B PISTON RING SET DJ170FB-12100-BQE CRANKSHAFT ASSEMBLY...
  • Page 31 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK ROCKER ARM ASSEMBLY DJ168F-13200-A DJ168F-13300-A PUSH ROD GUIDE DJ168F-13006-A DJ168F-13005-A VALVE RETURNER EXHAUST DJ168F-13004-A VALVE RETURNER INTAKE VALVE SPRING DJ168F-13003-A DJ170F-13002-B EXHAUST VALVE...
  • Page 32 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK SPACER,CARBURETOR DJ168F-14027-A CARBURETOR ASSEMBLY DJ168FD-14100-D DJ168F-14005-B GASKET, CARBURETOR DJ168F-14004-A CONNECTING BLOCK CARBURETOR DJ168F-14003-B GASKET INLET DJ168F-14008-A CLIP,FUEL LINE DJ168FD-14014-A RUBBER ,FUEL LINE DJ168FD-14007-C FUEL LINE...
  • Page 33 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK DJ168FD-14204-B AIR FILTER CAP DJ168FD-14201-B FILTER ELEMENT GB6177-N-6 NUT M6 DJ168FD-14203-E BOTTOM CAP,AIR FILTER GBT16674-B6-12 BOLT STUD M6*12 DF2500H-14205-A BRACKET,AIR FILTER DJ168FD-11013-A TUBE BREATHER...
  • Page 34 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK GBT16674-B6-12 FLANGE BOLT M6*12 DJ168F-16100-F-116 CASE COMP RECOIL STARTER DJ168F-16110-A STARTER DJ168F-16111-A ROPE DJ168F-16130-F-116 STARTER COMP,RECOIL 92140-B6-8 FLANGE BOLT M6*8 GBT97-W-6 PLAIN WASHER DJ168F-16101-A-116...
  • Page 35 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK FINE REGULATING SPRING C DJ168F-15008-A PULLING ROD DJ168F-15006-A BACK SPRING B DJ168F-15007-A SPEED REGULATING ARM DJ168F-15004-A DJ168F-15005-A LOCK BOLT GB6177-N-6 FLANGE NUT M6...
  • Page 36 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK DJ168F-16205-A NUT M16*1.5 STARTING CUP DJ168F-16000-A DJ168F-16002-A IMPELLER DJ168F-16200-AE FLYWHEEL ASSEMBLY GBT16674-B6-25 FLANGE BOLT M6*25 DJ168F-18100-C IGNITION COIL ASSEMBLY...
  • Page 37 PG4500B LPG+GASOLINE GENERAL PARTS LISTING This This This This list list list list is is is is provided provided provided provided for for reference reference reference reference purposes purposes purposes purposes only.All only.All only.All only.All repairs repairs repairs repairs and...
  • Page 38 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK GBT16674-B6-16 FLANGE BOLT M6*16 DF2500H-34106-A GASKET DF3500H-34100-QQ02 CONTROL PANEL ASSEMBLY 34203-011 SWITCH ASSEMBLY 34290-002 VOLTAGE.FREQUENCY.HOUR METER 34202-017 TRANSFER SWITCH 34204-038 GROUNDING POST 34204-039...
  • Page 39 PART PART PART PART NO NO..DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q'TY Q'TY Q'TY Q'TY REMARK REMARK REMARK REMARK GBT16674-B6-12 FLANGE BOLT M6*12 DF2500H-14018-A OUTER HOOD GB6170-N-8 FLANGE NUT M8 GBT93-LW-8 SPRING WASHER DJ168F-14006-C GASKET,EXHAUST DF3500H-14400- MUFFER ASSEMBLY GBT16674-B8-16 FLANGE BOLT M8*16 DF2500H-14404-B...
  • Page 40 PART PART NO..DESCRIPTION DESCRIPTION Q'TY Q'TY REMARK REMARK PART PART NO DESCRIPTION DESCRIPTION Q'TY Q'TY REMARK REMARK DF3500H-33100-BJ-23602 ALTERNATOR ASSEMBLY ROTOR DF3500H-33120-BJ CARBON BRUSH COMP. DF1800H-33001-A STATOR DF3500H-33110-BJ-23602 DF3800H-33002-B GROUNDING POST COMP. DF1800H-33005-C ALTERNATOR END BRACKET GBT97-W-8 PLAIN WASHER GBT93-LW-8...
  • Page 41 DESCRIPTION Q'TY PART REMARK PART PART ..DESCRIPTION DESCRIPTION DESCRIPTION REMARK REMARK REMARK RUBBER,HANDLE DF6500H-31016-A DF3000H-31058-A-117 HANDLE ASSEMBLY GBT16674 - B8- 35 FLANGE BOLT M8*35 GB6170 - N - 6 FLANGE NUT M6 DF3000H - 31014 - A - 117 INSULATOR,HANDLE FLANGE NUT M8 GB6177-N-8...

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