Pulsar PG3500M Owner's Manual
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Pulsar PG3500M Owner's Manual

3500 watt generator
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casey dungan
March 3, 2025

at idle,with no load, won't stay at low idle. Hunts up and down between low idle and half speed.

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1 comments:
Mr. Anderson
May 14, 2025

The Pulsar PG3500M could be hunting between low idle and half speed at idle with no load due to an issue with the fuel system, such as a partially clogged fuel strainer or carburetor. This can restrict fuel flow and cause unstable engine speed. Ensure the fuel strainer is clean and properly in place, and check the carburetor for blockages. Also, confirm that the choke lever is in the correct position (OPEN for a warm engine) and that the fuel valve is fully open.

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Summary of Contents for Pulsar PG3500M

  • Page 1 3500 3500 1-866-591-8921...
  • Page 2 3500W Generator 7500W Generator Topic Page Safety Guidelines General al Precautions elines General Parts ener l recautions Operation Battery Inspection, Cleaning and Maintenance Assembly Installation Operation roubles ooting nspection, Cleaning and Maintenance Specifications nstallation Wiring iagram Complia General Parts Listing p e cifications eneral Parts Listing WARNING! READ AND UNDERSTAND ALL SAFETY PRECAUTIONS...

  • Page 3: Safety Guidelines - Definitions

    Safety Guidelines - Definitions This manual contains important information that you need to know and understand in order to protect YOUR SAFETY and to PREVENT EQUIPMENT PROBLEMS. The following symbols help you recognize this information. Please read the manual and pay attention to these sections. Save These Important Safety Instructions! Read and understand all of these safety instructions.

  • Page 4: General Precautions

    7500W Generator General Precautions WARNING! FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH. CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO RESULT IN DAMAGE TO THE TOOL AND/OR THE ITEM YOU ARE WORKING Carbon Monoxide When this tool is running, ensure that the area is well ventilated. Never run the engine in an enclosed area.

  • Page 5: Hot Components

    Owner’s Manual General Precautions (cont’d) Gasoline and Oil (cont’d) • 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.

  • Page 6: Work Area

    7500W Generator General Precautions (cont’d) Work Area • Keep your 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. •...

  • Page 7: Personal Safety

    Owner’s Manual General Precautions (cont’d) Electrical Safety (cont’d) • 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. •...

  • Page 8: Generator Use And Care

    7500W Generator General Precautions (cont’d) Personal Safety (cont’d) • 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.

  • Page 9: Heart Pacemakers

    Maintain labels and name plates on the generator and engine. These carry important information. If unreadable or missing, contact immediately for a replacement. Pulsar Products Inc. Generator service must be performed only qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.
  • Page 10 7500W Generator General Precautions (cont’d) Installation (cont’d) • 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 10 lbs (approx). Two or more people should assist when moving or lifting this product.
  • Page 11 Owner’s Manual General Precautions (cont’d) Mechanical (cont’d) • 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.
  • Page 12 ener a l P a t s General Parts Fuel tank cap Frame Fuel tank Control Panel Choke lever Air filter Wheel Fuel valve Handel Oil dipstick Recoil starter Drain plug AC breaker AC breaker AC breaker Grounding terminal On/off switch 120V outlet Oil alert lamp DC terminal...

  • Page 13: Operation

    Owner’s Manual Operation Fuel tank k Lever Choke lever Control panel Fuel valve Pull start NOTE: THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE CONTROLS MENTIONED BELOW. CAUTION: PRIOR TO FIRST USING THE GENERATOR, THE ENGINE MUST BE FILLED WITH OIL OF A HIGH QUALITY SAE 10W-30 GRADE ENGINE OIL. TO DO SO, UNSCREW AND REMOVE THE ENGINE’S OIL DIPSTICK LOCATED AT THE BOTTOM OF THE ENGINE CRANKCASE.
  • Page 14 Operation (cont’d) Starting 1. Turn the engine switch to the ON position. The engine switch enables and disables the ignition system. OFF: To stop the engine ON: To run the engine 2. The fuel valve is located under the fuel tank . When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor.

  • Page 15: Stopping Engine

    Operation (cont’d) Starting 4. Operate the Recoil Starter: Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. Pulling the starter grip operates the recoil starter to crank the engine 5. If the choke lever has been moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up.

  • Page 16: Powering 120 Volt Ac Tools And Equipment

    Owner’s Manual Operation (cont’d) 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.
  • Page 17 7500W Generator Operation (cont’d) 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.

  • Page 18: Spark Plug Service

    Owner’s Manual Operation (cont’d) Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: NHSP LD F7TC. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1.

  • Page 19: Inspection, Cleaning, And Maintenance

    Owner’s Manual Inspection, Cleaning, and Maintenance WARNING! ALWAYS MAKE SURE THE ENGINE POWER SWITCH (2) IS IN ITS “OFF” POSITION. DISCONNECT THE SPARK PLUG WIRE FROM THE ENGINE. AND ALLOW SUFFICIENT TIME FOR THE ENGINE AND GENERATOR TO COMPLETELY COOL BEFORE PERFORMING ANY INSPECTIONS, MAINTENANCE, OR CLEANING.

  • Page 20: Installation

    7500W Generator Installation NOTE: PRIOR TO POWERING TOOLS AND EQUIPMENT MAKE SURE THE GENERATOR’S RATED VOLTAGE, WATTAGE AND AMPERAGE CAPACITY IS ADEQUATE TO SUPPLY ALL ELECTRICAL LOADS THAT THE UNIT WILL POWER. IF POWERING EXCEEDS THE GENERATOR’S CAPACITY, IT MAY BE NECCESSARY TO GROUP ONE OR MORE OF THE TOOLS AND/OR EQUIPMENT FOR CONNECTION TO A SEPERATE GENERATOR.
  • Page 21 Owner’s Manual Installation (cont’d) 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.

  • Page 22: Troubleshooting

    Troubleshooting Note: Troubleshooting problems may have similar causes and solutions. PROBLEM POSSIBLE CAUSE SOLUTION Is there fuel in the tank? Refill the fuel tank. Is there enough oil in the The engine Add the recommended oil. engine? will not start Is the spark plug in good Readjust gap and dry the spark plug.
  • Page 23 Sp ecifitions Model PG3500M Rated Frequency 60Hz Peak Power 3.5kW Generator Rated Power 3.0kW Rated Voltage 120V Power Factor Model DJ170FD Type 4-stroke/air cooling/single cyclinder/OHV/horizontal shaft Displacement(cc) Ignition Model Transistorized Magneto Engine Starting Model Recoil Start Max. Output (hp/rpm) 7.0/3600...
  • Page 24 Breaker Breaker Breaker 5-20R ² ² Gr QVR1mm DC coil 1 LB QVR1mm ² Bl QVR1mm Bl QVR0.5mm ² ² LB QVR1mm 2510 Ignition Switch ² ² QVR0.5mm QVR0.5mm Control Box Diagram Bl/W ² ² W QVR0.5mm QVR0.5mm ² Bl/W R QVR0.5mm ²...
  • Page 25 PG3500M ENGINE PARTS LISTING This list is provided for reference purposes only.All repairs and part replacement should be performed by a qualified technician. Some parts may not be available as single replacements. PART NO. DESCRIPTION Q'TY REMARK DJ170F-11100-HE CRANKCASE GB276-89-6205 BEARING RADIAL BALL 6205 OIL SEAL Φ...
  • Page 26 PART NO. DESCRIPTION Q'TY REMARK DJ168FD-11001-A CRANKCASE COVER ASSEMBLY GB276-89-6205 BEARING RADIAL BALL 6205 PIN Φ 8×14 DJ168F-11002-A OIL SEAL Φ 35×Φ 52×8 DJ168F-11014-A DJ168F-11003-B CRANKCASE GASKET DJ168F-11007-D DIPSTICK GBT16674-B8-30 BOLT FLANGE M8*30...
  • Page 27 PART NO. DESCRIPTION Q'TY REMARK GBT16674-B6-12 BOLT FLANGE M6*12 DJ168F-11300-C CYCLINDER HEAD COVER ASSEMBLY DJ168F-11011-A GASKET, CYCLINDER HEAD COVER DJ168F-18500-A SPARK PLUG F7TC GBT5789-B8-60 BOLT FLANGE M8*60 DJ168FD-14001-B BOLT STUD M6*96 DJ168F-14002-A BOLT, STUD M8*35 CYLINDER HEAD ASSEMBLY DJ170FB-11200-AE DJ168F-11009-A DJ170F-11010-B GASKET, CYLINDER HEAD DJ168F-11012-A...
  • Page 28 PART NO. DESCRIPTION Q'TY REMARK DJ168F-12003-A PISTON PIN CIR-CLIP DJ170FB-12001-B PISTON DJ170F-12002-A PISTON PIN DJ170F-12200-BE CONNECTING ROD ASSEMBLY DJ170F-12300-B PISTON RING SET DJ170FB-12100-BQE CRANKSHAFT ASSEMBLY...
  • Page 29 PART NO. DESCRIPTION Q'TY REMARK DJ168F-13200-A VALVE ROCKER ARM ASSEMBLY DJ168F-13300-A PUSH ROD GUIDE DJ168F-13006-A DJ168F-13005-A VALVE RETURNER EXHAUST DJ168F-13004-A VALVE RETURNER INTAKE DJ168F-13003-A VALVE SPRING DJ170F-13002-A EXHAUST VALVE DJ170F-13001-A INTAKE VALVE DJ168F-13010-A DJ168F-13008-B PUSH ROD DJ168F-13009-A TRAPPET LITTER VALVE DJ168F-13100-BE CAMSHAFT ASSEMBLY...
  • Page 30 PART NO. DESCRIPTION Q'TY REMARK DJ168F-14027-A SPACER,CARBURETOR DJ170FB-14100-AE CARBURETOR ASSEMBLY DJ168F-14005-B GASKET, CARBURETOR DJ168F-14004-A CONNECTING BLOCK CARBURETOR DJ168F-14003-B GASKET INLET DJ168F-14008-A CLIP,FUEL LINE DJ168FD-14014-A RUBBER ,FUEL LINE DJ168FD-14007-C FUEL LINE...
  • Page 31 PART NO. DESCRIPTION Q'TY REMARK DJ168FD-14200-E AIR FILTER ASSEMBLY DJ168FD-14204-B AIR FILTER CAP DJ168FD-14201-B FILTER ELEMENT DJ168FD-14203-E BOTTOM CAP,AIR FILTER GB6177-N-6 NUT FLANGE M6 GBT16674-B6-12 BOLT STUD M6*12 DJ168FD-11013-A BRACKET,AIR FILTER DF2500H-14205-A TUBE BREATHER...
  • Page 32 PART NO. DESCRIPTION Q'TY REMARK GBT16674-B6-12 BOLT FLANGE M6*12 DJ168F-16100-F-116 CASE COMP RECOIL STARTER DJ168F-16110-A STARTER DJ168F-16111-A ROPE DJ168F-16130-F-116 STARTER COMP,RECOIL 92140-B6-8 BOLT FLANGE M6*8 GBT97-W-6 PLAIN WASHER DJ168F-16101-A-116 RECOIL STARTER CASE...
  • Page 33 PART NO. DESCRIPTION Q'TY REMARK DJ168F-15008-A FINE REGULATING SPRING C DJ168F-15006-A PULLING ROD DJ168F-15007-A BACK SPRING B DJ168F-15004-A SPEED REGULATING ARM DJ168F-15005-A LOCK BOLT NUT FLANGE M6 GB6177-N-6...
  • Page 34 PART NO. DESCRIPTION Q'TY REMARK DJ168F-16205-A NUT M16*1.5 DJ168F-16000-A STARTING CUP DJ168F-16002-A IMPELLER DJ168F-16200-AE FLYWHEEL ASSEMBLY GBT16674-B6-25 BOLT FLANGE M6*25 DJ168F-18100-C IGNITION COIL ASSEMBLY...
  • Page 35 PG3500M GENERAL PARTS LISTING This list is provided for reference purposes only.All repairs and part replacement should be performed by a qualified technician. Some parts may not be available as single replacements. PART NO. DESCRIPTION Q'TY REMARK DJ168F-14008-A CLIP,FUEL LINE...
  • Page 36 PART NO. DESCRIPTION Q'TY REMARK GBT16674-B6-12 BOLT FLANGE M6*16 DF2500H-34106-A GASKET DF3000H-34100-QQ02 CONTROL PANEL ASSEMBLY 34203-004 SWITCH ASSEMBLY 34204-038 GROUNDING POST 34204-039 GROUNDING POST 34204-062 120V DUPLEX OUTLETS 34208-021 THERMAL PROTECTOR 34208-023 THERMAL PROTECTOR...
  • Page 37 PART NO. DESCRIPTION Q'TY REMARK GBT93-LW-8 SPRING WASHER GB6170-N-8 NUT FLANGE M8 DJ168F-14006-A GASKET,EXHAUST DF3000H-14400-V MUFFER ASSEMBLY GBT16674-B6-12 BOLT FLANGE M6*12 GBT16674-B8-16 BOLT FLANGE M8*16 DF3500H-14404-A MUFFLER STAY...
  • Page 38 PART NO. DESCRIPTION Q'TY REMARK DF3000H-33100-BJ-20302 ALTERNATOR ASSEMBLY DF3000H-33120-BJ ROTOR DF1800H-33001-A CARBON BRUSH COMP. DF3000H-33110-BJ-20302 STATOR DF3800H-33002-A GROUNDING POST COMP. DF1800H-33005-C ALTERNATOR END BRACKET GBT97-W-8 PLAIN WASHER GBT93-LW-8 SPRING WASHER DF3000H-33003-A BOLT M8*220 DF3000H-33015-A BOLT M6*165 DF1800H-33011-A VOLTAGE REGULATOR GBT16674-B5-12 BOLT FLANGE M5*12 DF1800H-33006-A-116 ALTERNATOR END COVER...
  • Page 39 PART NO. DESCRIPTION Q'TY REMARK DF4000H-31016-A RUBBER,HANDLE DF4000H-31060-A DF4000H-31058-A-117 HANDLE ASSEMBLY GBT16674-B6-35 BOLT FLANGE M6*35 GB889-N-6 NUT M6 DF4000H-31014-A-117 INSULATOR,HANDLE 92140-B6-40 BOLT M6*40 GB6177-N-6 NUT FLANGE M6 DF4000H-31204-A VIBRATION ISOLATION RUBBER,SQUARE FRAME DF3000H-31020-D-117 SUPPORT,FRAME RPG3000-31100-F-117 FRAME ASSEMBLY GB6170-N-8 NUT FLANGE M8 DF2500H-31202-A ISOLATOR B DF2500H-31201-A...

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