4500 4500B 1-866-591-8921
Topic Page Safety Guidelines 3 Precautions General al elines d aGui 4 General Parts 12 Operation 13 Inspection, Cleaning and Maintenance 21 Installation 22 T roubles hooting tenance 24 Specifications 25 Wiring D iagram 26 General Parts Listing 27 29 2
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.
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 ON. 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.
Owner’s Manual General Precautions (cont’d) Gasoline and Oil (cont’d) • 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.
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. • Keep bystanders, children, and visitors away while operating a generator. Provide barriers or shields as needed.
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. • The generator must be earth-grounded for fixed installations in accordance with all relevant electrical codes and standards before operation.
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. • Do not overreach. Keep proper footing and balance at all times. • Use safety equipment. Always wear eye protection.
Owner’s Manual General Precautions (cont’d) 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. When servicing a generator, use only identical replacement parts.
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 120lbs (approximately) . Two or more people should assist when moving or lifting this product. Never lift the generator using the engine or alternator lifting lugs.
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. • Keep access doors on enclosures closed and locked when access is not required.
Owner’s Manual Gen e ra l Pa r t s One way valve Fuel tank cap Fuel tank Frame Choke lever Control Panel Air filter Wheel Fuel valve Recoil starter On/off switch Drain plug Oil dipstick Voltage frequency hour meter 120V Duplex outlet Thermal protector 120V/240V Twist-lock outlet DC terminal 30 AMP RV outlet Grounding terminal 12
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. FILL THE ENGINE’S CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED LINE ON THE DIPSTICK.
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. Do not turn on propane source prior to following the steps outlined. Starting the Generator Set Ground Terminal Before using generator, a ground wire must be connected to the ground terminal.
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. Once running, shut off the propane fuel source and allow the engine to use up the remaining fuel.
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. Using the Generator Set 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.
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.
Owner’s Manual Operation (cont’d) 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.
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. 2. Connect the power cord of a 12 VDC powered tool or equipment to the DC Terminals.
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. Remove the spark plug cap. 2. Use a spark plug wrench to remove the spark plug. 3. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped.
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. • Before each use, inspect the generator.
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. Electrical and other permits may be required for the installation of emergency power systems.
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. Attach the frame to the concrete slab using 3/8” diameter expansion anchor bolts (not supplied).
Troubleshooting Note: Troubleshooting problems may have similar causes and solutions. PROBLEM POSSIBLE CAUSE Is there fuel in the tank? The engine will not start Is there enough oil in the condition? Add the recommended oil. Readjust gap and dry the spark plug. Replace it if necessary. Is the fuel reaching the carburetor? at the AC outlets Refill the fuel tank.
7500W Generator 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 13 Type 4-cycle OHV air-cooled recoil start Displacement 389cc Oil capacity 0.63 quart (0.6 liter) EPA approved yes Fuel Type Unleaded gasoline C 6.6 gallons (25 liters) Running time 9 hours (approx.) Fuel gauge included Approximate weight 210lbs.
Wiring Diagra R Breaker Gr R W R R R Gr W Bl W GNAJ Breaker W L14-30R R Bl 3in1 DigitalMeter TT-30R 5-20R YG BlQVR0.5mm IgnitionSwitch DCcoil1 GrQVR1.5mm LBQVR1.5mm BlQVR1.5mm LBQVR1.5mm 2510 WQVR0.5mm W R Bu Bu RQVR0.5mm BuQVR0.5mm BuQVR0.5mm R QVR0.5mm Generator Block O Orange Br Brown BrR BrownRed Bu Blue LB LightBlue Gr Gray Bl Black R Red W White LED Bl QVR0.5mm ControlBoxDiagram BlW A V R Bl QVR0.5mm BlW QVR0.5mm Bl Bl BlW OilAlert Unit W QVR0.
PG4500B 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 may not be available as single replacements. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO NO..
NO. 1 2 3 4 5 6 7 PART NO NO..
NO. 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION NO..
NO. 1 2 3 4 5 6 DESCRIPTION NO..
NO. 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION NO..
NO. 1 2 3 4 5 6 7 8 DESCRIPTION NO..
NO. 1 2 3 4 5 6 7 DESCRIPTION NO..
NO. 1 2 3 4 5 6 7 8 DESCRIPTION NO..
NO. DESCRIPTION NO..
NO. 1 2 3 4 5 6 DESCRIPTION NO.. PART NO DJ168F-16205-A DJ168F-16000-A DJ168F-16002-A DJ168F-16200-AE GBT16674-B6-25 DJ168F-18100-C NUT M16*1.
PG4500B LPG+GASOLINE 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 may not be available as single replacements. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NO..
NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION NO.. PART NO GBT16674-B6-16 DF2500H-34106-A DF3500H-34100-QQ02 34203-011 34290-002 34202-017 34204-038 34204-039 34204-015 34204-062 34204-003 34208-021 34208-017 FLANGE BOLT M6*16 GASKET CONTROL PANEL ASSEMBLY SWITCH ASSEMBLY VOLTAGE.FREQUENCY.
NO. 1 2 3 4 5 6 7 8 9 DESCRIPTION NO..
NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION NO.. PART NO DF3500H-33100-BJ-23602 DF3500H-33120-BJ DF1800H-33001-A DF3500H-33110-BJ-23602 DF3800H-33002-B DF1800H-33005-C GBT97-W-8 GBT93-LW-8 DF3500H-33003-A DF5000H-33015-A DF1800H-33011-A GBT16674-B5-12 DF1800H-33006-A-116 GBT16674-B5-16 GBT93-LW-5 GBT862-CW-5 DF3000H-34216-B GBT16674-B6-12 GBT97-W-6 GBT93-LW-6 DF3000H-31083-A DF2500H-33016-A ALTERNATOR ASSEMBLY ROTOR CARBON BRUSH COMP. STATOR GROUNDING POST COMP.
NO. M8*35 BOLT BOLT M8 N -8B6 NUT -55 -M6 NUT M6*55 , AB117 31072 M6*40 A CLIP A B6 31076 -FN 117 --HANDLE 8- -40 -31100 -A N 31020 20A -A N 31017 ---NUT 12 31018 W ASSEMBLY A B M12A Y 31019 31201 - 31202 B PIN AXLE- - PART NO. DESCRIPTION PART DESCRIPTION .
