2000
2000
1-866-591-8921
2000WGenerator
7500WGenerator
Topic Page
SafetyGuidelines
3
General
General
Battery13
Assembl19
Operation
ntenance22
23
Compliace24
pecifications25
eneralrecautions12
Operation
Inspection,CleaningandMaintenance
Installation
T h
roublesooting
Specifications
Wiringiagram
GeneralPartsListing
eneralPartsListing29
Precautions
al
Guidelines4
Parts
D
2
0
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.
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 AND UNDERSTAND ALL
WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING
THIS EQUIPMENT. WHEN USING AIR TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE
THE RISK OF PERSONAL INJURY.
3
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.
WARNING! THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE
GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS AND MAY LEAD TO
DEATH.
Gasoline and Oil
This product requires oil and fuel. Attempting to start the engine without oil will ruin
the engine and void the warranty. Work in a well ventilated area. Keep cigarettes,
flames or sparks away from the work area or where gasoline is stored.
WARNING! GASOLINE 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 and cleaning materials as per
any local, state, or federal codes and regulations. Store oily rags in a covered metal container.
• Never store fuel or other flammable materials near the generator.
4
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. Do not
operate the generator with known leaks in the fuel system
• Excessive buildup of unburned fuel gases in the exhaust system can create a potentially
explosive condition. This buildup can occur after repeated failed start attempts, valve testing, or
hot engine shutdown. If this occurs, open exhaust system drain plugs, if equipped, and allow the
gases to dissipate before attempting to restart the generator.
o
nly use engine oil and fuel recommended by manufacturer.
•
Hot Components
WARNING! ENGINE AND EXHAUST SYSTEM PARTS BECOME VERY
HOT AND REMAIN HOT FOR SOME TIME AFTER THE ENGINE
INSULATED GLOVES OR WAIT UNTIL THE ENGINE AND EXHAUST SYSTEM
HAVE COOLED BEFORE HANDLING THESE PARTS.
HAS STOPPED
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 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.
5
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.
Electrical Safety
• Grounded tools must be plugged into an outlet properly installed and
grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adapter
plugs.
• Grounding provides a low-resistance path to carry electricity away from the
user in the event of an electrical malfunction.
• Double insulated tools are equipped with a polarized 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 body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators.
There is an increased risk of electric shock if your body is grounded.
• Do not expose generator to rain or wet conditions. Water entering a generator will increase the
risk of electric shock.
• Do not abuse the power cord. Keep power cords away from heat, oil, sharp edges, or moving
parts. Replace damaged power cords immediately. Damaged power cords increase the risk of
electric shock.
• When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”.
These extension cords are rated for outdoor use, and reduce the risk of electric shock.
6
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.
• Do not attempt to connect or disconnect load connections while standing in water, or on wet or
soggy ground.
• Do not touch electrically energized parts of the generator and interconnecting cables or
conductors with any part of the body, or with any non-insulated conductive object.
• Connect the generator only to a load or electrical system (120 volt) that is compatible with the
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 connections and disconnected wires.
• Guard against electric shock. Prevent body contact with grounded surfaces such as pipes,
radiators, ranges, and refrigerator enclosures.
Personal Safety
• Stay alert. Watch what you are doing, and use common sense when operating a generator. Do
not use generator while tired or under the influence of drugs, alcohol, or medication. A moment
of inattention while operating generators may result in serious personal injury.
Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing,
•
and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in
moving parts.
7
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. Wear ANSI approved safety impact eye
goggles. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for
appropriate conditions.
• Do not force the generator. Use the correct generator for your application. The correct generator
will do the job better and safer at the rate for which it is designed.
• Do not use the generator if the power switch does not turn 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 preventat ive safety
measures reduce the risk of starting the generator accidentally.
Store idle generators out of reach of children and other untrained persons. Generators are
dangerous in the hands of untrained users.
Maintain generators with care. Do not use a damaged generator. Tag damaged generators “Do not
use” until repaired.
Check for misalignment or binding of moving parts, breakage of parts, and any other condition that
may affect the generator’s operation. If damaged, have the generator serviced before using. Many
accidents are caused by poorly maintained generators.
Use only accessories that are recommended by the manufacturer for your model. Accessories that
may be suitable for one generator may become hazardous when used on another generator.
8
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. Follow all appropriate
instructions in this manual. Use of unauthorized parts or failure to follow maintenance instructions
may create a risk of electric shock or injury.
Heart Pacemakers
WARNING! PEOPLE WITH PACEMAKERS SHOULD CONSULT THEIR
PHYSICIAN(S) BEFORE USING THIS PRODUCT. ELECTROMAGNETIC
FIELDS IN CLOSE PROXIMITY TO A HEART PACEMAKER COULD CAUSE
INTERFERENCE TO OR FAILURE OF THE PACEMAKER.
Installation
• Ensure installation meets all applicable safety, local and national electrical codes. Have
installation performed by a qualified, licensed 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 engine will generate carbon monoxide, a colorless, odorless gas that, if inhaled, can
cause serious injury or death. If the generator is installed indoors, exhaust fumes must be piped
out of the building using leak-free, heat resistant piping. Pipes and silencer should not use any
flammable materials, nor should they be installed near the same. Generator exhaust fumes
must be within legal limits and installation must always meet local building codes.
9
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) . Two or more people should assist
w
hen moving or lifting this
lifting lugs. Connect lifting
Before lifting the generator, ensure the lift rigging and supporting structure are in good
•
condition, and are rated to lift such a load.
• Keep all personnel away from the suspended generator during relocating.
• The supporting oor/ground surface should be level and strong enough to safely hold the weight
of the generator. If the floor/grounded surface is not level, strong cross members should be
placed under the full length of the generator frame at its low side.
• For trailer installation, the generator should be mounted on the center point of the trailer, over
the wheels. The trailer must be capable of supporting the weight of the generator and all
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.
fl
63
pr
oduct. Never lift the generator using the engine or alternator
equipment to the frame of the generator
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 damaged should
be carefully checked to determine that it will operate properly and perform its intended function.
Check for alignment and binding of moving parts, any broken parts or mounting fixtures, and any
other condition that may affect proper operation.
•
The generator is designed with guards for protection from moving parts. Care must
to protect personnel and equipment from other mechanical hazards when working
generator.
10
still be taken
around the
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.
•
When working on or around the generator, always wear protective clothing, including ANSI
approved safety gloves, 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 immediately. Do not induce vomiting if fuel is swallowed. For skin contact,
immediately wash with soap and water. For eye contact, immediately flush eyes with clean water
and seek medical attention.
Noise
• Prolonged exposure to noise levels above 68 DBA is hazardous to hearing. Always wear ANSI
approved ear protection when operating or working around the generator when it is running.
11
ene
General Parts
r
a
P
a
l
r
t
s
Choke lever
Air filter
Fuel valve
One way valve
Recoil starter
On/off switch
Fuel tank cap
Fuel gauge
Oil dipstick
Fuel tank
Frame
Control Panel
Drain plug
Voltage meter
Thermal protector
DC terminal
120V Duplex outlet
Grounding terminal
120V Duplex outlet
12
Owner’s Manual
Operation
kLever
Choke lever
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 10W30 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. THEN SCREW THE DIPSTICK BACK INTO
THE OIL FILL HOLE.
Fuel tank
Control panel
Before Starting the Generator
1. Check that the engine power switch is in the
“OFF” position.
2. Before the first use, remove the fuel
tank cap and fill the fuel tank with unleaded
gasoline. When fueling, be sure that the
fuel strainer is in place. Replace the fuel
tank cap. Thereafter, check the engine’s
fuel gauge for the amount 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.
Fuel Tank Cap
13
Operation (cont’d)
Starting
1. Turn the engine switch to the ON position.
The engine switch enables and disables the ignition
system.
OFF: To stop the engine
ON: To run the engine
2. The fuel valve is located under the fuel tank . When
the valve lever is in the ON position, fuel is allowed
to flow from the fuel tank to the carburetor. Be sur
to return the fuel valve lever to the OFF position after
stopping the engine.
e
3. To start a cold engine, move the choke lever to the
CLOSED position. To restart a warm engine, leave the
choke lever in the OPEN position.
The choke lever opens and closes the choke valve in
the carburetor.
The CLOSED position enriches the fuel mixture from
starting a cold engine.
The OPEN position provides the correct fuel mixture
for operation after starting, and for restarting a warm
engine.
14
Operation (cont’d)
Starting
4. Operate the Recoil Starter:
Pull the starter grip lightly until you feel resistance,
then pull briskly. Return the starter grip gently.
Pulling the starter grip operates the recoil starter to
crank the engine
5. If the choke lever has been moved to the CLOSED
position to start the engine, gradually move it to the
OPEN position as the engine warms up.
Stopping Engine
1. Turn the engine switch to the OFF position.
2. Turn the fuel valve lever to the OFF position.
When the engine is not in use, leave the fuel valve lever in
the OFF position to prevent carburetor flooding and to
reduce the possibility of fuel leakage.
15
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.
CAUTION: ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT
WITHOUT THE USE OF AN APPROVED LINE CONDITIONER MAY CAUSE
DAMAGE TO THE EQUIPMENT. IS NOT RESPONSIBLE
FOR ANY DIRECT OR INDIRECT DAMAGE CAUSED BY FAILURE TO USE AN
APPROVED LINE CONDITIONER.
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 THIS POSITION. THEN, RESET THE CIRCUITRY
SYSTEM BY TURNING THE CIRCUIT BREAKER TO ITS “ON” POSITION.
RESTART THE GENERATOR AND CONTINUE POWERING THE REMAINING
TOOLS AND EQUIPMENT.
PULSAR PRODUCTS INC.
3.
Disconnect all electrical powered tools and equipment from the generator s 120 volt Duplex
outlets.
4.
After the engine and generator have completely cooled,store generator in safe,chean,dry
location (if not already installed).
16
,
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.
CAUTION: MAKE SURE TO 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 the engine power switch to its “OFF” position. Turn
the fuel valve to its “OFF” position.
6. Disconnect the electrical powered tools’ power cord from the generator’s DC terminals.
7. After the engine and generator have completely cooled, store the generator in a safe, clean, dry
location (if not already installed in one).
17
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. 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.
6.
Install the spark plug by hand to prevent cross-threading.
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 AND COULD DAMAGE THE
ENGINE. NEVER USE SPARK PLUGS WHICH HAVE AN IMPROPER HEAT RANGE.
USE ONLY RECOMMENDED SPARK PLUS OR EQUIVALENT.
18
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. Check for:
- Loose screws
- Misaligned or bind
- Cracked or b
- Damaged electrical wiring
- Any other condition that may affect safe operation.
• If an engine problem occurs, have it checked by a qualified service technician
Do not use damaged equipment.
• Before each use, make sure the engine’s oil and gas levels are ad
crankcase until the oil level is even with the oil fill hole and/or fill the fuel tank.
• Before each use, r
• Lubricate all moving parts using a premium
quality, lightweight machine oil.
• Every 50 hours of use, drain the old engine oil
and replace with a high quality
SAE 10W-30 grade engine oil.
roken parts
ed moving parts
equate. If necessary, fill the
emove all debris with a soft brush, rag, or vacuum.
Upper Level
before further use.
• Every 300 hours of use, have a qualified, certified
tech
generator and engine.
• For long term storage, either drain fuel into
suitable container or add a fuel preservative/
st
nician perform thorough maintenance on the
abilizer (not included) to prevent fuel
breakdown.
19
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.
Investigate your local building and electrical codes before installing this unit. Installation must be
completed by licensed contractors.
WARNING! THE GENERATOR WEIGHS APPROXIMATELY 110 POUNDS. USE
CARE AND THE PROPER LIFTING OR HOISTING 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 may require
the placement of a barrier for protection. In normal weather conditions, the air vent should face
the prevailing wind direction.
• Install the generator on a concrete slab or other area where rain drainage or flood waters can
not reach it.
• Generator placement should allow four feet of access to all sides for maintenance.
• Place the generator as close as possible to the electrical tools and equipment being powered to
reduce the length of extension cords.
2
0
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).
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 copper or brass rod (electrode) which can adequately
ground the generator.
21
6
Troubleshooting
Note:
PROBLEM
The engine
will not start
No electricity
at the AC
outlets
If the engine still does not start, take the genera
Troubleshooting problems may have similar causes and solutions.
POSSIBLE CAUSE
Is there fuel in the tank?
Is there enough oil in the
engine?
Is the spark plug in good
condition?
Is the fuel reaching the
carburetor?
Is the AC circuit breaker ON?
Check the electrical appliance
or equipment for any defects.
SOLUTION
Refill the fuel tank.
Add the recommended oil.
Readjust gap and dry the spark plug.
Replace it if necessary.
Clean the fuel sediment cup.
Turn the AC circuit breaker ON.
·
Replace the electrical appliance or
equipment.
appliance or equipment to an
electrical shop for repair.
·
Take the electrical
tor to an authorized agent generator dealer.
22
75
00
W
G
Specifications
AC electrical
enerato
r
Cu
Continuous/rated Wattage 6,000
rrent Output 120V/240V 60Hz, 50A/25A
Peak Wattage 7,500
Outlet 4 AC 120V, 2 AC 120V/240V
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)
twist-lock outlet
EPA approved yes
Fuel
Type Unleaded gasoline
C 6.6 gallons (25 liters)
Running time 9 hours (approx.)
Fuel gauge included
Weight
Approximate weight 210lbs.
23
A
V
R
BuQVR0.5mm Ÿ
WQVR0.5mm Ÿ
RQVR0.5mm Ÿ
R
QVR0.5mmŸ
W
QVR0.5mmŸ
Bu
Bu
R
W
BuQVR0.5mm Ÿ
Bl Black Br Brown
O
Orange
BrR
BrownRed
Bu Blue
Gr
Gray
LB
LightBlue
Bl Black
W WhiteR Red
YG
YellowGreen
BlW
BlackWhite
G Green
LBQVR1.5mm Ÿ
LBQVR1.5mm Ÿ
DCcoil1
+
8A
2510
GrQVR1.5mm Ÿ
BlQVR1.5mm Ÿ
LED
EngineBlock
Fuel
Protector
Spark
Plug
IgnitionCoil
IgnitionSwitch
OilAlert
Unit
喞殉獄雅シ御
暖声
暗脳
えま銀
遷儁梯
シ御
欺眼偖漏
シ圜稽
憧玖
よ従
1 A 戻布
却"""勹""""甥"""勹
喞牒唄耕歌重
透へ啣冽仄慢喫培
暖声暖声
透後
啣布
迷回 損圜
遷儁梯
遷儁梯
BlQVR0.5mm Ÿ
BlW
QVR0.5mmŸ
Bl
QVR0.5mmŸ
Bl
QVR0.5mmŸ
Bl
Bl
BlW
BlW
Generator
Block
ControlBoxDiagram
YG
W
R
W
R
V
VoltMeter
5-20R
Breaker
R
Wiring Diagra
WIRINGDIAGRAMOF120VGENERATORSET
24
PG2000 ENGINE PARTS LISTING
qualified technician. Some parts may not be available as single replacements.
This list is provided for reference purposes only.All repairs and part replacement should be performed by a
NO. PART NO.
1 DJ156F-11048-A LEFT WIND SHIELD 1
2 GBT16674-B6-12 FLANGE BOLT M6*12 3
3 GB276-89-6203 BEARING RADIAL BALL 6203 1
4 DJ156F-11012-A
5 DJ156F-11100-BE CRANKCASE 1
6 DJ156F-18200-A
7 92140-B6-12-G FLANGE BOLT M6*12 2
8 DJ168F-18300-A
9 DJ168F-11005-A
10 DJ168F-11004-A
11 DJ168F-15003-A PIN,LOCK 1
12 DJ156F-15001-A
13 DJ156F-15002-A
14 DJ156F-11049-A RIGHT WIND SHIELD 1
15 DJ152F-11014-A
DESCRIPTION
AIR-LEADING COVER
OIL SENSOR ASSEMBLY
AMPLIFIER
WASHER DRAIN PLUG
DRAIN PLUG
MOVING STAFF
PLAIN WASHER
OIL SEAL Φ 17×Φ 30×6
25
Q'TY REMARK
1
1
1
1
1
1
1
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DJ152F-11014-A
2 GBT16674-B6-28 FLANGE BOLT M6*28 6
3 DJ156F-11001-A CRANKCASE COVER ASSEMBLY 1
4 DJ156F-11007-D
5 GB276-89-6303 BEARING RADIAL BALL 6303 1
6 DJ168F-11002-A
7 DJ156F-11003-B
8 DJ156F-15100-A
OIL SEAL Φ 17×Φ 30×6
DIPSTICK
PIN Φ8×14
CRANKCASE GASKET
SPEED REGULATING GEAR
26
1
1
2
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 GBT16674-B6-12 FLANGE BOLT M6*12 4
2 DJ168F-11300-C
3 DJ168F-11011-A
4 GBT16674-B8-50 FLANGE BOLT M8*50 4
5 DJ168F-14002-A
6 DJ156F-18500-A
7 DJ156F-11200-AE CYLINDER HEAD ASSEMBLY 1
8 DJ168FD-14001-A
9 DJ156F-11009-A
10 DJ156F-11010-B
CYCLINDER HEAD COVER ASSEMBLY
GASKET, CYCLINDER HEAD COVER
BOLT, STUD M8*35
SPARK PLUG F7TC
BOLT, STUD M6*90
PIN
GASKET, CYLINDER HEAD
27
1
1
2
1
1
2
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DJ156F-12003-A
2 DJ156F-12001-B
3 DJ156F-12002-A
4 DJ156F-12200-AE
5 DJ156F-12300-B
6 DJ156F-12100-BQE
PISTON PIN CIR-CLIP
PISTON
PISTON PIN
CONNECTING-ROD ASSEMBLY
PISTON RING SET
CRANKSHAFT ASSEMBLY
28
2
1
1
1
1
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DJ156F-13200-A
2 DJ156F-13300-A
3 DJ168F-13004-A
4 DJ156F-13003-A
5 DJ1P65F-13002-A
6 DJ1P65F-13001-A
7 DJ156F-13008-A
8 DJ156F-13009-A
9 DJ156F-13100-AE
ROCKER ARM ASSEMBLY
PUSH ROD GUIDE
INTAKE VALVE RETURNER
VALVE SPRING
EXHAUST VALVE
INTAKE VALVE
ROD PUSH
TRAPPET LITTER VALVE
CAMSHAFT ASSEMBLY
29
1
1
2
2
1
1
2
2
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DJ156F-14003-B
2 DJ156F-14004-A CONNECTING BLOCK CARBURETOR 1
3 DJ156F-14100-AE
4 DJ156F-14109-A FUEL INJECTION NEEDLE 1
5 DJ156F-14112-A MAIN JET 1
6 DJ156F-14106-A FLOAT 1
7 DJ56F-14101-A
8 DJ156F-14016-B
9
DJ168F-14008-A CLIP,FUEL LINE
10 DJ156F-14007-C
GASKET INLET
CARBURETOR ASSEMBLY
OIL CUP
GASKET,AIR FILTER
FUEL LINE
30
1
1
1
1
1
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DJ156FD-14200-AE
2 DJ156F-14203-C BOTTOM CAP,AIR FILTER 1
3
DJ165F-14201-A
4
DJ156F-14204-A
5
DJ156F-11013-A BRACKET,AIR FILTER
6
GB6170-N-6
AIR CLEANER ASSEMBLY
FILTER ELEMENT 1
AIR FILTER CAP 1
NUT M6 2
31
1
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 GBT16674-B6-12
2 DJ156F-16100-F-116 CASE COMP RECOIL STARTER 1
3 DJ168F-16110-A
4 DJ168F-16111-A ROPE 1
5 DJ156F-16130-F-116 STARTER COMP,RECOIL 1
6 92140-B6-8
7
GBT97-W-6
8 DJ168F-16101-A-116 RECOIL STARTER CASE 1
FLANGE BOLT M6*12
STARTER
FLANGE BOLT M6*8
PLAIN WASHER
32
4
1
3
3
NO. PART NO. DESCRIPTION Q'TY REMARK
DJ156F-15007-C
1
DJ156F-15008-A
2
DJ156F-15006-A
3
GB6170-N-6
4
DJ156F-15004-A
5
GBT16674-B6-12
6
DJ156F-15200-B
7
BACK SPRING B 1
FINE REGULATING SPRING C 1
PULLING ROD 1
FLANGE NUT M6
SPEED REGULATING ARM
LOCK BOLT
SPEED REGULATOR
33
2
1
2
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1 GB6177-N-12 FLANGE NUT M12 1
2 DJ156F-16000-A
3 DJ156F-16002-A
4 DJ156F-16200-AE
5 GBT16674-B6-25
6 DJ156F-18100-B
STARTING CUP
IMPELLER
FLYWHEEL ASSEMBLY
FLANGE BOLT M6*25
IGNITION COIL ASSEMBLY
34
1
1
1
2
1
PG2000 GENERAL PARTS LISTING
qualified technician. Some parts may not be available as single replacements.
This list is provided for reference purposes only.All repairs and part replacement should be performed by a
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DF1500H-14300-AR-116
2
DF1500H-14307-A FUEL FILTER
3
DJ156F-14306-CJ FUEL TANK CAP ASSEMBLY
4 GBT16674-B6-16
5 DF1200H-14024-A
6
DJ168F-14008-B CLIP,FUEL LINE
7 DF1500H-14302-B
8 DF1500H-14803-A
9 DF3000H-14008-A
10 DF3000H-14008-B
11 DJ168F-11039-E
12 784810-NT
13 DF6500H-34125-A
FUEL TANK ASSEMBLY
FLANGE BOLT M6*16
GASKET，FUEL TANK
FUEL COCK
CONNECTING PIPE
CLIP,FUEL LINE
CLIP,FUEL LINE
Q CLIP
ONE-WAY VALVE ASSEMBLY
SEAL GASKET,ONE-WAY VALVE
35
1
1
1
4
8
1
1
1
1
1
1
1
1
NO. PART NO. DESCRIPTION Q'TY REMARK
1
GBT16674-B6-16 FLANGE BOLT M6*16
2 DF2500H-34106-A
3 DF1500H-34100-QQ01
4
34203-011 SWITCH ASSEMBLY
5
34205-008 VOLTAGE METER
6
34204-038 GROUNDING POST
7
34204-039 GROUNDING POST
8 34204-062
9 34208-015
GASKET
CONTROL PANEL ASSEMBLY
120V DUPLEX OUTLETS
THERMAL PROTECTOR
4
4
1
1
1
1
1
1
1
36
NO. PART NO. DESCRIPTION Q'TY REMARK
GASKET,EXHAUST
GB6177-N-8
1
GBT93-LW-8
2
DJ156F-14006-A
3
DJ156F-14419-A
4
92140-B6-12
5
DF1500H-14400-C MUFFER ASSEMBLY
6
DJ156F-14037-A
7
DF4000H-14008-C
8
DF9000H-14423-A
9
DF9000H-14413-A
10
FLANGE NUT M8
SPRING WASHER
CONNECTING PIPE 1
FLANGE BOLT M6*12
EXHAUST PIPE
CLIP,FUEL LINE
GASKET，SECONDARY GAS INJECTION FILTER
SECONDARY GAS INJECTION FILTER
2
2
1
2
1
1
2
1
1
37
NO. PART NO. DESCRIPTION Q'TY REMARK
1 DF1800H-33008-A
2 GBT16674-B8-16
3 DF1500H-33100-BJ-20302
4 DF3000H-33120-BJ
5 DF1800H-33001-A
6 DF3800H-33002-A
7 DF1500H-33120-BJ-20302
8 DF1500H-33005-A
9 GBT93-LW-8
10 GBT97-W-8
11 DF1500H-33003-A
12 DF1800H-33015-B
13 GBT16674-B5-12
14 DF1800H-33006-A-116
15 DF1800H-33011-A
FRONT COVER,ALTERNATOR
FLANGE BOLT M8*16
ALTERNATOR ASSEMBLY
ROTOR
CARBON BRUSH COMP.
GROUNDING POST COMP.
STATOR
ALTERNATOR END BRACKET
PLAIN WASHER
SPRING WASHER
BOLT M8*190
BOLT M6*110
FLANGE BOLT M5*12
ALTERNATOR END COVER
VOLTAGE REGULATOR
16 GBT862-CW-5 TOOTH TYPE WASHER 1
17 GBT97-W-5
18 GBT16674-B6-12
19 GBT97-W-6
PLAIN WASHER
BOLT FLANGE M6*12
PLAIN WASHER
20 GBT862-CW-6 TOOTH TYPE WASHER 1
21
DF3000H-31083-A
22
DF3000H-34216-B GROUNDING WIRE
CONNECTING WIRE, FRAME 1
1
4
1
1
1
1
1
1
1
2
1
4
7
1
1
1
1
1
1
38
NO. PART NO. DESCRIPTION Q'TY REMARK
1
DF1500H-31100-N-117
FRAME ASSEMBLY 1
2 GB6170-N-8 FLANGE NUT M8 4
3 DF1500H-31201-A
ISOLATTOR A
4 GB6170-N-8 FLANGE NUT M8 4
5 GBT16674-B8-16
6 GBT16674-B6-12
7 DF1800H-31203-A
8 DF1500H-31202-A 2
9 GBT16674-B8-45
FLANGE BOLT M8*16
FLANGE BOLT M6*12
RUBBER, FRAME SHOCK ABSORPTION
ISOLATTOR B
FLANGE BOLT M8*45
39
2
2
4
4
1
Loading...