Pulsar PG10000, Owner'S Manual

Page 1: ...10000 10000 1 866 591 8921 ...

Page 2: ...tions 12 13 Operation 14 enance nstallation 22 23 p e cifications 24 eneral Parts Listing 29 2 al Precautions General Parts D Specifications 19 General Parts Listing Wiring iagram Troubleshooting Installation Inspection Cleaning and Maintenance Battery 25 20 Operation 10000W Generator ...

Page 3: ...ure 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 AN...

Page 4: ...ASOLINE 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 a...

Page 5: ...gine 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 SENSIT...

Page 6: ...zed 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 bo...

Page 7: ... 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 connecti...

Page 8: ... 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 generat...

Page 9: ...nsed 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 engi...

Page 10: ...ll 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 damag...

Page 11: ... 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 immediat...

Page 12: ...ol Panel Frame Wheel Fuel gauge Battery Fuel tank Oil dipstick Drain plug Engine key Recoil starter Fuel valve Handel Air filter Choke lever Voltage frequency hour meter Thermal protector 120V 240V Twist lock outlet 50 AMP RV outlet 120V Duplex outlet DC terminal 30 AMP RV outlet One way valve ...

Page 13: ...line engine Fuel Type Unleaded gasoline C 6 6 gallons 25 liters Running time 9 hours approx Fuel gauge included Weight Approximate weight 210lbs 7500W Generator Battery To start generator with electric start you will need a battery included Also this generator can also be started withthe pull start Photos below demonstrate battery plate attachment Put the battery on the frame have the battery asse...

Page 14: ...d 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 k Lever Choke lever Control panel 14 Fuel Tank Cap Fuel tank Pull start Handle Fuel valve Air filter Battery CAUTION PRIOR TO FIRST USING THE GENERATOR THE ENGINE MUST BE FILLED WITH A HIGH QUALITY SAE 10W30 GRADE ENGINE OIL TO DO SO U...

Page 15: ...e lever all the way 15 7 OL LUNPUL Z P JO VU OL 9 5 WVZP PVU OL LUNPUL Z P JO LUHISLZ HUK KPZHISLZ OL PNUP PVU Z Z LT ON OFF To stop the engine ON To run the engine E Start To start the engine OL M LS HS L PZ SVJH LK UKLY OL M LS HUR OLU OL HS L SL LY PZ PU OL 65 WVZP PVU M LS PZ HSSV LK V MSV MYVT OL M LS HUR V OL JHYI YL VY L Z YL V YL YU OL M LS HS L SL LY V OL 6 WVZP PVU HM LY Z VWWPUN OL LUNP...

Page 16: ...NER 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 T...

Page 17: ...CONNECT THE POSITIVE LEAD OF THE POWER CORD TO THE POSITIVE TERMINAL ON THE GENERATOR AND CONNECT THE NEGATIVE LEAD OF THE POWER CORD TO THE NEGATIVE TERMINAL ON THE GENERATOR 3 If using only a 12V volt DC tool or equipment turn the 120 volt AC If using only a 12V volt DC tool or equipment turn the 120 volt AC 4 Start and run the engine as described above 5 When finished using the generator turn t...

Page 18: ...scard it if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 4 Measure the plug gap with a feeler gauge 5 Check that the spark plug washer is in good condition 7 After the spark plug is seated tighten with a spark plug wrench to compress the washer NOTE THE SPARK PLUG MUST BE SECURELY TIGHTENED AN IMPROPERLY TIGHTENED SPARK PLUG CAN BECOME VERY HOT A...

Page 19: ...o not use damaged equipment Before each use make sure the engine s oil and gas levels are adequate If necessary fill the crankcase until the oil level is even with the oil fill hole and or fill the fuel tank Before each use remove all debris with a soft brush rag or vacuum Lubricate all moving parts using a premium quality lightweight machine oil Every hours of use drain the old engine oil and rep...

Page 20: ...EQUIPMENT WHEN MOVING IT TO THE INSTALLATION LOCATION ALWAYS CONNECT HOIST LINES TO THE FRAME OF THE GENERATOR General Location Make sure to locate and install the generator outdoors where cooling air is readily available Install the generator so that the air inlets and outlets are not blocked by obstructions such as bushes trees or snow drifts Locating it in the path of heavy winds or snowdrifts ...

Page 21: ... to the concrete slab using 3 8 diameter expansion anchor bolts not supplied Grounding NOTE IT IS RECOMMENDED THAT ONLY A TRAINED AND LICENSED ELECTRICIAN PERFORM THIS PROCEDURE Connect a 6 AWG grounding wire not included from the ground connector 8 on the generator to a grounding rod not included that has been driven at least 24 inches deep into the earth The grounding rod must be an earth driven...

Page 22: ...arburetor Clean the fuel sediment cup outlets Is the AC circuit breaker ON Turn the AC circuit breaker ON Check the electrical appliance or equipment for any defects Replace the electrical appliance or equipment Take the electrical appliance or equipment to an electrical shop for repair tor to an authorized agent generator dealer No electricity at the AC If the engine still does not start take the...

Page 23: ...20V 240V 60Hz 50A 25A Continuous rated Wattage 6 000 Peak Wattage 7 500 Outlet 4 AC 120V 2 AC 120V 240V twist lock outlet 23 Specifications AC electrical DC electrical none none Gasoline engine Fuel Type Unleaded gasoline C 6 6 gallons 25 liters Running time 9 hours approx Fuel gauge included Weight Approximate weight 210lbs 7500W Generator ...

Page 24: ... BrR BrownRed Bu Blue Gr Gray LB LightBlue Bl Black W White R Red YG YellowGreen BlW BlackWhite G Green IgnitionSwitchConnecting 20A 20A M Oilalertunit BlW QVR0 5mm Ignitioncoil Spark plug Br QVR0 5mm Br QVR0 5mm O QVR0 5mm O QVR0 5mm O QVR0 5mm BrRQVR0 5mm BrRQVR0 5mm RQVR6mm W QVR6mm Fuel protector Motor Battery Fuelsolenoid valve Chargecoil ControlBoxDiagram OFF ON start Bl QVR0 5mm Bl QVR0 5mm...

Page 25: ... A PLAIN WASHER 1 8 DJ188F 15009 A OIL SEAL Φ 8 Φ 14 5 1 9 DJ188F 15003 A PIN LOCK 1 10 DJ188F 18200 B OIL SENSOR ASSEMBLY 1 11 GBT16674 B6 16 FLANGE BOLT M6 16 2 12 DJ168F 18300 A AMPLIFIER 1 13 GBT16674 B6 12 FLANGE BOLT M6 12 1 PG10000 ENGINE PARTS LISTING This list is provided for reference purposes only All repairs and part replacement should be performed by a qualified technician Some parts ...

Page 26: ...GULATING GEAR 1 4 GB276 89 6207 BEARING RADIAL BALL 6207 1 5 DJ188FD 11001 A CRANKCASE COVER ASSEMBLY 1 6 DJ188FD 11007 D DIPSTICK 1 7 DJ188F 11014 A OIL SEAL Φ 35 Φ 52 8 1 8 GBT820 B5 12 FLANGE BOLT M5 12 3 9 DF6500H 11032 A CRANKCASE COVER GUARD 1 10 GBT16674 B8 35 FLANGE BOLT M8 35 5 11 GBT16674 B8 40 FLANGE BOLT M8 40 2 26 ...

Page 27: ...0 4 4 DJ188F 11015 A BOLT 1 5 DJ188F 11300 C CYCLINDER HEAD COVER ASSEMBLY 1 6 DJ188F 11011 A GASKET CYCLINDER HEAD COVER 1 7 DJ188F 11200 BE CYLINDER HEAD ASSEMBLY 1 8 DJ188F 11009 A PIN 1 9 DJ188F 11010 C GASKET CYLINDER HEAD 1 10 GBT16674 B6 12 FLANGE BOLT M6 12 1 11 DJ188F 11012 A AIR LEADING COVER 1 12 DJ168F 14002 A BOLT STUD M8 35 2 27 ...

Page 28: ...ASSEMBLY 1 2 GB276 89 6202 BALL RADIAL BEARING 6202 2 3 DJ188F 12004 A BALANCING SHAFT 1 4 DJ190F 12300 C PISTON RING SET 1 5 DJ188F 12003 A PISTON PIN CIR CLIP 2 6 DJ190F 12001 D PISTON 1 7 DJ188F 12002 A PISTON PIN 1 8 DJ190F 12200 AE CONNECTING ROD ASSEMBLY 1 28 ...

Page 29: ...005 A EXHAUST VALVE RETURNER 1 5 DJ188F 13004 A INTAKE VALVE RETURNER 1 6 DJ188F 13003 A VALVE SPRING 2 7 DJ188F 13002 A EXHAUST VALVE 1 8 DJ188F 13001 A INTAKE VALVE 1 9 DJ188F 13011 A OIL SEAL VALVE 1 10 DJ188F 13010 A OIL SEAL 1 11 DJ188F 13008 A ROD PUSH 2 12 DJ188F 13009 A TRAPPET LITTER VALVE 2 13 DJ188F 13100 AE CAMSHAFT ASSEMBLY 1 29 ...

Page 30: ...F 14109 A FUEL INJECTION NEEDLE 1 5 14112 100 MAIN JET 1 6 DJ188F 14106 A FLOAT 1 7 DJ188F 14101 B OIL CUP 1 8 DJ188F 14005 B GASKET CARBURETOR 1 9 DJ188F 14004 A CONNECTING BLOCK CARBURETOR 1 10 DJ188F 14003 B GASKET INLET 1 11 DJ188F 11039 B Q CLIP 2 12 DJ168F 14008 A CLIP FUEL LINE 1 13 DJ188FD 14007 C FUEL LINE 1 14 DJ168FD 14014 A RUBBER FUEL LINE 1 30 ...

Page 31: ...8FD 14200 C AIR FILTER ASSEMBLY 1 2 DJ188FD 14204 A AIR FILTER CAP 1 3 DJ188FD 14201 A FILTER ELEMENT 1 4 DJ188FD 14203 C BOTTOM CAP AIR FILTER 1 5 GB6177 N 6 NUT M6 3 6 DJ188FD 11013 A TUBE BREATHER 1 7 DF6500H 14205 A BRACKET AIR FILTER 1 31 ...

Page 32: ... BOLT M6 12 5 2 DJ188F 16100 F 116 CASE COMP RECOIL STARTER 1 3 DJ168F 16110 A STARTER 1 4 DJ188F 16111 A ROPE 1 5 DJ188F 16130 F 116 STARTER COMP RECOIL 1 6 92140 B6 8 FLANGE BOLT M6 8 3 7 GBT97 W 6 PLAIN WASHER 3 8 DJ188F 16101 A 116 RECOIL STARTER CASE 1 32 ...

Page 33: ...E BOLT M6 12 2 2 DJ188FD 15200 A SPEED REGULATOR 1 3 DJ188F 15008 A FINE REGULATING SPRING C 1 4 DJ188F 15006 A PULLING ROD 1 5 DJ188F 15007 A BACK SPRING B 1 6 DJ188F 15004 A SPEED REGULATING ARM 1 7 DJ168F 15005 A LOCK BOLT 1 8 GB6177 N 6 FLANGE NUT M6 1 33 ...

Page 34: ...WHEEL ASSEMBLY 1 5 GBT16674 B6 25 FLANGE BOLT M6 25 2 6 DJ188F 18100 C IGNITION COIL ASSEMBLY 1 7 GBT16674 B6 8 FLANGE BOLT M6 8 1 8 DJ168F 18007 A CLAMPER CORD A 1 9 GBT16674 B8 35 FLANGE BOLT M8 35 2 10 DJ188F 18007 A CLAMPER CORD A 1 11 DJ188F 18600 A ALTERNATOR ASSEMBLY 1 12 GBT16674 B6 28 FLANGE BOLT M6 28 2 13 DJ168F 18004 A CHARGE COIL 1 34 ...

Page 35: ...7 DF3800H 14300 CY 116 FUEL TANK ASSEMBLY 1 8 DF3000H 14008 A CLIP FUEL LINE 1 9 DF3000H 14008 B CLIP FUEL LINE 1 10 DF6500H 14803 A CONNECTING PIPE 1 11 784810 NT ONE WAY VALVE ASSEMBLY 1 12 DF6500H 34125 A GASKET ONE WAY VALVE 1 PG10000 GENERAL PARTS LISTING This list is provided for reference purposes only All repairs and part replacement should be performed by a qualified technician Some parts...

Page 36: ...Y 1 4 34203 010 SWITCH ASSEMBLY 1 5 34290 002 VOLTAGE FREQUENCY HOUR METER 1 6 34204 038 GROUNDING POST 1 7 34204 039 GROUNDING POST 1 8 34204 062 120V DUPLEX OUTLETS 2 9 34204 015 30 AMP RV OUTLET 1 10 34204 004 50 AMP RV OUTLET 1 11 34204 003 120V 240V TWIST LOCK OUTLET 1 12 34208 021 THERMAL PROTECTOR 2 13 34208 028 THERMAL PROTECTOR 2 36 ...

Page 37: ... M8 2 4 DJ188FD 14009 A MUFFLER CONNECTING PIPE 1 5 GBT16674 B8 30 FLANGE BOLT M8 30 2 6 DF9000H 14400 DB MUFFER ASSEMBLY 1 7 GBT16674 B6 12 FLANGE BOLT M6 12 7 8 DF3800H 14018 A OUTER HOOD 1 9 DF3800H 14403 A SIDE HOOD 1 10 GBT16674 B8 16 FLANGE BOLT M8 16 4 11 DF3800H 14404 A MUFFLER STAY 1 12 DF9000H 14416 A INNER HOOD 1 37 ...

Page 38: ...10 GBT97 W 10 PLAIN WASHER 1 11 GBT93 LW 10 SPRING WASHER 2 12 DF9000H 33015 A BOLT M6 175 4 13 DF9000H 33021 A BOLT M5 230 2 14 DF9000H 33003 A BOLT M10 1 25 283 1 15 GBT16674 B5 12 FLANGE BOLT M5 12 4 16 GBT16674 B5 16 FLANGE BOLT M5 16 3 17 DF8000H 33011 A VOLTAGE REGULATOR 1 18 DF3800H 33006 A 116 ALTERNATOR END COVER 1 19 GBT862 CW 5 TOOTH TYPE WASHER 1 20 DF6500H 34216 A GROUNDING WIRE 1 21 ...

Page 39: ...20 A 117 SUPPORT FRAME 2 10 GBT16674 B8 16 FLANGE BOLT M8 16 4 11 DF9000H 31204 A VIBRATION ISOLATION PAD SQUARE FRAME 2 12 92140 B6 25 FLANGE BOLT M6 25 2 13 GB6170 N 8 FLANGE NUT M8 4 14 DF3800H 31202 A ISOLATOR B 2 15 GB6177 N 10 FLANGE NUT M10 4 16 DF3800H 31201 A ISOLATOR A 2 17 GB6177 N 12 FLANGE NUT M12 2 18 DF6500H 31017 V WHEEL 2 19 DF3000H 31018 A WHEEL AXLE ASSEMBLY 2 20 DF2500H 31019 B...