3500 3500 1-866-591-8921
3500WGenerator 7500WGenerator Topic Page SafetyGuidelines 3 Precautions al General elines d aGui 4 General ener l Parts recautions 12 Operation Battery 13 Inspection,CleaningandMaintenance Assembly 19 Installation Operation 20 n h Troublesooting nspection,CleaningandMaintenance 22
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. Be sure to retain them for future use.
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 ON. Carbon Monoxide When this tool is running, ensure that the area is well ventilated. Never run the engine in an enclosed area. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
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. 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.
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. • Keep bystanders, children, and visitors away while operating a generator. Provide barriers or shields as needed.
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. • The generator must be earth-grounded for fixed installations in accordance with all relevant electrical codes and standards before operation.
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. • Do not overreach. Keep proper footing and balance at all times. • Use safety equipment. Always wear eye protection.
Owner’s Manual General Precautions (cont’d) 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 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.
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 105lbs (approx). Two or more people should assist when moving or lifting this product. Never lift the generator using the engine or alternator lifting lugs.
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. • Keep access doors on enclosures closed and locked when access is not required.
Par t s enera l Parts General 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 On/off switch Oil alert lamp DC terminal 12 120V outlet AC breaker Grounding terminal
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. FILL THE ENGINE’S CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED LINE ON THE DIPSTICK.
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. Be sur to return the fuel valve lever to the OFF position after stopping the engine. 3. To start a cold engine, move the choke lever to the CLOSED position.
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. Stopping Engine 1. Turn the engine switch to the OFF position. 2. Turn the fuel valve lever to the OFF position.
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. 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.
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. 2. Connect the power cord of a 12 VDC powered tool or equipment to the DC Terminals.
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. 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.
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. • Before each use, inspect the generator.
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. Electrical and other permits may be required for the installation of emergency power systems.
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. Attach the frame to the concrete slab using 3/8” diameter expansion anchor bolts (not supplied).
Troubleshooting Note: Troubleshooting problems may have similar causes and solutions. PROBLEM POSSIBLE CAUSE SOLUTION Is there fuel in the tank? The engine will not start Refill the fuel tank. Is there enough oil in the engine? Is the spark plug in good condition? at the AC outlets Readjust gap and dry the spark plug. Replace it if necessary. Is the fuel reaching the carburetor? No electricity Add the recommended oil. Clean the fuel sediment cup.
Specifitions Model PG3500M Rated Frequency 60Hz Peak Power 3.5kW Generator Rated Power 3.0kW Rated Voltage 120V Power Factor 1 Model DJ170FD Type 4-stroke/air cooling/single cyclinder/OHV/horizontal shaft Displacement(cc) Engine 208 Ignition Model Transistorized Magneto Starting Model Recoil Start Max. Output (hp/rpm) 7.0/3600 Fuel Tank Capacity 15L/4Gal 0.6L Oil Capacity Continuous Work 15 Time half load (h) Length(inch) 24 Dimensions Width(inch) 18 Height(inch) 19.
Breaker Wiring Diagra R R Breaker Breaker 5-20R W Y/G DC coil 1 Gr QVR1mm ² LB QVR1mm ² Bl QVR1mm ² + LB QVR1mm ² 2510 8A Bl QVR0.5mm ² Ignition Switch LED Bl QVR0.5mm ² Bl QVR0.5mm ² Control Box Diagram W QVR0.5mm ² W R Bu Bu R QVR0.5mm ² Bu QVR0.5mm ² Bu QVR0.5mm ² R QVR0.5mm ² Bl/W Bl A V R Bl Bl/W Oil Alert Unit W QVR0.5mm ² Generator Block Bl Black Br Brown O Bl/W QVR0.
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. N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO.
N PART NO. DJ168F-16205-A DJ168F-16000-A DJ168F-16002-A DJ168F-16200-AE GBT16674-B6-25 DJ168F-18100-C DESCRIPTION NUT M16*1.
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. N PART NO.
N PART NO.
N PART NO.
N PART NO. DESCRIPTION DF3000H-33100-BJ-20302 DF3000H-33120-BJ DF1800H-33001-A DF3000H-33110-BJ-20302 DF3800H-33002-A DF1800H-33005-C GBT97-W-8 GBT93-LW-8 DF3000H-33003-A DF3000H-33015-A DF1800H-33011-A GBT16674-B5-12 DF1800H-33006-A-116 GBT16674-B5-16 GBT93-LW-5 GBT862-CW-5 DF3000H-34216-B GBT16674-B6-12 GBT97-W-6 GBT93-LW-6 GBT862-CW-6 ALTERNATOR ASSEMBLY ROTOR CARBON BRUSH COMP. STATOR GROUNDING POST COMP.
N PART NO.
