Pulsar 5,250/4,250-Watt Gasoline Powered Recoil Start Portable Generator Manual

Model: PG5250
Generator
OPERATOR’S MANUAL
www.pulsar-products.com
TABLE OF CONTENTS
Introduction..............................................................................................................................................................................3
Product Specifications..................................................................................................................................................3
Parts Ordering / Customer Service...............................................................................................................................3
Safety Rules.............................................................................................................................................................................4
Safety Symbols.............................................................................................................................................................4
Safety Instructions ......................................................................................................................................................4
Features....................................................................................................................................................................................7
Assembly..................................................................................................................................................................................9
Unpacking ....................................................................................................................................................................9
Packing List .................................................................................................................................................................9
Attaching Wheels........................................................................................................................................................10
Adding Oil...................................................................................................................................................................11
Adding Fuel................................................................................................................................................................12
Connecting Generator to an Electrical System.........................................................................................................12
Operation................................................................................................................................................................................13
Grounding the Generator ...........................................................................................................................................13
How to Start Engine....................................................................................................................................................13
How to Stop Engine.....................................................................................................................................................14
Receptacles and Extension Cords..............................................................................................................................15
Don’t Overload Generator...........................................................................................................................................16
Wattage Reference Guide...........................................................................................................................................17
Cold Weather Operation.............................................................................................................................................18
Maintenance ..........................................................................................................................................................................19
Maintenance Schedule ...............................................................................................................................................19
Engine Maintenance ..................................................................................................................................................20
Changing Oil ..............................................................................................................................................................19
How to Store .............................................................................................................................................................22
Troubleshooting ....................................................................................................................................................................23
Diagrams.................................................................................................................................................................................24
Warranty .................................................................................................................................................................................25
INTRODUCTION
Thank you for purchasing this superior quality portable generator from Pulsar Products Inc. When operating and
maintaining this product as instructed in this manual, your generator will give you many years of reliable service.
Product Specifications:
This generator is an engine-driven, revolving field, alternating current (AC) portable generator. It is designed to supply
electrical power to operate tools, appliances, camping equipment, lighting, or serve as a back up power source during
power outages.
AC Output
Engine
Engine Oil
Fuel Tank
Rated Wattage
4250W (4.25kW)
Rated Voltage
120/240V
Rated Frequency
60Hz
Rated Ampere
35.4A / 17.7A
Rated Output
4.25kVA
Maximum Output
5.25kVA
224cc OHV, 4 Stroke, Air Cooled
10W30 - 20oz(0.6 L)
4.0 Gal(18 L) Unleaded Gasoline
The emissions control system for this generator is compliant with all standards set by the Environmental Protection Agency.
How to contact us:
To order parts, receive warranty assistance, or other services inquiries, you can contact us by internet at
www.pulsar-products.com or write to us at:
PULSAR PRODUCTS LTD
2051 S Lynx Place
Ontario, CA 91761.
1-866-591-8921
Record the following information bellow for service or warranty assistance.
Date of Purchase:
Model Number:
Serial Number
SAVE THIS MANUAL FOR FUTURE REFERENCE
This manual contains important information regarding safety, operation, and maintenance.
3
SAFETY RULES
Safety Symbols
WARNING!
Indicates a potentially hazardous
situation which could result in
serious injury or death if not avoided.
CAUTION!
Indicates a potentially hazardous
situation which could result in
damage to equipment or property.
Toxic Fumes
Risk of electric shock
Risk of fire
Risk of explosion
Hot surface
Lifting hazard
Safety Instructions
The manufacturer cannot anticipate every possible hazardous circumstance that the user may encounter. Therefore, the
warnings in this manual, on tags, and on affixed decals are not all-inclusive. To avoid accidents, the user must understand
and follow all manual instructions and use common sense.
WARNING!
Read and understand this manual in its entirety before operating this generator. Improper
use of this generator could result in serious injury or death.
Do not operate indoors or in a confined space preventing dangerous carbon
monoxide gas from dissipating.
Using a generator indoors WILL KILL YOU IN MINUTES!
Carbon monoxide gas is a poisonous, odorless gas that can cause headache, confusion, fatigue, nausea, fainting,
sickness, seizures, or death. If you start to experience any of these symptoms, IMMEDIATELY get fresh air and seek
medical attention.
Never use indoors, in a covered area, or in a confined space, even if doors and windows are open.
Install a battery operated carbon monoxide alarm near bedrooms.
Keep exhaust from this unit from entering a confined area through windows, doors, vents, or other openings.
When working in areas where vapors could be inhaled, use a respirator mask according to all of its instructions.
WARNING!
•
•
•
•
•
•
WARNING!
Engine exhaust contains chemicals that lead to cause cancer and birth defects.
• Always wash hands after handling generator.
WARNING!
To reduce the risk of serious injury, avoid attempting to lift the generator alone.
4
SAFETY RULES
WARNING!
Never exceed generator’s wattage / amperage capacity. This could damage the generator
and / or connected electrical devices.
•
Check operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator.
•
•
Never start or stop engine with electrical devices plugged in to the receptacles. Failure to do
so could damage the generator and / or connected electrical devices.
Always start the engine and let it stabilize before connecting any electronic devices.
Disconnect all electronic devices before stopping the engine.
WARNING!
WARNING! Starter and other moving parts can catch on clothing, jewelry, and hair.
•
•
•
Do not wear loose clothing or gloves.
Remove jewelry or anything else that could be caught in moving parts.
Tie back or wear protective head covering to contain long hair.
WARNING!
•
•
•
•
•
•
•
•
•
•
The fuel and its vapors used to power this unit are highly flammable and could explode resulting in serious injury or
death.
Never fill or drain fuel tank indoors.
Never overfill fuel tank. If fuel spills, move the unit at least 30 feet away from the spill and wipe up any remaining fuel
on the unit before starting the engine.
Never smoke while operating or fueling this unit.
Never operate or store this unit near an open flame, heat, or any other ignition source.
Generator should have at least 5 feet of clearance from buildings or other equipment during operation.
Keep engine free of grass, leaves, or grease which are flammable.
When adding or draining fuel, unit should be turned off for at least 2 minutes to cool before removing fuel cap. If unit
has been running then the fuel cap is under pressure, remove slowly.
To keep fuel from spilling, secure unit so it cannot tip while operating or transporting.
When transporting unit, disconnect the spark plug wire and make sure the fuel tank is empty with the fuel shutoff valve
turned to the off position.
WARNING!
•
Pull cord recoils rapidly and pulls arm towards engine faster than you can let go which
could result in injury.
To avoid recoil, pull starter cord slowly until resistance is felt, then pull rapidly.
WARNING!
•
•
Keep engine away from flammable objects and other hazardous materials.
Avoid contacting hot areas of this unit.
Use caution around the muffler, cylinder, and other engine parts as they can be extremely hot.
Allow hot components to cool before touching.
5
SAFETY RULES
This generator produces a very high voltage which could result in burns or
electrocution causing serious injury or death.
Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands
or feet are wet.
Always keep the generator dry. Never operate generator in rain or under wet conditions.
Use a ground fault circuit interrupter (GFCI) in a damp or highly conductive area, such as metal decking
or steel work.
Never plug electronic devices into generator having frayed, worn, or bare wires. Never touch bare wires or make
contact with receptacles.
Never permit a child or unqualified person to operate generator. Keep children a minimum of 10 feet away from the
generator at all times.
If using the generator for back up power, notify the utility company.
If connecting generator to a building’s electrical system for standby power, you must use a qualified electrician to
install a transfer switch. Failure to isolate the generator from the power utility could result in serious injury or death to
electric utility workers.
WARNING!
•
•
•
•
•
•
•
WARNING!
•
•
Generator must be properly grounded to prevent electrocution.
Only operate generator on a level surface.
Always connect the nut and ground terminal on the frame to an appropriate ground source.
WARNING! Never modify this unit in any way or modify governed speed.
•
•
•
Increasing governing speed is dangerous which can result in personal injury and / or damaged equipment.
Decreasing governing speed adds an excessive load and can damage equipment.
Only when operating at the preset governing speed will this generator will supply the correct rated frequency and
voltage.
WARNING! Only use this unit as intended or serious injury or death could result.
•
•
•
Do not bypass any safety device. Moving parts are covered with guards. Make sure all protective covers are in place.
Never transport or make adjustments to this unit while it is running.
Never insert objects through cooling slots.
WARNING!
•
•
•
Never operate this unit if there are any broken or missing parts and only use Pulsar
replacement parts specifically designed for this unit.
Improper treatment of generator can damage the unit and shorten it’s life.
Always repair this unit as specified in this manual. If you have any questions contact your dealer or consult a qualified
service center.
Shut generator off if electrical output is missing, unit vibrates excessively or begins to smoke, spark or emit flames.
PROP 65 WARNING: This product contains chemicals known to the state of California to cause cancer and birth defects or
other reproductive harm.
6
FEATURES
C
B
A
G
H
I
A - ON/OFF Start Switch
B - Hour Meter
C - 2-120V Receptacles
D - 120 Volt 30Amp RV Receptacle
E - Circuit Protectors
D
E
F
J
F -120V / 240V 30 Amp Twist Lock (L14-30)
G - Oil Alert
H - 12V DC Output (For Charging Batteries Only)
I- Grounding Connection
J - Voltage Selector Switch
7
FEATURES
K
R
L
M
N
O
S
P
Q
K - Fuel Tank Vapor Vent
L -Choke Level
M - Fuel Valve (ON/OFF)
N - Recoil Starter Grip
O - Air Filter
P - Handle
Q - Support Foot
R - Fuel Tank
S - No Flat Tires
8
ASSEMBLY
Unpacking
1. Place box on a level surface.
2. Remove all items from box except the generator. Make sure all items listed on the packing list are included and not
damaged.
3. Cut down the sides of the box being careful to avoid hitting the generator.
4. Leave generator on box to install wheel assembly.
Packing List
Check all loose parts to the following list. Contact your dealer if any loose parts are not included.
Description
Generator
Operator’s manual
Product registration card
Spark Plug Wrench
Qty
1
1
1
Description
Handle
Handle Bracket
Handle Clip
Screw
Nut
Wheels
Axles
Washer
Hair pin
1
Toolkit fill cup (20oz)
1
Funnel
Qty
1
1
1
4
4
2
2
2
2
Description
Supporting Leg
Screw
Nut
Handle Assembly
+
+
+
+
Wheel Assembly
+ +
+
+
Qty
2
2
2
+
+
Foot Assembly
+ +
9
+ + +
(
)
+
ASSEMBLY
Attaching Handle (See fig 1)
• Parts needed - 1 handle, 1 handle bracket , 1 handle clip, 4 screws and nuts.
• Install handle bracket to generator frame. (fig. 1)
• Then attach handle to the bracket handle.
• Lastly install handle clip.
Attaching Wheels (See fig 2)
• Parts needed - 2 wheels, 2 axles, 2 hair pins, and 2 washers.
• Raise or tilt generator so you can slide the wheel axle pin into the wheel, the washer, the wheel mounting hole located
on the side of the frame.
• Secure the wheel assembly by reinserting a hair pin through hole at the end of the wheel axle and pressing until it locks
into place.
• Repeat process on the other side of the generator to install the second wheel.
Fig 2
Fig 1
Installing Support Leg (See fig 3)
•
•
•
•
Parts needed - Support leg & M8 screw (2) and 2 nuts.
Raise the front end of the generator high enough to gain access to the bottom of the frame. Securely position props
underneath to support.
Line up holes on the support leg bracket to the holes on the front of the generator frame.
Attach the support leg using M8 screws (2) and nuts.
Fig 3
10
ASSEMBLY
Adding / Checking Engine Oil (See fig 4)
•
•
•
•
•
Place generator on a level surface.
Remove the crankcase dipstick to ensure you do not overfill the engine.
Insert a funnel into the crankcase dipstick hold and carefully add 4-Cycle engine oil (SAE10W- 30) to empty reservoir
until oil reaches the outer edge of the oil fill hole (crankcase dipstick hole).
Be sure to replace dipstick before attempting to start the engine.
To check oil, set generator on a level surface, wipe dipstick clean, then reinsert dipstick without rethreading.
CAUTION!
You must add oil before first operating this generator. Always check oil level before each
operation.
DO NOT USE E15 OR E85 FUEL IN THIS UNIT. IT IS A VIOLATION OF FEDERAL LAW AND
WILL DAMAGE THE UNIT AND VOID YOUR WARRANTY.
10W30
Un
Ga lea
so ded
lin
e
OIL
Fig 5
Fig 4
11
ASSEMBLY
Adding Fuel (See fig 5)
•
•
•
Set generator on a clean and level surface in an area that is well ventilated.
Remove fuel cap.
Insert a funnel into the fuel tank and carefully pour gasoline into the tank until fuel level reaches 1 ½ inches below the
top of the neck. Be careful not to overfill the tank to provide space for fuel expansion.
CAUTION!
You must add oil before first operating this generator. Always check oil level before each
operation.
DO NOT USE E15 OR E85 FUEL IN THIS UNIT. IT IS A VIOLATION OF FEDERAL LAW AND
WILL DAMAGE THE UNIT AND VOID YOUR WARRANTY.
Connecting Generator to an Electrical System
•
If connecting generator to a building’s electrical system for standby power, you must use a qualified electrician to install
a transfer switch. The power from the generator must be isolated from the circuit breaker or alternative power source.
The connection must comply with all electrical codes and applicable laws.
This generator produces a very high voltage which could result in burn or
electrocution causing serious injury or death.
Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands or
feet are wet.
Always keep the generator dry. Never operate generator in rain or under wet conditions.
Use a ground fault circuit interrupter (GFCI) in a damp or highly conductive area, such as metal decking or steel
work.
Never plug electronic devices into generator having frayed, worn, or bare wires. Never touch bare wires or make
contact with receptacles.
Never permit a child or unqualified person to operate generator. Keep children a minimum of 10 feet away from the
generator at all times.
If using the generator for back up power, notify the utility company.
If connecting generator to a building’s electrical system for standby power, you must use a qualified electrician to
install a transfer switch. Failure to isolate the generator from the power utility could result in serious injury or death to
electric utility workers.
WARNING!
•
•
•
•
•
•
•
12
OPERATION
Grounding the Generator (See fig 6)
The ground terminal located on the front panel of the generator must always be used
to connect generator to a driven ground rod. Connect the ground terminal to the driven
ground rod with a No 8 AWG (American Wire Gauge) copper wire. The wire connects
to the terminal between the lock washer and nut. Tighten the nut securely to ensure
proper connection. Grounding the generator protects you from electric shock that
results from a build up of static electricity or undetected ground faults.
Fig 6
WARNING!
•
•
Generator must be properly grounded to prevent electrocution.
Only operate generator on a level surface.
Always connect the nut and ground terminal on the frame to an appropriate ground source.
How to Start Engine (See fig 7-10)
Place generator on a level surface. All electrical loads MUST be disconnected from generator.
Turn fuel valve to the “ON” position. (See fig 7)
Slide the choke lever to the “Choke” position. (See fig 8) SKIP THIS IF THE ENGINE IS WARM OR HOT.
For manual start, turn the engine ON/OFF switch to the “ON” position. Pull the recoil handle (starter cord) slowly
until resistance is felt, then pull rapidly. (See fig 9)
Let engine run for several seconds and then gradually, as engine warms up, slide the choke lever towards the “RUN”
position until the choke is fully slid to the “RUN” position. (See fig 10)
•
•
•
•
•
Never start or stop engine with electrical devices plugged in to the receptacles. Failure to
do so could damage the generator and / or connected electrical devices.
Always start the engine and let it stabilize before connecting any electronic devices.
Disconnect all electronic devices before stopping the engine.
WARNING!
•
•
WARNING!
•
Pull cord recoils rapidly and pulls arm towards engine faster than you can let go which
could result in injury.
To avoid recoil, pull starter cord slowly until resistance is felt, then pull rapidly.
13
OPERATION
CHOKE
RUN
CHOKE LEVER
Fig 7
Fig 8
WAIT
5sec
1
CHOKE
RUN
CHOKE LEVER
2
Fig 10
Fig 9 Recoil Start
How to Stop Engine (See fig 11-13)
•
•
All loads MUST be disconnected from the generator. Never start or stop the engine with electrical devices plugged in to
the receptacles.
Turn the fuel valve to the “OFF” position.
• Turn the engine ON/OFF switch to the “OFF” position.
2
Fig 11
Fig 12
Fig 13
14
OPERATION
Receptacles and Extension Cords
Only use high quality, well-insulated, grounded extension cords in good condition with generator receptacles. Extension
cords should have a minimum rating of 125 Volts AC, 20 Amps and should be kept as short as possible to minimize voltage
drop. Follow each load manufacturer’s power rating recommendation when selecting receptacle and extension cord.
This generator is equipped with the following receptacles:
• Two 120 Volt AC, 20 Amp receptacles.
• One 120 Volt AC,30Amp RV receptacle
• 120 / 240 Volt AC, 30 Amp twist lock receptacle (NEMA L14-30).
• 12 Volt 8.3 Amp Output (For charging batteries only)
120 Volt AC, 20 Amp receptacle
• This receptacle has a 20 Amp push-to reset circuit breaker to protect against overload.
• Each socket is rated to operate 120 Volt, AC, single phase, 60Hz loads requiring up to 2400 watts (2.4 kW) at 20 Amps.
• Use extension cords having a minimum rating of 125 Volts AC, 20 Amps.
120 / 240 Volt AC, 30 Amp locking receptacle
• This receptacle has a 30 Amp push-to reset circuit breaker to protect against overload.
• This receptacle is rated to operate 120 Volt, AC, single phase, 60Hz loads requiring up to 3600 watts (3.6 kW) at 30
Amps. It is also rated to operate 240 Volt AC, single phase, 60Hz loads requiring up to 7,200 watts (7.2 kW).
• Use a NEMA L14-30 plug with this receptacle.
• Use a 4-wire cord rated for 240 Volts AC, 30 Amps to the plug. You can use the same 4-wire cord to operate a 120 Volt
load.
Voltage selector switch
This switch allows the generator to operate in either single voltage (120V) or dual voltage (120V/24V) mode. When placed in
the 120V position it allows you to receive the full capacity of the generator by duplex (5-20R) at 120V receptacles. When placed
in the 120/240V position, you will only be able to receive half the available watts when using the 120 volt receptacles and
the full available watts when using the 240V 4--prong twist-lock receptacle.
CAUTION!
CAUTION!
Do not move the voltage selector switch while powering electrical devices. Disconnect all
electrical loads before moving the switch. Failure to disconnect electrical loads could damage the
switch or generator.
Do not connect 3-phase loads to generator.
WARNING! 12 Volt 8.3 Amp Output is for charging batteries only!
15
OPERATION
Extension Cord Selection
Refer to the below table to ensure the extension cord used has the capacity to carry the required load. If the size of the
cable is inadequate it can cause a voltage drop, which can damage the electrical device and cord.
Current
(Amps)
2.5
5
7.5
10
15
20
25
30
Load (Watts)
120V
300
600
900
1200
1800
2400
3000
3600
240V
600
1200
1800
2400
3800
4800
6000
7200
Maximum Cord Length
#8 Wire
#10 Wire
X
1000 ft.
X
500 ft.
X
350 ft.
X
250 ft.
X
150 ft.
175 ft.
125 ft.
150 ft.
100 ft.
125 ft.
65 ft.
#12 Wire
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
X
X
#14 Wire
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
X
X
X
#16 Wire
250 ft.
125 ft.
100 ft.
50 ft.
X
X
X
X
Ground Fault Circuit Interrupter
Receptacles are protected by a Ground Fault Circuit Interrupter (GFCI) to prevent users from electrocution caused by
moisture or from faulty electrical devices attached to generator. (GFCI) receptacles do not protect against short circuits,
overloads, or shocks. To test the (GFCI) receptacles depress the TEST button and make sure the RESET button pops
out. To restore power to the receptacle, depress the RESET button. It is highly recommended that you test the (GFCI)
receptacles prior to each use.
Moving the Generator
•
•
•
•
Disconnect any electronic devices from generator then turn generator off.
Turn fuel valve to the “OFF” position.
Tilt generator until it balances on wheels. Roll machine to desired location.
If the generator must be carried, fold handle to the down position. Never lift or carry generator by its handle.
CAUTION!
This product is heavy and requires several people to lift. Lift and lower with your legs by bending
at the knees, not your back, to avoid injury.
Don’t Overload Generator
Make sure you can supply enough rated watts and surge watts for all electronic devices connected to the generator. Rated
watts refer to the power a generator must supply to keep a device running. Surge watts refer to the power a generator
must supply to start an electronic device. This power surge for starting a device usually lasts between 2-3 seconds but this
additional output must be taken into account when selecting the electronic devices you plan to attach to the generator. To
prevent overloading the generator take the following steps:
1. Add up the total rated wattage of all electronic devices that will be connected to the generator simultaneously.
2. Estimate surge watts by adding the item(s) with the highest output (it is unnecessary to calculate the surge output for all
devices as they should be connected one at a time).
3. Add the Surge Watts to the total Rated Watts in step 1. Keep total load within generator’s power capacity.
16
OPERATION
Operating voltage and frequency requirement of all electronic equipment should be checked prior to plugging them into this
generator. Damage may result if the equipment is not designed to operate within a +/- 10% voltage variation, and +/- 3 Hz
frequency variation from the generator name plate ratings. To reduce the risk of damage, always have an additional load
plugged into the generator if solid state equipment (such as television set) is used. A power line conditioner is recommended
for some solid state applications.
Wattage Reference Guide
(Wattages listed are just approximations. Check electronic device for actual wattage)
Essentials
Rated Watts Surge Watts
Bathroom
Rated Watts Surge Watts
75W Light Bulbs
75 each
75 each
Hair Dryer
1250
0
18 CU Ft Refrigerator / Freezer
800
2200
Curling Iron
1500
0
Furnace Fan (⅓ HP)
800
2350
Family Room
Sump Pump (⅓ HP)
1000
2000
X-Box or Play Station
40
0
Water Pump (⅓ HP)
1000
3000
AM/FM Radio
100
100
VCR
100
100
500
500
Heating/Cooling
Dehumidifier
650
800
Color TV (27”)
Table Fan
800
2000
Home Office
Window AC (10k BTU)
1200
3600
Fax Machine
65
0
Central Air (10k BTU)
1500
6000
Personal Computer (17” Monitor)
800
0
Electric Blanket
400
400
Laser Printer
950
0
Space Heater
1800
1800
Copy Machine
1600
0
Kitchen
Power Tools
Blender
300
900
1000W Quartz Halogen Work Light
1000
0
Toaster (2 slice)
1000
1600
Airless Sprayer (⅓ HP)
600
1200
Coffee Maker
1500
1500
Reciprocating Saw
960
0
Electric Range (1 element)
1500
1500
Circular Saw (7 ¼”)
1400
2300
Dishwasher
1500
3000
Miter Saw (10”)
1800
1800
Electric Oven
3410
3410
Table/Radial Arm Saw
2000
2000
Electric Water Heater
4000
4000
Laundry Room
Electric Drill (½ HP, 5.4 Amps)
600
900
Hammer Drill
1000
3000
1600
4500
Iron
1200
1200
Air Compressor
Washing Machine
1150
3400
Other
Gas Clothes Dryer
700
2500
Home Security System
500
500
Electric Clothes Dryer
5400
6750
Garage Door Opener (⅓ HP)
750
750
WARNING!
•
Never exceed generator’s wattage / amperage capacity. This could damage the generator
and / or connected electrical devices.
Check operating voltage and frequency requirements of all electrical devices prior to plugging them into the generator.
17
OPERATION
Hour Meter (See Fig 14)
The digital hour meter operates whenever the engine is running and keeps track of how many hours the unit has been used.
Use this meter along with the manual to determine when and what type of service on the unit is needed. The display will
show the word “LUBE” at the first 25 hours of operation and again at every 100 hours of operation after.
Fig 14
Power Management
•
•
•
Start engine without anything connected to generator.
When engine has stabilized, plug in and turn on first load. It is strongly recommended to plug in devices with the largest
output first and the smallest output last to help prevent overloading the generator.
Allow generator output to stabilize (engine and attached devices run evenly) before plugging in the next load.
Cold Weather Operation
Under humid conditions where temperatures drop to 40ºF (4ºC) the carburetor and/or crankcase breather system may begin
to freeze. To prevent icing take the following steps:
1. Replace any old fuel with clean, fresh fuel.
2. Use synthetic 5W-30 or SAE 5W-30 engine oil. Check oil daily or after every 8 hours of use.
3. Turn fuel valve to the open position.
4. Ensure generator is serviced according to the maintenance schedule under “Maintenance” section of manual.
5. Shelter unit from elements.
18
MAINTENANCE
Regular maintenance will extend the life of this generator and improve its performance. The warranty does not cover items
that result from operator negligence, misuse, or abuse. To receive full value from the warranty, operator must maintain the
generator as instructed in this manual, including proper storage.
Before inspecting or servicing this machine, make sure the engine is off and no parts are
WARNING! moving. Disconnect the spark plug wire and move it away from the spark plug.
Pre-Operation Steps
Before starting the engine, perform the following pre-operation steps:
• Check the level of the engine oil and the fuel tank level.
• Make sure the air filter is clean.
• Remove any debris that has collected on the generator and around the muffler and controls. Use a vacuum cleaner to
pick up loose debris. If dirt is caked on, use a soft bristle brush.
• Inspect the work area for hazards.
After Each Use
Follow the following procedure after each use:
• Shut off engine.
• Charge electric starter. (see Battery Charger for Electric Starter pg 15)
• Store unit in a clean and dry area.
Maintenance Schedule
After First 5 Hours
Change Oil
After 8 Hours or Daily Clean Debris
Check Engine Oil Level
Annually (25 hr Use) Check and Clean Air Cleaner
Change Engine Oil (Service more often under dirty or dusty conditions)
Check Muffler and Spark Arrester
Annually (100 hr Use) Service Spark Plug (Replace with NGK BP6ES, Champion N9YC or equivalent)
Service Fuel Valve
Inspect Muffler and Spark Arrester
Check and Clean Air Cleaner, Replace Air Filter
Clean Cooling System
19
MAINTENANCE
Changing Oil (See Fig 15)
Oil drainage plug
Fig 15
104
86
68
50
*
32
14
-4
40
*
*
30
20
10
0
5W-30
Do not use special additives.
Outdoor temperatures determine the proper oil viscosity for the engine.
Use the chart to select the best viscosity for the outdoor temperature range
expected.
Synthetic 5W-30
•
•
C
F
Oil Recommendations
10W-30
•
Run the Generator until the Engine is warm.
Place generator on a level surface.
Remove the crankcase dipstick.
Place an oil pan underneath the oil drainage bolt to collect used oil.
Remove the oil drainage plug and allow oil to drain completely.
Reinstall oil drainage plug, tighten securely.
Carefully add SAE 10W-30 to empty reservoir until the oil reaches the
outer edge of the oil fill hole (Crankcase Dipstick hole).
Replace crankcase dipstick.
SAE 30
•
•
•
•
•
•
•
-22
CAUTION!
Used oil should be disposed of at an approved disposal
site. See your local oil retailer for more information.
-10
-20
-30
Note: *Below 40°F (4°C) the use of SAE 30 will result in hard
starting.**Above 80°F (27°C) the use of 10W-30 may cause
increased oil consumption. Check oil level more frequently
Air Filter (See Fig 16)
A dirty air filter will reduce the life span of the engine, make it difficult to start the engine, and reduce the unit’s performance.
• To clean, remove the air filter cover.
• Carefully pull the air filter out by lifting up along the edges.
• Remove dirt from filter by tapping on it or having it blown out. Replace with new filter annually.
• Reinstall air filter so that it seals and replace air filter cover.
Checking Spark Plug (See Fig 17)
•
•
•
•
•
•
•
Disconnect the spark plug wire from the spark plug.
Before removing the spark plug, clean the area around its base to prevent debris from entering the engine.
Clean carbon deposits off the electrode with a wire brush.
Check the electrode gap and slowly adjust to 0.762 mm - 0.80 mm (.030 - .031") if necessary.
Reinstall spark plug and tighten to Torque 22.0 – 26.9 Nm (16-20 ft-lb).
Reconnect spark plug wire.
If spark plug is worn replace only with an equivalent replacement part. Spark plug should be replaced annually.
(BOSCH F7TC, NGK BP6ES, CHAMPION N9YC or Equivalent)
0.762 - 0.800 mm
Fig 16
20
Fig 17
MAINTENANCE
Spark Arrestor (See Fig 18 If Appicable)
•
•
•
Inspect the spark arrestor for breaks or holes. Replace if necessary. To purchase a replacement spark arrestor contact
PULSAR customer service.
Use a brush to remove carbon deposits from the spark arrestor screen as needed.
To remove the spark arrestor: While the muffler is cool, loosen the locking clamp and slide the spark arrestor out of the
muffler. Reverse this process to install it.
Cooling System
Cooling system should only be serviced by an authorized dealer.
Carburetor Adjustment
The carburetor is low emission and is equipped with a non-adjustable idle mixture valve. If adjustment is needed contact
an authorized dealer.
Replacing Fuel Filter (See Fig 19 If Appicable)
Occasionally the fuel filter may become clogged and need replacing. To purchase a replacement fuel filter contact PULSAR
customer service or your local small Engine repair shop.
• Turn the fuel valve to the “OFF” position.
• Remove the fuel line from both sides of the filter by squeezing the ends of the retaining clip with pliers.
• Slide the fuel line off.
• Replace with new fuel filter.
• Reinstall fuel lines to new fuel filter.
• Turn the fuel valve to the “ON” position.
CAUTION!
Fuel tank must be empty before replacing fuel filter. Run unit until tank is empty, if needed,
or inspect filter prior to fill-up.
OFF
Fig 18
Fig 19
Draining Fuel Tank and Carburetor
To help prevent gum deposits in the fuel system, drain the fuel from the tank and carburetor before storing the unit for long
periods of time. This will help prevent starting problems in the future. If the unit is stored with fuel and the fuel becomes
stale or turns gummy or to varnish the warranty does not cover this repair or service.
21
MAINTENANCE
Draining the fuel tank
• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Push the fuel valve knob through the valve holder bracket allowing you to access the petcock.
• Remove the fuel line that leads to the carburetor from the petcock by squeezing the ends of the hose clamps and
sliding the fuel line off.
• If needed, install a fuel hose that will extend to a suitable fuel container large enough to catch the fuel being drained
from the tank.
• Turn the fuel valve to the ON position.
• When the fuel has drained from the tank, close the fuel valve and reinstall fuel line securely on petcock.
• Reinstall the fuel valve knob in the valve bracket. Push forward until knob snaps securely into position.
Draining the carburetor
• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Position a suitable container under the carburetor drain screw to catch fuel; loosen the screw.
• Allow fuel to drain completely into container.
• Retighten drain screw.
CAUTION!
Consult your local hazardous waste management in your area for the proper way to dispose
of used fuel.
Storage
•
•
•
•
•
•
Remove any debris that has collected on the generator and around the muffler and controls. Use a vacuum cleaner to
pick up loose debris. If dirt is caked on, use a soft bristle brush.
Inspect air cooling slots. Remove any debris if obstructed.
Disconnect negative battery cable from battery.
For short-term storage, start generator once every 7 days.
For long-term storage, add fuel stabilizer to prevent stale fuel from causing acid and gum deposits in the fuel system
and carburetor.
Store indoors and use a protective cover to protect from dust.
22
TROUBLESHOOTING
Problem
Engine is running, but AC output is not
available
Cause
1. Open circuit breaker
2. Poor connection
3. Defective cord set
4. Connected device is faulty
5. Fault in generator
Engine runs well without load but bogs 1. Short circuit in connected device
down when loads are connected
2. Generator is overloaded
3. Clogged fuel filter
4. Engine speed is too slow
5. Short circuit in generator
Engine will not start, shuts down during 1. ON/OFF switch set to “OFF”
operation, or starts and runs rough.
2. Dirty Air filter
3. Clogged fuel filter
4. Stale fuel
5. Spark plug wire disconnected from
spark plug
6. Bad spark plug
7. Water in fuel
8. Fuel valve is in “OFF” position
9. Over choking
10. Low oil level
11. Rich fuel mixture
12. Intake valve stuck open or closed
13. Loss of engine compression
14. Dead battery
15. Engine has flooded
Engine lacks power
1. Generator is overloaded
2. Clogged fuel filter
3. Dirty Air filter
4. Engine needs servicing
Engine “hunts” or falters
1. Choke was removed too soon
2. Clogged fuel filter
3. Carburetor is running too rich or too
lean
23
Solution
1. Reset circuit breaker
2. Check and repair
3. Check and repair
4. Connect a device that is working
properly
5. Contact service department
1. Disconnect device
2. See pg 17 “Don’t overload
generator”
3. Clean or replace fuel filter
4. Contact service department
5. Contact service department
1. Turn switch to “ON”
2. Replace Air filter
3. Clean or replace fuel filter
4. Replace fuel
5. Reconnect spark plug wire
6. Replace spark plug
7. Drain fuel tank and replace fuel
8. Turn fuel valve to “ON” position
9. Turn off choke
10. Fill crankcase to proper oil level &
place generator on a level surface
11. Contact service department
12. Contact service department
13. Contact service department
14. Recharge or replace battery
15. Wait 5 minutes and recrank engine
1. See pg 17 “Don’t overload
generator”
2. Clean or replace fuel filter
3. Replace Air filter
4. Contact service department
1. Move choke to middle position until
engine runs evenly
2. Clean or replace fuel filter
3. Contact service department
DIAGRAMS
+
24
WARRANTY
Pulsar Products Inc. Limited 2 Year Warranty:
From the date of original purchase, Pulsar Products Inc. warrants to the original purchaser that each portable generator
sold, shall be free from defect in material and workmanship for the items and time period set forth below. Pulsar Products
Inc., at its discretion, agrees to repair or replace any defective part that upon examination, inspection, and testing by
a Pulsar Products Inc. authorized service dealer, is found to be defective within the original warranty period. Pulsar
Products Inc. will also decide upon the use of new or rebuilt parts or comparable product. Any part or product that is replaced
will be retained by Pulsar Products Inc.. This warranty period shall not be extended and any repaired product shall be
warranted for the remaining period of the original warranty. The consumer is responsible, and shall prepay all transportation
costs, including returning items to the factory or warehouse. This warranty is non-transferable and proof of purchase must
be presented for requesting warranty service. If a proof-of-purchase receipt is not provided, the product’s shipping date by
the manufacturer will be used to determine the warranty period.
Length of Warranty:
Personal use applications of this portable generator are warranted for two (2) years or 500 hours which ever comes first.
Proof of purchase and of maintenance must be provided.
• Year 1 - Limited coverage on generator engine and alternator components parts and labor.
• Year 2 - Limited coverage on generator engine components, parts only.
“Personal use” means personal residential household use or recreational use by the retail consumer. “Commercial use”
means all other uses including commercial, construction, or other income producing purposes. Once a generator has been
used for commercial purposes, it shall thereafter be considered as a “commercial use” generator for the purposes of this
warranty. Any portable generator used for commercial use, as rental equipment or for the purpose of primary power in place
of utility, will not be covered under this warranty.
Consumer Responsibilities:
• Consumer is responsible for carefully reading and following all instructions in the owner’s manual. Any product that is
damaged due to misuse or abuse will not be covered by this warranty.
• Consumer is responsible for all transportation costs to an authorized Pulsar Products Inc. Service Center. Unless
otherwise requested, ground shipping will be applied for part shipment and customer will pay any additional charges for
expedited shipments.
• Consumer is responsible for labor costs associated with warranted repairs twelve (12) months after the purchase date.
Labor rates will only be based on normal working hours.
• Consumer is responsible for maintaining generator as specified in the owner’s manual. Documentation of this
maintenance may be required to cover warranty requests.
• Consumer is responsible for presenting any problems with the generator to an authorized Pulsar Products Inc.
Service Center as soon as the problem exists. Warranted repairs will be completed in a reasonable period of time, not
to exceed 30 days.
25
WARRANTY
What this Warranty Does Not Cover:
• Normal wear: This warranty excludes normal wear items such as filters, spark plugs, gaskets, O-rings, adapter cord
sets, wheels, and starting batteries.
• Maintenance: This warranty does not apply to tune-ups or routine maintenance and does not cover any adjustments or
repairs not performed by an authorized repair facility.
• Misuse: This warranty does not apply if your product has failed due to abuse, misuse, neglect, using incorrect fuels or
lubricants, overloading, overspeeding, improper maintenance, improper storage, unapproved modifications, or has been
operated in any way contrary to the instructions found in the products owner’s manual.
• Adverse conditions: This warranty does not apply if your product has failed due to freezing, accident or natural
disasters.
• Product shipment: This warranty does not apply to damage resulting from shipping, handling, or warehousing. Any
damage claims to this product caused by shipment must be filed with freighter.
• Other exclusions: This warranty does not apply if your product has been sold “as is” or where the factory applied serial
number has been removed. Refurbished, used, demonstration or floor models are not covered by this warranty.
Where Warranty is Valid:
For warranty coverage, this product must be purchased from an authorized Pulsar Products Inc. dealer and the warranty
only extends to the original purchaser in the United States, Canada, or Mexico. Refurbished, used, demonstration, or floor
models are not covered by this warranty. Products purchased from on-line auction websites, such as ebay, are not covered
under this warranty. Products used for commercial use are not covered under this warranty.
How to Obtain Warranty Service:
Take the original receipt and product to the place of purchase or mail the original receipt and product to the address found
on the web site if purchased on-line. You can also locate your nearest Pulsar Products Inc. dealer for service or warranty
questions by calling toll free at 1-866-591-8921. Pulsar Products Inc. recommends you retain all of your receipts
covering the purchase and maintenance of your Portable Generator, but will not deny you warranty coverage as long as
proof of purchase or service can be obtained.
Pulsar Products Inc.’s obligation under this warranty is exclusively limited to product repair or replacement and
shall not be liable for any incidental or consequential damages including, but not limited to, the expense of
delivering product to and from a repair center, loss or damage to personal property, loss of revenue, telephone
charges, loss of time, or inconvenience. Some states, provinces or jurisdictions do not allow the exclusion or
limitation of incidental damages, so the above limitation may not apply to you. The warranty gives you specific
legal rights, and you may also have other rights which vary from state to state or province to province.
Image of products may slightly differ due to continued improvement of product.
IM PG5250
Rev.A 7/01/2016
26