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Pulsar PG3500M User Manual

Pulsar PG3500M
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7500W Generator
General Precautions (contd)
Personal Safety (contd)
• Avoid accidental starting. Make sure the power switch is in its “OFF” position, and disconnect
the spark plug wire when not in use.
Remove adjusting keys or wrenches before turning the generator on. A wrench or a key that is
left attached to a rotating part of the generator may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times.
• Use safety equipment. Always wear eye protection. Wear ANSI approved safety impact eye
goggles. Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for
appropriate conditions.
• Do not force the generator. Use the correct generator for your application. The correct generator
will do the job better and safer at the rate for which it is designed.
• Do not use the generator if the power switch does not turn it on or off. Any generator that cannot
be controlled with the power switch is dangerous and must be replaced.
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 preventive 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 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.
8
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Pulsar PG3500M Specifications

General IconGeneral
BrandPulsar
ModelPG3500M
CategoryPortable Generator
LanguageEnglish

Summary

Safety Guidelines

Safety Guidelines - Definitions

Explains safety symbols and instructions for understanding the manual.

Important Safety Instructions

Read and understand all safety instructions for future reference and safe operation.

Safety Symbol Definitions

Defines WARNING, CAUTION, and NOTE symbols to identify hazards and helpful information.

General Precautions

Carbon Monoxide Hazards

Warning about poisonous carbon monoxide gas from exhaust and the need for ventilation.

Gasoline and Oil Safety

Precautions regarding flammable gasoline, oil requirements, and safe storage.

General Precautions (cont'd)

Hot Components Warning

Engine and exhaust parts get very hot; use insulated gloves or wait for cooling.

Sensitive Electronic Equipment

Generator not designed for sensitive electronics without a line conditioner; causes damage.

General Precautions (cont'd)

Work Area Safety

Keep work area clean, avoid explosive atmospheres, keep bystanders away.

Electrical Safety Basics

Proper grounding, avoiding wet conditions, and using correct extension cords.

General Precautions (cont'd)

Electrical Connection Safety

Proper installation, grounding, connecting compatible loads, and maintaining wiring.

Personal Safety Guidelines

Stay alert, use common sense, avoid distractions, and dress properly.

General Precautions (cont'd)

Preventing Accidental Starting

Disconnect spark plug wire, ensure power switch is off before adjustments.

Generator Use and Care

Proper operation, maintenance, storage, and using recommended accessories.

General Precautions (cont'd)

Servicing and Maintenance

Maintain labels, use qualified personnel, identical parts, and follow instructions.

Pacemaker Safety Warning

Consult physician before use; electromagnetic fields can interfere with pacemakers.

Installation Requirements

Follow codes, use licensed contractors, ensure proper ventilation for exhaust.

General Precautions (cont'd)

Outdoor Installation & Soundproofing

Weatherproof and soundproof for outdoor use; protect from elements.

Lifting and Mounting

Proper lifting techniques using frame, ensure stable mounting surface.

Mechanical Safety

Ensure power is off, disconnect spark plug, check for damaged parts before use.

General Precautions (cont'd)

Mechanical Operation Safety

Do not operate with guards removed, keep clear of moving parts, wear protective clothing.

Chemical Handling

Avoid contact with fuel, oil, exhaust; use soap and water for skin, flush eyes for contact.

Noise Exposure

Prolonged exposure above 68 DBA is hazardous; wear ear protection.

General Parts

Generator Components Overview

Identification of major parts like fuel tank, control panel, and recoil starter.

Control Panel Details

Labels for on/off switch, oil alert lamp, AC breakers, and outlets.

Operation

Initial Oil Fill Caution

Must fill engine with SAE 10W-30 oil before first use; check dipstick level.

Before Starting the Generator

Ensure power switch is off; fill fuel tank with unleaded gasoline.

Operation (cont'd)

Starting Procedure

Turn engine switch ON, use fuel valve, adjust choke for cold/warm start.

Choke Lever Function

Explains CLOSED (rich mixture) and OPEN (correct mixture) positions for starting.

Operation (cont'd)

Recoil Starter Operation

How to pull the starter grip for engine cranking.

Stopping the Engine

Turn engine switch OFF and fuel valve OFF to stop and prevent issues.

Operation (cont'd)

Powering 120 Volt AC Tools

Check generator capacity, connect tools to outlets, understand circuit breaker function.

Sensitive Electronics Caution

Reiteration of caution for sensitive electronics without a line conditioner.

Operation (cont'd)

Powering 12 Volt DC Tools

Connect 12VDC tools to DC terminals, ensuring correct polarity.

Operation (cont'd)

Spark Plug Service

Instructions for removing, inspecting, cleaning, and gapping the spark plug.

Inspection, Cleaning, and Maintenance

Pre-Operation Checks

Inspect for loose screws, damaged parts, wiring, and check fluid levels.

Lubrication and Oil Changes

Lubricate moving parts, drain and replace oil every 50 hours.

Long-Term Storage

Drain fuel or add stabilizer for storage to prevent fuel breakdown.

Installation

Installation Capacity Check

Ensure generator capacity meets electrical load requirements before powering.

General Location Requirements

Install outdoors with good airflow, on a level surface, with maintenance access.

Installation (cont'd)

Supporting and Mounting

Mount on a concrete slab, extend slab beyond frame, use anchor bolts.

Grounding Procedure

Connect #6 AWG wire to grounding rod driven into earth. Recommended for electricians.

Troubleshooting

Engine Will Not Start Issues

Covers causes like no fuel, low oil, spark plug condition, and fuel to carburetor.

No Electricity at AC Outlets

Checks AC breaker, appliance defects, and suggests repair for faulty equipment.

Specifications

Generator Specifications

Details on rated frequency, power, voltage, power factor, and dimensions.

Engine Specifications

Information on engine model, type, displacement, ignition, and starting model.

Wiring Diagram

120V Generator Wiring

Schematic showing connections for AC/DC circuits, ignition, and control box.

PG3500M ENGINE PARTS LISTING

Crankcase and Related Parts

Lists part numbers, descriptions, and quantities for crankcase and associated components.

Crankcase Cover Assembly Parts

Crankcase Cover Components

Lists parts for the crankcase cover assembly, including bearings and gaskets.

Cylinder Head Parts

Cylinder Head Components

Lists parts for the cylinder head, spark plug, and air-leading cover.

Piston and Crankshaft Parts

Piston and Crankshaft Components

Lists parts including piston, piston pin, connecting rod, and crankshaft assembly.

Valve and Camshaft Parts

Valve Train Components

Lists parts for valve rocker arm, push rod, valves, and camshaft assembly.

Carburetor Parts

Carburetor Assembly Components

Lists parts for the carburetor, including spacers, gaskets, and fuel lines.

Air Filter Parts

Air Filter Assembly Components

Lists parts for the air filter, including cap, element, and bracket.

Recoil Starter Parts

Recoil Starter Components

Lists parts for the recoil starter, including case, rope, and starter mechanism.

Speed Regulating Arm Parts

Speed Control Components

Lists parts for the speed regulating arm, springs, and pull rod.

Flywheel and Ignition Coil Parts

Flywheel and Ignition Components

Lists parts for flywheel assembly, starting cup, and ignition coil.

PG3500M GENERAL PARTS LISTING

Fuel System Components

Lists parts for fuel lines, fuel cock, fuel filter, and fuel tank assembly.

Control Panel Parts

Control Panel Components

Lists parts for the control panel assembly, switches, outlets, and thermal protectors.

Muffler Parts

Muffler Assembly Components

Lists parts for the muffler assembly, gasket, and muffler stay.

Alternator Parts

Alternator Assembly Components

Lists parts for the alternator assembly, rotor, stator, brushes, and voltage regulator.

Frame and Wheel Parts

Frame and Wheel Assembly Components

Lists parts for the frame, handle, wheels, and vibration isolators.

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