Pulsar 10000 Watt Dual Fuel Generator Owner's Manual

Safety Guidelines - Definitions

This manual contains important information to protect user safety and prevent equipment problems. The following symbols help recognize this information. Please read the manual and pay attention to these sections.

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General Precautions

Carbon Monoxide

When the generator is running, ensure the area is well ventilated. Never run the engine in an enclosed area. Operate the engine in an open area or with an exhaust evacuation system in an enclosed area.

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.

• 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.
• 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.
• Only use engine oil and fuel recommended by the manufacturer.

Hot Components

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.

Work Area

• Keep the 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 the 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.
• 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 is being done, and use common sense when operating a generator. Do not use the 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 hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts.

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 preventative 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.

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

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.
• 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 approximately 212lbs. Two or more people should assist when moving or lifting this product. Never lift the generator using the engine or alternator lifting lugs. Connect lifting equipment to the frame of the generator.
• 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 floor/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.

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 still be taken to protect personnel and equipment from other mechanical hazards when working around the generator.
• 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.

General Parts

The Pulsar 10000 Watt Generator features several key components:

• Frame: The structural support for the generator.
• Fuel Tank: Holds gasoline.
• Fuel Tank Cap: Secures the fuel tank.
• One Way Valve: Part of the fuel system.
• Fuel Gauge: Indicates fuel level.
• Choke Lever: Used for starting the engine, especially when cold.
• Air Filter: Filters air entering the engine.
• Handle: For portability and moving the unit.
• Fuel Valve: Controls fuel flow.
• Recoil Starter: Manual pull-start mechanism.
• Fuel Selector Switch: For choosing between gasoline and LPG fuel sources.
• Oil Dipstick: Used to check engine oil level.
• Battery: For electric start functionality.
• Voltage Frequency Hour Meter: Displays voltage, frequency, and engine hours.
• Thermal Protector: Protects against overheating.
• Engine Switch: Controls engine operation (ON/OFF).
• Control Panel: Central interface for outlets and controls.
• Wheel: For mobility.
• LPG Connection: For connecting to an LPG fuel source.
• 120V/240V Twist-lock Outlet: High-power AC output.
• 120V/240V Outlet: Standard AC output.
• 120V Duplex Outlet: Standard AC output.
• DC Terminal: For 12V DC output.

Battery

To start the generator with electric start, a battery (included) is needed. This generator can also be started with the pull start. Using a battery not designed for this unit may void the warranty.

To attach the battery: Place the battery on the frame and assemble it with the provided accessories.

Operation

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.

Connecting to LPG Fuel Source

1. Locate the LPG converter on the backside of the generator.
2. Attach the small end of the Gas Hose to the LPG converter.
3. Connect the gas hose to the propane fuel source. Do not turn on the propane source prior to following the steps outlined.

Electric Start Battery Connection

Batteries produce explosive gases. Keep sparks, flames, and cigarettes away from the battery. To prevent the possibility of creating a spark near the battery, connect charging cables to battery terminals first, then to the generator. When disconnecting, disconnect the cables at the generator first.

1. Connect the red cable with the positive terminal of the battery. Ensure the connection is secured by using the fastener at the battery terminal.
2. Connect the black cable with the negative terminal of the battery. Ensure the connection is secured by using the fastener at the battery terminal. Be sure to connect the Electric Start Battery to the Dual Fuel Generator set before operation. Improper connection will cause malfunction.

Do not reverse the polarity of the terminals when charging the battery. Serious damage to the generator and/or battery may occur. Do not attempt to connect the battery while the generator engine is running. Disconnect the cables from the battery while the generator is in storage.

3. When using gasoline to start the engine, the battery must be properly connected to the generator and check the battery voltage is normal.

Starting the Generator Set

Ground Terminal

Before using the generator, a ground wire must be connected to the ground terminal. The Ground terminal is located on the Front Panel. Before using the ground terminal, consult a qualified electrician.

Ground Terminal Symbol: ⏚

The 7750 Watt dual fuel generator can be started using the Recoil Start Method or Electronic Start Method.

IF USING PROPANE FUEL SOURCE (Starting Procedure)

1. Connect the gas pipe to the intake nozzle of the regulator.
2. Open the valve of the LPG bottle.
3. Turn the fuel selector to “LPG” position.
4. Push the engine switch to “ON” position.
5. Close the choke.
6. Continue to desired start-up method.

IF USING GASOLINE FUEL SOURCE (Starting Procedure)

1. The battery must be properly connected to the generator and check the battery voltage is normal.
2. Turn on fuel valve.
3. Close the choke.
4. Push the engine switch to "ON" position.
5. Turn the fuel selector to "GAS” position.
6. Continue to desired start-up method.

RECOIL START METHOD

1. Disconnect all devices from the outlets on the generator panel.
2. Press the engine switch to the "ON" position.
3. Grasp the recoil starter handle and pull it until the engine starts.

Do not allow the recoil starter to snap back. Return it slowly by hand.

4. Push the choke lever to the OPEN position as the engine warms up. The choke is used to provide the proper mixture when the engine is cold. It can be opened and closed by operating the choke lever manually by starting.

ELECTRIC STARTING METHOD

Batteries produce explosive gases. Keep sparks, flames, and cigarettes away from the battery. To prevent the possibility of creating sparks near the battery, connect the charging cables to the battery terminals first, then to the generator. When disconnecting, remove cables at the generator first.

1. Follow fuel source selection steps.
2. Push the engine ignition button until the generator starts. Do not push the ignition button for more than 5 seconds. Doing so may damage the alternator.

If electric start does not turn on the generator after three attempts, contact customer support. Repeated attempts could damage the ignition mechanism.

3. Follow steps 6-7 from the Recoil Start Method (referring to the choke adjustment).

Using the Generator Set

1. Turn off the switches of the device before connecting to the generator.
2. Start the generator.
3. Insert the plug of the device into the receptacle based on the voltage requirement of the device.

To stop the engine in an emergency, turn the engine switch "OFF".

In order to maintain generator's performance:

• Always connect the generator to the ground terminal to prevent electrical shock.
• Add the watt ratings of all the loads that the generator set will be powering at the same time. Make sure that total wattage will not exceed the generator rating.

Using DC Output Terminals

The 12V 8.3A DC output can be used to charge automotive batteries. Be sure to monitor the battery charge time. Over-charge may cause explosion and injury.

1. Connect the positive (red) terminal of the battery to the red (positive) terminal of the 12V 8.3A DC Output Terminal on the front panel.
2. Connect the negative (black) terminal of the battery to the black (negative) terminal of the 12V 8.3A DC Output terminal on the front panel (DO NOT REVERSE POLARITY OF CONNECTIONS).
3. Start the generator.

Stopping the Generator Set

When using gasoline

1. Turn off all the connected devices.
2. Allow the generator set to run for a few minutes to cool down.
3. Stop the generator set by pressing and holding the engine switch in the OFF position until the generator set stops.
4. Rotate the fuel valve lever back to the OFF position.

When using LPG

1. Turn off all the connected devices.
2. Allow the generator set to run for a few minutes to cool down.
3. Turn off the LPG valve.
4. Push the engine switch to “OFF” position.

Powering 120 Volt AC Tools and 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.

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.

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 the generator in a safe, clean, dry location (if not already installed).

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.

3. If using only a 12V volt DC tool or equipment, turn the 120 volt AC (This sentence seems to have a typo in the original PDF, repeating part of the phrase. It likely means: If using only a 12V DC tool or equipment, ensure the 120V AC circuit is off or not in use).
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).

Spark Plug Service

To service the spark plug, a spark plug wrench (commercially available) is needed. 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.

Inspection, Cleaning, and Maintenance

• Before each use, inspect the generator. Check for:
  • Loose screws
  • Misaligned or binded moving parts
  • Cracked or broken parts
  • Damaged electrical wiring
  • Any other condition that may affect safe operation.
• If an engine problem occurs, have it checked by a qualified service technician before further use. Do not use damaged equipment.
• Before each use, make sure the engine's oil and gas levels are adequate. If necessary, fill the crankcase until the oil level is even with the oil fill hole and/or fill the fuel tank.
• Before each use, remove all debris with a soft brush, rag, or vacuum.
• 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. (Diagram shows oil fill level with an arrow pointing to 'Upper Level').
• Every 300 hours of use, have a qualified, certified technician perform thorough maintenance on the generator and engine.
• For long term storage, either drain fuel into a suitable container or add a fuel preservative/stabilizer (not included) to prevent fuel breakdown.

Installation

Electrical and other permits may be required for the installation of emergency power systems. Investigate local building and electrical codes before installing this unit. Installation must be completed by licensed contractors.

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 cannot 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.

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

Connect a #6 AWG grounding wire (not included) from the ground connector 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.

Troubleshooting

Troubleshooting problems may have similar causes and solutions.

If the engine still does not start, take the generator to an authorized agent generator dealer.

Specifications

Wiring Diagram

This section presents the wiring diagram for the 120/240V Generator Set. The diagram illustrates the electrical connections between various components including the alternator, engine, control panel, breakers, switches, and sensors. Key components shown include:

• Control Panel: With multiple breakers (e.g., 14-50R, L14-30R, 5-20R) and a multi-meter.
• Alternator: Showing stator winding (excitation) and rotor.
• Engine: Including the engine switch, fuel selector switch, battery, motor, oil sensor, spark plug, and ignition coil.
• Charger and PPTC: For battery charging and protection.
• Fuel Solenoid Valve: For fuel control.

The diagram uses standard wiring color codes (e.g., Black (BI), Brown (Br), Orange (O), Blue (Bu), Gray (Gr), Red (R), White (W), Yellow/Green (Y/G), Light Blue (LB), Pink (P)) to denote different connections within the system, ensuring proper electrical flow and functionality for both 120V and 240V outputs.