PG1202S Generator User Manual

PG1202S Generator User Manual

INTRODUCTIONS

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.

The emissions control system for this generator is compliant with all standards set by the U.S. Agency.

How to contact us:

To order parts, receive warranty assistance, or other services inquiries, you can contact us by Internet atwww.pulsar-products.com

PULSAR PRODUCTS INC2051 S Lynx PlaceOntario, California, U.S.A 91761

Record the following information bellow for service or warranty assistance.

SAVE THIS MANUAL FOR FUTURE REFERENCEThis manual contains important information regarding safety, operation, and maintenance.

SAFETY RULES

Safety Symbols

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.

FEATURES

Handle
Fuel Cap
Fuel Tank
Fuel Shut-Off
Recoil Starter
Engine On-Off Switch
Throttle Lever
Air Cleaner
Control Panel
Generator
Muffler
Cylinder

ASSEMBLY

Unpacking

Place box on a level surface.
Remove all items from the box. Make sure all items listed on the packing list are included and not damaged.

Packing List

Check all loose parts to the following list. Contact your service center (866-591-8921) if any loose parts are not included.

Description QtyGenerator 1Quick Start Guide 1Spark Plug Wrench 1Handle 1Bolts Screws 2

Installing the Handle

Grounding the Generator

The ground terminal located on the side of the generator frame 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.

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.

Before starting please make sure you have the correct gasoline and oil mixture in 50:1.

How to Start Engine

OPERATION

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.

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.

How to Stop Engine

Receptacles and Extension Cords

Only use high quality, well-insulated, grounded extension cords in good condition with generator receptacles. Follow each load manufacturer’s power rating recommendation when selecting receptacle and extension cord.

The receptacles are not protected by a GFCI. Use a GFCI protected spider box or GFCI adapter to connect load to the receptacle.

This generator is equipped with the following receptacles:

Two 120 Volt AC Receptacles.

If reset trips, disconnect all external electrical appliances before pushing the reset button. After reconnecting the external electrical appliance, if reset continues to trip that indicates that the electrical lead connected to the generator from one or more of the appliances may have a short circuit. In that event, discontinue use of that item until it has been checked and/or repaired by a qualified technician.

Do not connect 3-phase loads to generator.

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.

Moving the Generator

Disconnect any electronic devices from generator then turn generator off.
Turn fuel valve to the “OFF” position.

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:

Add up the total rated wattage of all electronic devices that will be connected to the generator simultaneously.
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).
Add the Surge Watts to the total Rated Watts in step 1. Keep total load within generator’s power capacity.

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)

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.

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:

Replace any old fuel with clean, fresh fuel.
Turn fuel valve to the open position.
Ensure generator is serviced according to the maintenance schedule under “Maintenance” section of manual.
Shelter unit from elements.

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 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 fuel.
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.)
Store unit in a clean and dry area.

Maintenance Schedule

Air Filter

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

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 .700 mm – .80 mm (.028 – .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)

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.

Draining the fuel tank

Turn the engine OFF.
Turn the fuel valve to the OFF position.
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.

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.

Consult your local hazardous waste management in your area for the proper way to dispose of used fuel.

Storage and Transportation of the Generator:

Remove any debris that has collected on the generator and around the muffler and control panel. Use a brush or vacuum to remove loose dirt.
Inspect air cooling slots. Remove any debris if obstructed.
For short-term storage, start generator once every 7 days.
For semi-long term storage, add fuel stabilizer to prevent stale fuel from causing acid and gum deposits in the fuel system and carburetor.
For long-term storage, drain the fuel.
Store the generator indoors to prevent freezing.
The generator must be Shipped, Run and Stored in the upright position as seen in this image.

Engine Long Term Storage:

Remove the spark plug and pour about 1 teaspoon of 10W30 Engine oil into the spark plug hole. Reinstall the spark plug. With the ON/OFF switch in the OFF position pull the recoil starter cord several time to coat the cylinder walls with oil.
Slowly pull the recoil Starter until you feel the engine build compression (When you feel resistance). Leave the Engine in this state as this will prevent any corrosion on the cylinder walls if stored for a long period of time.

DIAGRAMS

TROUBLESHOOTING

WARRANTY

Pulsar Products Inc Limited 1 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 a 12-month period or 250 hrs (Whichever comes first). Proof of purchase and of maintenance must be provided.

6 Month – Limited comprehensive coverage on all generator components and labor.
12 Month – Limited coverage on generator engine and alternator 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.

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. 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 warrantyquestions 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.