Pulsar PG7500B Owner'S Manual Download | Manualshive

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Safety Guidelines

Gui

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General

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Battery

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aintenance

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pe ci fications

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eneral Parts Listing

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WARNING! READ AND UNDERSTAND ALL SAFETY PRECAUTIONS
IN THIS MANUAL BEFORE OPERATING. FAILURE TO COMPLY WITH
INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PERSONAL
INJURY, PROPERTY DAMAGE, AND/ OR VOIDING OF YOUR
WARRANTY. ALL POWER AMERICA WILL NOT BE LIABLE FOR ANY
DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS.

2

al Precautions

General Parts

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Specifications

23

General Parts Listing

Wiring iagram

Troubleshooting

Installation

Inspection, Cleaning and Maintenance

Battery

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24

Operation

7500W Generator

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Summary of Contents for PG7500B

Page 1: ...7500 7500B 1 866 591 8921 ...

Page 2: ...RE OPERATING FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PERSONAL INJURY PROPERTY DAMAGE AND OR VOIDING OF YOUR WARRANTY ALL POWER AMERICA WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS 2 al Precautions General Parts D Specifications 23 General Parts Listing Wiring iagram Troubleshooting Installation Inspection Cleaning and Maintenance Batt...

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: ...el tank Frame Control Panel Wheel Drain plug Recoil starter Fuel valve Voltage frequency hour meter Thermal protector Twist lock outlet 120V Twist lock outlet Battery Handle Air filter Choke lever 120V Duplex outlet DC terminal 120V 240V Oil dipstick Engine key Thermal protector Fuel gauge 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: ...nt 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 k Lever Fuel valve Choke lever Control panel Fuel tank 14 Fuel Tank Cap Pull start 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 RE...

Page 15: ...th 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 Be sure to connect the Electric Start Battery to the Dual fuel Generator set the connection is secured by using the fastener at the battery terminal before operation Improper connection will cause malfuncti...

Page 16: ...allow engine to run until all remaining gasoline has been used After the engine stops continue to step 2 2 Ensure that the fuel valve lever is in the CLOSE position 3 After tank is properly connected turn on propane fuel source Refer to LPG connection procedure Electronic Start Method 4 Push LPG Converter button 2 3 times to bleed air in the LPG path 5 Push the choke lever in OPEN position 6 Conti...

Page 17: ...ion 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 Batteries produce explosive gases Keep sparks flames and cigarettes away from the battery To prevent the possibility creating sparks near the battery conn...

Page 18: ... attempts contact 3 Follow steps 6 7 from the Recoil Start Method customer support Repeated attempts could damage the ignition mechanism alternator 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 ...

Page 19: ...he fuel valve lever back to the OFF position 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 ...

Page 20: ...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 21: ...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 22: ...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 23: ... 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 0 hours of use drain the old engine oil and re...

Page 24: ...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 25: ... 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 26: ...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 27: ...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 27 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 28: ...wn O Orange 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 ...

Page 29: ...parts parts parts may may may may not not not not be be be be available available available available as as as as single single single single replacements replacements replacements replacements NO NO NO NO PART PART PART PART NO NO NO NO DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q TY Q TY Q TY Q TY REMARK REMARK REMARK REMARK 1 DJ188F 11014 A OIL SEAL Φ35 Φ52 8 1 2 DJ188F 11004 A DRAIN PLUG ...

Page 30: ... 11003 B CRANKCASE GASKET 1 3 DJ188F 15100 A SPEED REGULATING 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 Φ35 Φ52 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 30 ...

Page 31: ...PARK PLUG F7TC 1 3 GBT16674 B10 80 FLANGE BOLT M10 80 4 4 DJ188F 11015 A BOLT 1 5 DJ188F 11300 H CYCLINDER HEAD COVER ASSEMBLY 1 6 DJ188F 11011 A GASKET CYCLINDER HEAD COVER 1 7 DJ188F 11200 LE CYLINDER HEAD ASSEMBLY 1 8 DJ188F 11009 A PIN 1 9 DJ190F 11010 B 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 31 ...

Page 32: ...RK REMARK REMARK REMARK 1 DJ190F 12100 BE CRANKSHAFT 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 32 ...

Page 33: ...A PUSH ROD GUIDE 1 3 DJ188F 13006 A CAP 1 4 DJ188F 13005 A VALVE RETURNER EXHAUST 1 5 DJ188F 13004 A VALVE RETURNER INTAKE 1 6 DJ188F 13003 A VALVE SPRING 2 7 DJ188F 13002 B 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 PUSH ROD 2 12 DJ188F 13009 A TRAPPET LITTER VALVE 2 13 DJ188F 13100 AE CAMSHAFT ASSEMBLY 1 33 ...

Page 34: ...14100 D CARBURETOR ASSEMBLY 1 3 DJ188F 14005 B GASKET CARBURETOR 1 4 DJ188F 14004 A 14005 B CONNECTING BLOCK CARBURETOR 1 5 DJ188F 14003 B 14004 A GASKET INTET 1 6 DJ188F 11039 B 14003 B Q CLIP ASKET INLET 2 7 DJ168F 14008 A 11039 B CLIP FUEL LINE CLIP 1 8 DJ188FD 14007 C 14008 A FUEL LINE LINE 1 9 DJ168FD 14014 A 14007 C RUBBER FUEL LINE LINE 1 10 DJ168FD 14014 A RUBBER FUEL LINE 1 34 ...

Page 35: ...TY Q TY Q TY Q TY REMARK REMARK REMARK REMARK 1 DJ188FD 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 35 ...

Page 36: ... REMARK REMARK REMARK REMARK 1 GBT16674 B6 12 FLANGE 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 36 ...

Page 37: ...Y REMARK REMARK REMARK REMARK 1 GBT16674 B6 12 FLANGE 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 37 ...

Page 38: ... 1 3 DJ188F 16002 A IMPELLER 1 4 DJ188F 16200 BE FLYWHEEL 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 3...

Page 39: ...gle single replacements replacements replacements replacements NO NO NO NO PART PART PART PART NO NO NO NO DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION Q TY Q TY Q TY Q TY REMARK REMARK REMARK REMARK 1 DF3500H 32022 A CLIP COMP 2 2 DF3500H 14036 A LOW PRESSURE PIPE 1 3 DF3500H 14035 A HIGH PRESSURE PIPE 1 4 DF9000H 35000 B DECOMPRESSION VALVE 1 5 GBT16674 B6 12 FLANGE BOLT M6 12 2 6 LPG4400E 31...

Page 40: ...2500H 34106 A GASKET 4 3 DFD6500H 34100 QQ01 CONTROL PANEL ASSEMBLY 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 OUTLET 2 9 34204 003 120V 240V TWIST LOCK OUTLET 1 10 34204 002 120V TWIST LOCK OUTLET 1 11 34208 021 THERMAL PROTECTOR 2 12 34208 022 THERMAL PROTECTOR 2 40 ...

Page 41: ... 2 GBT93 LW 8 SPRING WASHER 4 3 GB6170 N 8 FLANGE NUT M8 2 4 DJ188FD 14009 A MUFFLER CONNECTING PIPE 1 5 GBT16674 B8 30 FLANGE BOLT M8 30 2 6 DF5500H 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 DF5000H 14416 A INNER HOOD 1 41 ...

Page 42: ...GBT97 W 5 PLAIN WASHER 2 9 GBT93 LW 5 SPRING WASHER 9 10 GBT97 W 10 PLAIN WASHER 1 11 GBT93 LW 10 SPRING WASHER 2 12 DF5500H 33015 A BOLT M6 175 4 13 DF6500H 33021 A BOLT M5 214 2 14 DF5500H 33003 A BOLT M10 1 25 270 1 15 GBT16674 B5 12 FLANGE BOLT M5 12 4 16 GBT16674 B5 16 FLANGE BOLT M5 16 3 17 DF3800H 33011 A VOLTAGE REGULATOR 1 18 DF3800H 33006 A 116 ALTERNATOR END COVER 1 19 GBT862 CW 5 TOOTH...

Page 43: ...RAME ASSEMBLY 1 8 GB6170 N 6 FLANGE NUT M6 4 9 DF6500H 31020 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 NUT FLANGE M10 4 16 DF3800H 31201 A ISOLATOR A 2 17 GB6177 N 12 FLANGE NUT M12 2 18 DF6500H 31017 V WHEEL 2 1...

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