Pulsar GD400BN 4000 Watt Dual Fuel Inverter Generator Operator's Manual

Introduction

Thank you for choosing Pulsar Products! This manual provides instructions on how to operate and use the generator safely and correctly. It is essential to read and understand this manual before using the generator. For any questions, contact Pulsar Support at 866.591.8921 (M-F) or email support@pulsar-products.com BEFORE using the generator.

All details and images in this Operator's Manual are believed to be accurate at the time of publication. Pulsar Products reserves the right to make updates to this manual at any time. This manual is a permanent part of the generator set and should be included if the generator is resold.

Safety Warnings and Notices

Throughout this manual and on generator decals, various safety notices may appear. These Safety Warnings alert users to potential hazards that could cause death, injury, or property damage. The decals use one of four words: "DANGER", "WARNING", "CAUTION", and "NOTICE". Definitions are as follows:

Safety Instructions

Before operating the generator, users must read and understand the Operator's Manual and familiarize themselves with safe operation practices.

• Never use a generator indoors! Exhaust and Carbon Monoxide can KILL in minutes. (Illustration: A generator operating inside a house with a person collapsing and a skull symbol, indicating carbon monoxide danger.)
• Avoid running the generator in the rain or very high, condensing humidity. (Illustration: A generator outdoors in heavy rain with a large 'X' over it, indicating it should not be used in wet conditions.)
• This is a portable generator, DO NOT attempt to connect it to any mains panel. (Illustration: A generator connected to a house's electrical panel with a large 'X' over the connection, indicating it should not be directly wired to a home's electrical system.)
• Never smoke or allow any heat source near the generator while refueling it. (Illustration: A person smoking near a generator being refueled with a large 'X' over the person, indicating fire hazard.)
• Make sure not to spill any gasoline and wipe up any accidental spills at once. (Illustration: Spilled gasoline on the ground near a generator with a large 'X' over it, indicating the need to clean spills immediately.)
• Always shut down the generator and allow it to cool before refueling! (Illustration: A generator being refueled while running with a large 'X' over it, indicating it must be off and cool before refueling.)

Names of Components

Familiarize yourself with the generator's parts for safe operation.

• Lifting Handle: Top handle for carrying.
• Fuel Tank Cap: Located on top for fuel access.
• Left Enclosure: Side casing.
• Control Panel: Front panel with controls and indicators.
• Recoil Start: Pull cord for manual starting.
• Spark Plug Access: Cover for spark plug maintenance.
• Right Enclosure: Side casing.
• Rear Panel: Back side with muffler and ventilation.
• Air Filter Access: Cover for air filter maintenance.
• Oil Fill Access: Cover for engine oil access.
• Muffler: Exhaust component.

(Illustration: Top-down and side views of the generator with labels pointing to each component.)

Control Panel

The control panel features various switches, indicators, and outlets:

• LOW IDLE Switch: Rocker switch with 'ON' and 'OFF' positions.
• INDICATOR LIGHTS:
• LOW OIL: Illuminates when oil level is low.
• OVERLOAD: Illuminates when electrical load is excessive.
• OUTPUT: Illuminates when stable AC output is present.
• CIRCUIT BREAKER (30A): Push-button breaker for 120V 30A outlet.
• FUEL SOURCE Switch: Rocker switch with icons for Gasoline (gas pump) and Propane (LPG tank).
• MULTI-SWITCH: Large rotary knob with 'OFF', 'RUN', 'START' (CHOKE) positions.
• AC 120V 30A Outlet: Twist-lock receptacle (Neutral Floating).
• PARALLEL CONNECTION: Two receptacles for connecting parallel cables.
• LPG INLET: Connection point for propane hose.
• CIRCUIT BREAKER (20A): Push-button breaker for 120V 20A outlets.
• AC 120V 20A Outlets: Two standard receptacles (Neutral Floating).

⚠ To avoid damage, DO NOT connect or disconnect parallel cables while the unit is running.

(Illustration: Detailed diagram of the control panel with all elements labeled.)

Control Functions

Multi-Switch

• OFF: Ignition circuit is off, fuel valve is closed, engine will not run.
• RUN: Ignition circuit is on, fuel valve is open, choke is open, engine runs normally.
• START (CHOKE): Only used for cold starting. Ignition circuit is on, fuel valve is open, choke is closed.

(Illustration: Diagram of the Multi-Switch knob with OFF, RUN, START/CHOKE positions.)

Overload Indicator (Red)

When the overload indicator illuminates, the generator has detected excess electrical load, and the circuit breaker may open (trip). If the overload indicator illuminates and the generator has no electrical output, perform the following:

1. Disconnect all electrical loads and shut down the generator.
2. Reduce total draw of electrical loads connected to less than rated output.
3. Confirm no debris blocks the air inlet; correct as necessary.
4. Ensure all circuit breakers are pushed in.
5. Restart the engine and add electrical load in gradual steps.

Tip: When using electrical equipment with high starting current (e.g., compressors, saws, pumps), the overload indicator may illuminate for a few seconds, which is normal.

Oil Indicator (Red)

When the engine oil level drops too low, the engine automatically shuts down, and the oil alarm indicator illuminates. The engine can be restarted only after the engine oil is filled correctly.

Tip: If the engine will not start, turn the Multi-Switch knob to "RUN" position and pull the recoil handle. If the oil indicator flashes for a few seconds, the oil volume is insufficient; fill oil to the dipstick high mark and restart.

AC Indicator (Green)

The AC indicator illuminates when electrical output is stable.

Energy Saving (Idle) Switch

• ON: When the energy saving switch is "ON", engine speed is reduced under light load, reducing fuel consumption and noise.
• OFF: When the energy saving switch is "OFF", the engine runs at rated speed regardless of connected load.

AC Circuit Breaker

If the total AC load exceeds the rated current, the AC circuit breaker will open (trip) and the button will pop out. In this case, disconnect all loads, restart the generator, and push in the AC circuit breaker(s).

Grounding Terminal

If grounding is required by code or application, follow the guidelines on page 10.

Preparing Your Generator

Engine Oil

The generator ships without engine oil. Do not attempt to start it without sufficient engine oil in the crankcase.

1. Place the generator on a flat, stable surface.
2. Unscrew the knob to remove the oil access cover.
3. Unscrew the oil dipstick.
4. Use a funnel to add 12 fluid ounces (0.35L) of 10w-30 engine oil to the crankcase. Verify oil level with the dipstick.
5. Reassemble the oil access cover and tighten the knob.

(Illustration: Sequence showing removing oil access cover, dipstick, and adding oil.)

Pre-use Inspection

Fuel

Check fuel level; add if necessary.

Oil

Check oil level; add if necessary. Check for any oil leaks.

Gasoline

Do not overfill the fuel tank! Heat and vibration can cause fuel to leak from an over-filled fuel tank.

After refueling, confirm that the fuel tank cap has been tightened.

Fuel tank capacity: 1 US gallon.

Propane (LPG)

Never bring a propane tank inside the home or any enclosed structure.

After connection, check for leaks: Open the tank supply valve, apply soapy water to the gas fittings, and ensure there are no bubbles.

Propane has an added odorant (sulfur/rotten eggs smell). If this smell is detected, close the propane tank valve at once, then find and correct the problem before attempting to restart the generator.

Starting The Generator

How to Start A Cold Engine with Gasoline

1. Place generator on a level surface.
2. Disconnect all electrical loads, including parallel cables, from the generator.
3. Set the Upper Left "Low Idle" rocker switch to 'OFF'.
4. Set the Upper Right "Fuel Source" rocker switch to "GASOLINE".
5. Turn the Multi-Switch to 'START' (choke) to start a cold engine.

Tip: Turn the Multi-Switch to 'RUN' to restart a warm engine.

1. Gently pull the recoil handle out until resistance (engine compression) is felt. (Illustration: Person gently pulling recoil handle until resistance is met.)
2. Let the recoil handle retract completely. (Illustration: Recoil handle retracting.)
3. Grasp the top handle securely and pull the recoil handle swiftly and completely; the engine should start. (Illustration: Person pulling recoil handle swiftly.)

With the engine started, ensure the Multi-Switch is in the 'RUN' position, then set the "Low Idle" rocker switch to your load-based preference.

How to Start Cold Engine with Propane

1. Place generator on a level surface.
2. Disconnect all electrical loads, including parallel cables, from the generator.
3. Set the Upper Left "Low Idle" rocker switch to 'OFF'.
4. Set the Upper Right "Fuel Source" rocker switch to "PROPANE".
5. Connect the propane regulator to the propane tank. (Illustration: Propane tank connected to propane hose.)
6. Connect the propane hose to the front panel propane inlet; tighten until snug. (Illustration: Propane hose connecting to the LPG INLET on the generator.)
7. Open the propane tank valve. Be aware of any smell of gas and apply soapy water to the fittings to check for leaks. Only proceed if there are no leaks.
8. Turn the Multi-Switch to 'START' (choke) to start a cold engine.

Tip: Turn the Multi-Switch to 'RUN' to restart a warm engine.

9. Follow the three steps below for a safe recoil engine start:

1. Gently pull the recoil handle out until resistance (engine compression) is felt. (Illustration: Person gently pulling recoil handle until resistance is met.)

Shutting Down the Generator

1. Turn the Multi-Switch to "OFF" position. (Illustration: Multi-Switch knob in OFF position.)
2. After the generator has completely cooled down, remove the propane hose if applicable and store the generator in a cool, dry, sheltered storage area.
3. Remove or consume all untreated gasoline if planning to store the generator longer than 3 months.

Connecting Loads to the Generator

1. Start the engine.
2. Move Energy Saving switch to "OFF".
3. Insert the plug(s) into AC outlet(s).
4. Make sure that AC indicator is illuminated.
5. Switch on electrical equipment.

Tip: If total load is less than half rated capacity, move the Energy Saving Switch to 'ON'. If the generator supplies power to multiple devices, plug in those devices from largest to smallest according to rated electrical load.

(Illustration: Sequence showing connecting electrical loads to the generator outlets.)

Using the Generator

Operating Range of the Generator

• Ambient air temperature: 23°F~104°F (-5°C~40°C)
• Relative humidity: <95%
• Recommended elevation: <5,000 feet (1,500m); reduced power at >3,300 feet (1,000 m).

Ideal Atmospheric Conditions

• Ambient air temperature: 77°F (25°C)
• Relative humidity: 30%
• Atmospheric pressure: 1,000 millibars

Standard Deration

• Every 9°F (5°C) increase in ambient air temperature will reduce generator output by about 2%.
• Every 30% increase in relative humidity of air will reduce generator output by about 1.5%.
• Every 1,000 feet (300m) elevation increase will reduce generator output by about 3.5%.

Generator Grounding

If grounding is required by code or application, follow the guidelines below. If there is any doubt, contact a licensed electrician.

1. Use grounding wire of minimum 12 gauge.
2. Connect one end of grounding wire to the grounding bolt on the control panel.
3. Connect the other end of the grounding wire to a suitable ground point.

(Illustration: Diagram showing grounding bolt on control panel and connection to a ground point.)

Range of Application

Before using the generator, ensure that the total load is within the rated load range of the generator, otherwise the generator may be damaged.

Service and Maintenance

Good maintenance is essential for safe, economical operation and long service life. The maintenance schedule is below:

** These tasks should be completed by an authorized Pulsar service center.

Spark Plug

1. Remove access cover and spark plug boot.
2. Use the (included) thin-wall T-socket wrench to remove the spark plug by turning it counter-clockwise. (Illustration: Steps for removing spark plug.)
3. Inspect spark plug for discoloration and remove carbon deposits; replace if necessary.
4. Adjust the gap 0.7~0.8mm.

Spark Plug # A5RTC, Gap: 0.7-0.8mm.

5. Install new or serviced spark plug in reverse order.

Spark Plug torque: 12.5 Nm; 110 in lbs.

Tip: If no torque wrench is available, turn the spark plug 1/4 - 1/2 turn after the gasket contacts the cylinder head.

Adjustment of the Carburetor

This carburetor is not adjustable; only maintenance and cleaning are possible. Pulsar Service Center strongly recommends leaving this work to an authorized service center.

Oil Change

1. Raise the generator up on support blocks on a flat, stable surface.
2. Unscrew the knob to remove oil access cover.
3. Unscrew oil dipstick.
4. Place an oil pan under the engine, tilt the generator toward the oil pan until all oil has drained; wipe up any spills. (Illustration: Sequence showing tilting generator to drain oil.)
5. Refill crankcase with 12 ounces (0.35l) 10w-30 engine oil; check with dipstick.
6. Tighten oil dipstick, replace oil access cover, and tighten the knob.

Air Filter

A dirty air filter can cause poor performance and engine damage. Perform inspection and cleaning per the maintenance schedule on page 11.

1. Remove screws to remove air filter housing.
2. Remove foam filter element.
3. Clean foam filter element with a mild soap solution, rinse well, and let it dry.
4. Place a few drops of engine oil on the foam filter element and squeeze gently to distribute the oil film evenly.
5. Reinstall the air filter element in reverse order. (Illustration: Sequence showing air filter removal, cleaning, oiling, and reinstallation.)

Fuel Filter Screen

1. Remove fuel tank cap and fuel tank filter screen.
2. Clean fuel tank filter screen with mild soap and hot water.
3. Allow filter screen to dry thoroughly and replace it in the fuel tank.
4. Replace fuel cap tightly. (Illustration: Sequence showing removal and cleaning of fuel filter screen.)

Storage and Transport

Generator Long Term Storage

1. Turn the Multi-Switch to "OFF" and allow generator to cool completely.
2. Remove the spark plug boot to prevent accidental engine start.
3. Remove bolts and the right service access panel.
4. Using a Phillips screwdriver, open the fuel drain valve on the carburetor and drain remaining fuel into an approved gasoline container.
5. Tighten the fuel drain valve.
6. Change engine oil per page 12.
7. Remove the spark plug and instill one teaspoon (5ml) of new engine oil into the combustion chamber. Pull the recoil a few times to distribute oil, then reinstall the spark plug.
8. Replace the right service access panel.
9. Gently pull the recoil handle until resistance is felt, indicating the intake and exhaust valves are closed.
10. Store the generator in a clean and dry area.

Generator Transport

Pulsar Products recommends that the generator should be empty of fuel when transported unless it is secured in an open truck bed and secured from tipping. In that case, follow the guidelines below:

• Do not completely fill the fuel tank; leave some expansion space.
• Do not run the generator while transporting.
• Protect from direct sunlight.
• Do not transport the generator across rough terrain.

Troubleshooting

Engine No-Start

Fuel System

1. No fuel.
2. Fuel doesn't reach the combustion chamber.
3. Contaminated or old fuel.
4. Debris in the fuel valve.
5. Carburetor is fouled; service carburetor.

Insufficient Engine Oil

Oil level is too low.

Ignition System

1. Verify Multi-Switch is at 'RUN' or 'CHOKE'.
2. No spark from ignition coil failure.
3. Spark plug is fouled; service it per page 12.

Low Compression

1. Worn out engine.
2. Cylinder head bolts have loosened; have an authorized Pulsar Service Center re-torque them properly.
3. Head gasket leak.

Engine Runs, No Power Output

1. Ensure all circuit breakers are pushed in.
2. If generator was exposed to moisture or rain, move it to a dry location for several hours.
3. Vibration may have caused one or more connectors to loosen over time; check with Pulsar Technical Support for guidance.
4. Check electrical receptacles for damage.
5. Generator may be overloaded; remove load, shut down, then restart the engine.

Technical Parameters

Electrical Schematic

This section provides an electrical schematic for the 120V, 60Hz Electrical System. It illustrates the connections between the GENERATOR BLOCK and the CONTROL PANEL BLOCK, detailing components such as the Main Winding, Stepping Motor, Inverter, AC receptacles (125V 20A, 125V 30A), Circuit Breakers (20A, 30A), Paralleling Receptacle, ECO switch, Overload Recovery switch, various indicator lights (AC pilot, Overload, Oil warning), Engine Switch, CO actuators, CO module, Igniter, Spark Plug, Trigger Coil, Oil Sensor, and CO alarm lamp. The schematic includes wire color codes for identification (B: Black, R: Red, Y: Yellow, W: White, Bu: Blue, Br: Brown, G: Green, Gr: Grey, P: Pink, O: Orange).