7000W DIESEL GENERATOR
Owner’s Manual
Model No. PG7000D
For Service Please Call Toll Free: 1-866-591-8921
WARNING
Read and follow all safety rules and instructions in this manual before attempting
to operate this machine. Failure to comply with these instructions may result in
personal injury.
Diagrams within this manual may not be drawn proportionally. Due to continuing improvements,
actual product may differ slightly from the product described herein.
7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA
TABLE OF CONTENTS
Page number
Chapter 1 Technical Specifications and Data
3
1-1 Technical specifications and data
3
1-2 Basic operating instructions
5
1-3 General dimensions and overview of generator
5
1-1 Technical specifications and data
CHANGFA Single-cylinder diesel generator
Rated frequency (Hz)
Chapter 2 Operating the Diesel Generator
7
2-1 Main points of safety during operation of the generator
7
2-2 Preparation before operation
9
2-3 Checking the operation of the diesel engine
12
2-4 Starting the generator
12
2-5 Procedures for starting the generator
15
2-6 Proper operation of the generator
17
2-7 Loading
17
2-8 Stopping the generator
19
20
Chapter 3 Maintenance
3-1 Maintenance schedules
20
3-2 Storing for a long period of time
22
Chapter 5 Generator Parts Diagrams and Listings
23
Limited Warranty……………………………………………………………. 24
2
Rated voltage (V)
Rated output power
(kVA)
Max output power
(kVA)
Rated rotation speed
(rpm)
Power factor cos_
Phase number
Pole number
Excitation
Transistorized
ATS type
Structure type
Fuel
consumption(g/kw.h)
Fuel tank capacity(L)
Continuour running
t i me(hr)(at rated power)
Noise level [dBA/7m]
(zero full load)
Net weight (kg)
Overall dimension
(L W H)
60
220 230 240 110
/220 115/230 120/2
40
5.0
6.5
3600
1
Single
2
self-excitation ,
Brushless
without ATS
Open-frame
340
12.5
7.5
75-79
L X:95; E:100
29”x19”x26.25”
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
1-2 Basic operating instructions
Starter system
Fuel type
Lube oil
Engine type
Bore _ stroke(mm)
Displacement(cm3)
Compression ratio
Rated power [kW/rpm]
Rotation direction(from
the flywheel)
C: recoil starter
E: recoil starter/electric
0# (summer), 10#
(winter), 3 5 # (chill
cold) diesel
SAE 15W 40
C: recoil starter
E: recoil starter/electric starter
Table 1.
0# (summer), 10# (winter),
35#(chill cold) diesel
SAE 15W 40
Single-cylinder,4-stroke,
Single-cylinder,4-stroke,airair-cooled,vertical,diesel
cooled,vertical,diesel engine
engine
86_72
0.418
19 1
6.3/3600
86_72
0.418
19 1
6.3/3600
clockwise
clockwise
4
1-2.1 Under the given conditions, the generator will output the specified power in the table
listed below.
Height above sea level (ft) Ambient temperature ( oF) RH
0
60%
+60 (+20 oC)
1-2.1 Under the given conditions, the generator will output the approximate
power in the table listed below.
Table 2
Height above sea level (ft) Ambient temperature ( oF) RH
<3280.8 (<1000 m)
90%
41~104 (5-40 oC)
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
CHAPTER 2 OPERATING THE DIESEL GENERATOR
2-1 General main points of safety during operation of the generator set.
In order to operate the generator set safely, please follow all the instructions provided
in this manual carefully. Doing so otherwise may lead to accidents and or equipment
damage.
2-1.1 Fire prevention
The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline,
kerosene and or other fuels other than light diesel fuel. Keep all flammable fuels
away from the generator as the generator may spark and ignite these gases. In order
to prevent fires from occurring and to provide enough ventilation for people and the
machine, keep the diesel generator at least 1.5 meters away from buildings and or
other equipment. Always operate your diesel generator on a level site. If the
generator is operated on an incline, the lubricating system within the engine will not
perform well and may lead to failure of the engine.
2-1.2 Prevention from inhaling exhaust gases
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic
carbon monoxide. Never operate your generator in places with poor ventilation. In
order to operate this machinery indoors, a suitable ventilation system for the building
is required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental burns
Never touch the muffler and its cover when the diesel engine is running. Never touch
the muffler and cover after the diesel engine has been used, as the muffler remains hot
for a long period of time.
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet. Also never touch the generator if
your hand is wet. Never operate your generator if the weather conditions call for any
type of precipitation such as rain, snow, or fog. To prevent electrical shocks, the
generator should be grounded. Use a lead to connect the grounding end of the
generator to the grounding surface of choice. Please refer to Fig. 2-1 before
beginning to use the electric generator.
Note: When connecting devices to the generator, make sure all other devices are
rated lower than the generators output. Any generator socket should not be
overloaded over its regulated limit
2-1.5 Other safety points
Before operating this generator, all operators should have a good knowledge of how
to break the circuit if any accidents occur. Also, all operators should be familiar with
all the switches and functions of the generator before using this machine. While
operating the generator, wear safe shoes and suitable clothes during operation.
Always keep children and animals away from the generator.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric acid.
In order to protect your eyes, skin, and clothing, wear protective gear when working
with the battery. If you come in contact with the electrolytic liquid, wash it
immediately with clean water. Also, if the electrolytic liquid comes in contact with
your eyes, see a doctor immediately.
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2-2 Preparation before operation
2-2.2 Filling engine oil
2-2.1 Fuel choices and fuel treatment
Fuel tank
Use only light diesel fuel. The fuel should be filtered clean. Never let dust and
water mix with fuel in the fuel tank. Otherwise it will clog the fuel lines and oil
nozzles. It may also damage your pressure pump.
Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the
filter.
Remove the dipstick from the engine
Make sure the generator is on level ground, and fill the engine with 15W40 engine oil.
Put the dipstick back into the hole to check the engine oil level.
Type
PG7000DOF
The effective volume of fuel
tank:(L)
(US gal)
12.5
3.3
a. After purchasing fuel, put it into a
drum and let it sit for 3-4 days.
b. 3-4 days later, insert half of the fuel
siphon into the drum, (water and
impurities stay in the lower portion
of the drum)
Air filter element
Do not wash the air filter. The element is made of dry material, which does not
permit washing. When the output of the diesel engine is bad or the color of the
exhaust gas is abnormal, replace the air filter element. Never start the diesel engine
without the air filter.
Engine oil is the most important factor in determining the life of your generator
engine. If you use poor engine oil or if you don’t change the oil regularly, the piston
and cylinder will wear easily or seize up. Also, the life of the other parts in your
engine such as bearings, and other rotating parts will shorten considerably.
FIRST USE
Although there is an oil sensor that checks for low oil pressure, it is always a good
idea to check the amount of oil inside the engine. If the oil level is low, fill it before
starting the engine. A good time to drain the oil from the engine is when the diesel
engine is warm. If the engine is fully cooled, it is more difficult to drain all the oil out
or some impurities will remain in the engine.
Note:
Never smoke near the opening of the fuel tank.
Do not let sparks get near the fuel or fuel tank
and do not overfill tank. After filling, tighten the
fuel cap.
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7000W DIESEL GENERATOR
2-2.3 Checking the air filter
7000W DIESEL GENERATOR
2-3.3 Engine break in
(1) Loosen the butterfly nut, take the cover of the air
filter off and take the air filter element out.
Do not wash the air filter element.
When the performance of the engine decreases or
when the color of the exhaust gases is bad, exchange
the filter element. Never start the engine without the
air filter as foreign objects may enter the intake and damage the engine.
Use dry compressed air (with pressure about 28 PSI to blow the dust out in
the electric control cabinet and at the surface of the generator. Check to see
how clean the surface of the sliding ring is. Check the pressure of the carbon
brush. Also, check whether the position of the carbon brush at the slide rig is
correct and the fixture is reliable with a good contact.
2-2.5 The fuel and oil in a new engine is drained before sold. Before you start the
engine, please fill the fuel tank and engine oil first.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure oil switch.
CF diesel engines have a low-pressure sensor system where if the oil pressure
drops too low, the sensor will shut the engine off. The purpose of having this
system is to ensure that the engine does not seize up. If there is not enough oil
in the engine, the temperature of the oil will be raised too high. On the
contrary, if there is too much oil in the engine, the engine oil can slow the
engine down considerably.
When you purchase a brand new engine, the engine must be properly broken
in. The break in period is about 20 hours.
(1) Avoid overloading the engine when brand new
(2) Change the engine oil according to specifications. An oil change for a
brand new engine is about 20 hours or every month, an older engine, the
oil change is about 100 hours or three months.
2-4 Starting the generator set
2-4.1 Manual starting.
Start the engine in accordance with procedures below:
(1) Put the fuel switch in the “On” position.
(2) Turn the handle of the engine to the
“RUN” position.
(3) Pull the recoil starter handle out until
you feel resistance. It will reset to its original
position
automatically. The handle
should be reset into its recoil device slowly to
prolong the life of the engine starter.
(4) In cold climate, it is difficult to start the engine. Rubber plug
To remedy this, pull the rubber plug out from the
rocker of the diesel engine and fill 1/2 a cap full of engine
oil. Before starting, put the rubber plug back in
place. If you don’t put the rubber plug back in place,
rain, dust and other dirt can enter into the diesel engine. It will cause the parts inside the
diesel engine to wear quickly and lead to engine failure.
2-4.2 Electric starting
The procedures for preparing to start the engine are the same as the manual starting
engine.
2-4.3 Battery
1. Insert key into ignition and put it in the “off” position.
2. Put the speed handle in the “Run” position.
3. Turn the start switch clockwise to the “START” position; to set the silent
type, first turn it clockwise to the “RUN” (ON) position for 1-2 seconds.
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7000W DIESEL GENERATOR
The electromagnetic iron will be triggered, now turn it clockwise to the “START”
position.
4. After the diesel engine is started, remove your hand from the switch handle; the
switch will automatically reset itself to the “ON” position.
5. If the engine is not starting after 10 seconds of cranking, wait about 15 seconds
before trying it again. If you crank to long, the voltage of the battery will drop. This
can lead to improper ignition. When the diesel engine is operating, let the ignition
retain on the “ON” position.
7000W DIESEL GENERATOR
2-5 Procedures for starting the generator
This procedure applies to the CF series recoil starting style models.
Open the fuel valve
Note:
If you crank the starter to long, the battery may be drained too much to provide
enough energy for proper engine ignition. Also, when the diesel engine is
operating, let the key retain in the “ON” position.
Important Notice:
All of our units come with a dry battery for shipping
safety purposes. In order to get your generator started
for the first time; the battery must be filled with
battery acid which can be purchased at a local
automotive supply store and slowly charged (trickle
charged) for a day.
To properly maintain your battery; check the height of the battery acid once a month.
If the level of the liquid drops too low, fill it with distilled water until it reaches the
high mark. If there is not enough battery acid, then the diesel engine cannot be
started. It is important to keep the liquid level between the high and low limits.
If the level in the battery is to high, the liquid may flow out and end up on
surrounding parts resulting in corrosion of these parts.
Note: Avoid too much or too little of battery acid. Check and fill it once a month
if necessary.
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
2-6 Proper operation of the generator
2-6.1 Operating the diesel engine
1. Pre-heat the diesel engine for 3
minutes under no load conditions.
2. First check the height of the
lubricating oil level, if it is
low, refill it. Our diesel
engines are equipped with
an oil switch that will
notify you if the oil pressure
is too low. The system will
shut down the engine if the oil
pressures too low.
3. Do not adjust the speed limit
regulation bolt or the fuel adjustment
bolt.These bolts have been set by the
factory already, changing them will affect the properties of the engine
performance.
2-6.2 Checks during engine operation
1. Check to see if there are abnormal noises.
2. Check to see if the performance is good or bad
3. Check the color of the exhaust gases (whether it is too black or too white).
If any of these conditions exist, stop the engine and find the cause of the
problem. If no problems are found, please contact your local dealer or our
nearest company branch.
2-7 Loading
2-7.1 Load conditions
Exert loads in accordance with the specified parameters.
2-7.2 Output of electricity
1. Raise the revolutions per minute (turn the speed handle to the max setting) of the
generator to get the maximum power out of the generator. If not, the
automatic voltage regulator device will excite and doing this for long periods of time
will cause the AVR to burn. For the rated speed of the generator, please refer to
Chapter 1, item 1-1 technical specification and data.
2. Observe the pointer of the voltmeter, it should point to 240 (60Hz). Meanwhile
put the switch in the GEN (generator) position. The AC voltage from the socket of
the power supply can be output.
3. When connecting devices to the generator, make sure to connect these devices in order.
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7000W DIESEL GENERATOR
Connect the large loads onto the generator first. If everything is functional, smaller loads can then
be added. If the generator shuts off, it may be because the load being drawn by all the various
devices are too high. In this event, decrease the number of small devices until everything is
functional. The total drawn power should not exceed the maximum output power of the generator.
Please see Table 1-1 for technical specifications of what the generator can output. In order to reset
the generator after overdrawn power, let it sit for several minutes. If the indication of the
voltmeter is too high or too low, adjust the speed accordingly. If there are problems, stop the
generator immediately and fix the issue.
4. During operation, the generator should be in a place that has very good ventilation.
Never cover the engine to solve a ventilation problem, as this will damage your
equipment.
7000W DIESEL GENERATOR
2-8 Stopping the generator
1. Take the electrical load of f the
generator
.
2. Put the speed handle in the “RUN”
position and let the engine run for 3
minutes after unloading. Do not stop the
engine immediately let it warm down.
Stopping the diesel engine suddenly may
the temperature of the engine abnormally
lock the nozzle and damage the diesel
engine.
Note: Do not start more than two devices simultaneously. Each device should be
started one by one to prevent overloading the generator.
The generator should be running at 3600 revolutions per minute in order to
achieve the (60 Hz) frequency. The speed of the engine can be adjusted from the
speed governor.
2-7.3 Charging the battery
1. For the electric starter on the generator sets, the 12V battery is automatically
charged through the regulator on the side of the engine when it is running.
2. If the generator is not used for long periods of time, the battery should be
disconnected to avoid energy loss from the battery.
3. Do not connect the negative and positive terminals of the battery together at any
time. Doing so will cause the battery to explode and cause serious injuries.
4. Do not reverse the polarities when attaching the battery cables to the battery.
Doing so will damage both the battery and the electric starter.
5. When charging the battery, the battery produces flammable gases. Do only on well
ventilated area.
Do not smoke, let flames, and sparks get near the battery while it is charging as
this may cause a fire.
To avoid sparking while connecting the cables to the battery, first, connect the cables
to the battery then to the motor. To disconnect battery cables, first disconnect the
motor end of the cable.
16
1. If the speed handle is in the “Stop position and the engine is still running , turn the
fuel switch to the “OFF” position or loosen the high pressure oil pipe nut. The engine
could be stopped more than one-wayother than the speed handle way.
2. If you cannot stop the engine with a load on it, then remove the load first than stop
the engine.
3. Press down on the brake handle
4. If equipped with an electric starter , turn the key to the “Of f” position
5. Put the fuel handle to the “S” position
6. Finally, pull slowly on the recoil handle until you feel resistance (this is when the
piston is on the compression stroke, where the intake and exhaust valves are closed).
What this does is prevent the engine from rusting when not in use.
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
3-1.1 Changing the engine oil (every 200 hours)
CHAPTER 3 MAINTENANCE
3-1 Maintenance schedules
Keeping your generator well maintained will prolong the life of your generator. Everything needs to be
checked including the diesel engine, generator, control cabinet, and frame.
Take the oil cover off. Remove the oil
drain plug when the diesel engine is still
hot. Be careful of hot oil and hot engine
as you may get burned. The bolt is
located at the bottom of the cylinder.
After draining the oil, put the bolt back
and tighten it. Then fill with the proper
engine oil to the proper level.
Before starting the maintenance, make sure the diesel engine is off.
Please refer to the Table 3-1 for the proper maintenance schedule.
time
item
Check the fuel level and
refill
Drain the fuel tank
Check and fill enough
engine oil
Clean the fuel filter
Check fuel oil leakage
Check and screw each
fastered part
Check injector
Check injection pump
Everyday
After 1 month
or 50hours
Every 3 month or
200 hours
Replace the lube. oil
Clean lube. Oil filter
Check the air cleaner
element
Change the core of air filter
Check the battery liquid
level and refill
Adjusting the intake and
exhaust valve clearance
Grind air intake and air
exhausted gate
Exchange piston ring
Check electric brush and
slide ring
Check insulation resistance
Every 1year or
1000 hours
3-1.2 Air filter maintenance schedule
_
1. Clean air-filter every 6 months or 400 hours of operation.
2. If necessary, exchange it.
_
_
_after every
operating
3. Do not use detergent to clean air filter element.
_screw the bolt of
cylinder head firmly
_
_
Note:
_
_If necessary exchange
it
Cheak fuel pipe
Check the lube. oil level in
the oil pan and refill
Every 6 month or 400
hours
_Before
starting
_before
starting
_the second time and
afterward
_the second time and
_the first time
afterward
_the second time and
_the first time
afterward
If damaged or smeary , change it in time
_the first time
1. The fuel filter should be cleaned often to keep the engine running at maximum
performance.
_
2. The recommended time period for cleaning the fuel filter is 6 months or 400
hours of operation.
_the second time and
afterward
_the first time
Never start the engine without the air filter
.
This can cause serious damage to the engine if
foreign objects enter the intake system.
Always change the air filter on time.
3-1.3 Fuel filter maintenance
_
_
a. To do this, first drain the fuel from the fuel tank.
_
The time of stop is over 10 days
_
b. Loosen the small screws on the fuel switch and remove the fuel filter
form the port. Use diesel fuel to clean the fuel filter. Also, remove the
fuel injector and clean the carbon deposit around it. The recommended
time period for this is 3 months or 200 hours.
3-1.4 Cylinder head bolt tensions
The cylinder head bolts should be tightened to specifications please refer to the
diesel engine manual for specifications and the special tools required to do
this.
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
4-1 Questions and doubts
3-1.5 Battery check
Make sure the battery acid is full. The engine uses a 12V battery. Due to
numerous starting cycles, the battery acid may be used up. Also, before
filling, verify that the battery is not damaged in any way. Add distilled water
to the battery when filling. Perform checks on the battery once a month.
3-2 Storing for long periods of time
If your generator needs to be stored for long periods of time, the following
preparations should be made.
1. Start the diesel engine for 3 minutes then stop it.
If you do not understand anything or have any questions, please feel free to
contact your local dealer or with our company directly. Below is a list of some
information you should have ready before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred, in other words,
climate and atmosphere
5. Original receipt
6. Serial #
2. When the engine is still warm, change the engine oil with new engine oil of the
proper grade.
3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating
oil in it, then cover the plughole up again.
4. For manual starting generator welders, press the decompression handle down
and pull the recoil handle 2 or 3 times. This pushes the intake out. (Do not
start the engine)
5. For electric started generator welders, press the decompression handle down
and crank the engine for 2-3 seconds. To do this, put the starter switch in the
“Start” position. (Do not start the diesel engine)
6. Finally, pull the recoil starter until you feel resistance; this is when the piston is
on the compression stroke where the intake and exhaust valves are closed.
Having the intake and exhaust valves closed will prevent rust, as moisture
cannot get inside the combustion chamber.
7. Clean the engine and store it in a dry place.
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
CHAPTER 5 GENERATOR PARTS DIAGRAMS AND LISTINGS
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7000W DIESEL GENERATOR
7000W DIESEL GENERATOR
Limited Warranty
Limited Warranty (cont’d)
Pulsar Products Inc. warrants to the original purchaser who uses the product in a
consumer application (personal, residential or household usage) that all products
covered under this Warranty are free from defects in material and workmanship for
one year from the date of purchase. All products covered by this limited Warranty
which are used in commercial applications (i.e. income producing) are warranted to
be free of defects in material and workmanship for 90 days from the date of original
purchase. Products covered under this Warranty include air compressors, air tools,
service parts, pressure washers and generators.
THIS WARRANTY DOES NOT COVER:
Merchandise sold as reconditioned, used as rental equipment, or floor or
display models.
Merchandise that has become damaged or inoperative because of ordinary
wear, misuse, cold, heat, rain, excessive humidity, freeze damage, use of
improper chemicals, negligence, accident, failure to operate the product
in accordance with the instructions provided in the Owner’s Manual(s)
supplied with the product, improper maintenance, the use of accessories
or attachments not recommended by Pulsar Products Inc., or
unauthorized repair or alterations.
Pulsar Products Inc. will repair or replace at Pulsar Products Inc.'s sole option,
products or components which have failed within the warranty period. Service will be
scheduled according to the normal work flow and business hours at the service center
location, and the availability of replacement parts. All decisions of Pulsar
Products Inc. with regard to this limited warranty shall be final.
This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state.
RESPONSIBILITY OF ORIGINAL PURCHASER (Initial User):
To process a warranty claim on this product, DO NOT return item to the retailer.
The product must be evaluated by an Authorized Warranty Service Center. For the
location of the nearest Authorized Warranty Service Center contact the retailer or
place of purchase.
Retain original cash register sales receipt as proof of purchase for warranty work.
Use reasonable care in the operation and maintenance of the product as described
in the Owner’s Manual(s).
Deliver or ship the product to the nearest Authorized Warranty Service Center.
Freight costs, if any, must be paid by the purchaser.
If the purchaser does not receive satisfactory results from the Authorized Warranty
Service Center, the purchaser should contact Pulsar Products Inc..
24
Repair and transportation costs of merchandise determined not to be defective.
Costs associated with assembly, required oil, adjustments or other
installation and start-up costs.
Expendable parts or accessories supplied with the product which are
expected to become inoperative or unusable after a reasonable period of
use.
Merchandise sold by Pulsar Products Inc. which has been manufactured by
and identified as the product of another company, such as gasoline
engines. The product manufacturer's Warranty, if any, will apply.
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS,
DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY
DEFECTS, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT
COVERED BY THIS WARRANTY. Some states do not allow the
exclusion, so it may not apply to you.
IMPLIED
W A R R A N T I E S , IN C L UDI N G T HO S E O F
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,
ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL
PURCHASE. Some states do not allow limitations on how long an implied
warranty lasts, so the above limitations may not apply.
25
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