Pulsar PG3500MR Generator Operator's Manual

Introduction

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 Environmental Protection Agency.

How to contact us:

To order parts, receive warranty assistance, or other services inquiries, you can contact us by internet at www.pulsar-products.com or write to us at:

PULSAR PRODUCTS INC.
5721 E. SANTA ANA ST.
ONTARIO, CA 91761
1-866-591-8921

Record the following information below for service or warranty assistance.

Date of Purchase: _________________________
Model Number: _________________________
Serial Number: _________________________

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

Safety Rules

Safety Symbols

WARNING! Indicates a potentially hazardous situation which could result in serious injury or death if not avoided.

CAUTION! Indicates a potentially hazardous situation which could result in damage to equipment or property.

• ⚠️ Toxic Fumes
• ⚡ Risk of electric shock
• ? Risk of fire
• ? Risk of explosion
• ? Hot surface
• ?️ Lifting hazard

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.

⚠️ WARNING! Read and understand this manual in its entirety before operating this generator. Improper use of this generator could result in serious injury or death.

⚠️ WARNING! Do not operate indoors or in a confined space preventing dangerous carbon monoxide gas from dissipating.

• Using a generator indoors WILL KILL YOU IN MINUTES!
• Carbon monoxide gas is a poisonous, odorless gas that can cause headache, confusion, fatigue, nausea, fainting, sickness, seizures, or death. If you start to experience any of these symptoms, IMMEDIATELY get fresh air and seek medical attention.
• Never use indoors, in a covered area, or in a confined space, even if doors and windows are open.
• Install a battery operated carbon monoxide alarm near bedrooms.
• Keep exhaust from this unit from entering a confined area through windows, doors, vents, or other openings.
• When working in areas where vapors could be inhaled, use a respirator mask according to all of its instructions.

⚠️ WARNING! Engine exhaust contains chemicals that lead to cause cancer and birth defects.

• Always wash hands after handling generator.

⚠️ WARNING! To reduce the risk of serious injury, avoid attempting to lift the generator alone.

Features

The generator features the following components:

• A - ON/OFF Start Switch: Controls the engine's power state.
• B - DC Circuit Protectors: Protects the DC output circuits.
• C - AC Circuit Protectors: Protects the AC output circuits.
• D - Main Circuit Protectors: Main circuit breakers for the generator's output.
• E - Grounding Connection: Terminal for grounding the generator.
• F - 120V Twist Lock (L14-30): A specific type of 120V AC receptacle.
• G - 12V DC Output: Provides 12V DC power, typically for battery charging.
• H - Oil Alert: Indicates low oil level.
• I - Fuel Tank Vapor Vent: Allows air into the fuel tank as fuel is consumed.
• J - Choke Level: Adjusts the fuel-air mixture for starting.
• K - Fuel Valve (ON/OFF): Controls the flow of fuel to the engine.
• L - Recoil Starter Grip: Used to manually start the engine.
• M - Air Filter: Filters air entering the engine.
• N - Handle: For moving the generator.
• O - Support Foot: Provides stability when the generator is stationary.
• P - Fuel Tank: Holds the gasoline.
• Q - No Flat Tires: Indicates the tires are designed to prevent flats.

Assembly

Unpacking

1. Place the box on a level surface.
2. Remove all items from the box except the generator. Verify all items listed on the packing list are included and not damaged.
3. Carefully cut down the sides of the box to avoid damaging the generator.
4. Leave the generator on the box to facilitate the installation of the wheel assembly.

Packing List

Check all loose parts against the following list. Contact your dealer if any parts are missing.

Handle Assembly: Involves attaching the handle bracket to the generator frame using screws and nuts, then attaching the handle to the bracket, and finally securing with a handle clip.

Wheel Assembly: Requires attaching wheels to axles, then securing the wheel assembly to the generator frame using hair pins.

Foot Assembly: Involves attaching support legs to the generator frame using screws and nuts.

Attaching Handle (See fig 1)

• Parts needed: 1 handle, 1 handle bracket, 1 handle clip, 4 screws and nuts.
• Install the handle bracket to the generator frame.
• Then attach the handle to the bracket.
• Lastly, install the handle clip.

Attaching Wheels (See fig 2)

• Parts needed: 2 wheels, 2 axles, 2 hair pins, and 2 washers.
• Raise or tilt the generator to slide the wheel axle pin through the wheel, the washer, and the wheel mounting hole on the side of the frame.
• Secure the wheel assembly by inserting a hair pin through the hole at the end of the wheel axle and pressing until it locks into place.
• Repeat the process on the other side of the generator to install the second wheel.

Installing Support Leg (See fig 3)

• Parts needed: Support legs & M8 screws (2) and 2 nuts.
• Raise the front end of the generator high enough to access the bottom of the frame. Securely position props underneath for support.
• Align the holes on the support leg bracket with the holes on the front of the generator frame.
• Attach the support leg using M8 screws (2) and nuts.

Adding / Checking Engine Oil (See fig 4)

• Place the generator on a level surface.
• Remove the crankcase dipstick to ensure you do not overfill the engine.
• Insert a funnel into the crankcase dipstick hole and carefully add 4-Cycle engine oil (SAE10W-30) until oil reaches the outer edge of the oil fill hole.
• Replace the dipstick before attempting to start the engine.
• To check oil, set the generator on a level surface, wipe the dipstick clean, then reinsert it without threading.

❗ CAUTION! You must add oil before first operating this generator. Always check oil level before each operation.

DO NOT USE E15 OR E85 FUEL IN THIS UNIT. IT IS A VIOLATION OF FEDERAL LAW AND WILL DAMAGE THE UNIT AND VOID YOUR WARRANTY.

Adding Fuel (See fig 5)

• Set the generator on a clean and level surface in a well-ventilated area.
• Remove the fuel cap.
• Insert a funnel into the fuel tank and carefully pour gasoline until the fuel level is 1 ½ inches below the top of the neck. Do not overfill to allow space for fuel expansion.

❗ CAUTION! You must add oil before first operating this generator. Always check oil level before each operation.

DO NOT USE E15 OR E85 FUEL IN THIS UNIT. IT IS A VIOLATION OF FEDERAL LAW AND WILL DAMAGE THE UNIT AND VOID YOUR WARRANTY.

Connecting Generator to an Electrical System

• If connecting the generator to a building's electrical system for standby power, use a qualified electrician to install a transfer switch. The generator's power must be isolated from the circuit breaker or alternative power source. The connection must comply with all electrical codes and applicable laws.

⚠️ WARNING! This generator produces a very high voltage which could result in burn or electrocution causing serious injury or death.

• Never handle the generator, electronic devices, or any cord while standing in water, barefoot, or with wet hands or feet.
• Always keep the generator dry. Never operate in rain or wet conditions.
• Use a ground fault circuit interrupter (GFCI) in damp or highly conductive areas, such as metal decking or steel work.
• Never plug electronic devices into the generator using frayed, worn, or bare wires. Never touch bare wires or receptacles.
• Never permit a child or unqualified person to operate the generator. Keep children at least 10 feet away from the generator at all times.
• If using the generator for backup power, notify the utility company.
• If connecting to a building's electrical system for standby power, use a qualified electrician to install a transfer switch. Failure to isolate the generator from the power utility could result in serious injury or death to electric utility workers.

Operation

Grounding the Generator (See fig 6)

The ground terminal on the front panel must be used to connect the generator to a driven ground rod using a No. 8 AWG copper wire. Connect the wire between the lock washer and nut, and tighten securely. Grounding protects against electric shock from static electricity or ground faults.

⚠️ WARNING! Generator must be properly grounded to prevent electrocution.

• Only operate the generator on a level surface.
• Always connect the nut and ground terminal on the frame to an appropriate ground source.

How to Start Engine (See fig 7-10)

1. Place the generator on a level surface. All electrical loads MUST be disconnected.
2. Turn the fuel valve to the “ON” position. (See fig 7)
3. Slide the choke lever to the “Choke” position. (Skip if the engine is warm or hot). (See fig 8)
4. For manual start, turn the engine ON/OFF switch to the "ON" position. Pull the recoil handle (starter cord) slowly until resistance is felt, then pull rapidly. (See fig 9)
5. Let the engine run for several seconds. As the engine warms up, gradually slide the choke lever towards the “RUN” position until it is fully engaged. (See fig 10)

⚠️ WARNING! Never start or stop the engine with electrical devices plugged into 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.

⚠️ WARNING! Pull cord recoils rapidly and pulls arm towards engine faster than you can let go which could result in injury.

• To avoid recoil, pull the starter cord slowly until resistance is felt, then pull rapidly.

How to Stop Engine (See fig 11-13)

• All loads MUST be disconnected from the generator. Never start or stop the engine with electrical devices plugged in to the receptacles.
• Turn the fuel valve to the “OFF” position.
• Turn the engine ON/OFF switch to the “OFF” position.

Receptacles and Extension Cords

Use only high-quality, well-insulated, grounded extension cords in good condition. Extension cords should have a minimum rating of 125 Volts AC, 20 Amps and be as short as possible to minimize voltage drop. Follow the load manufacturer's power rating recommendations.

This generator is equipped with:

• Two 120 Volt AC, 20 Amp receptacles.
• 12 Volt 8.3 Amp Output (For charging batteries only).

120 Volt AC, 20 Amp receptacle:

• This receptacle has a 20 Amp push-to-reset circuit breaker to protect against overload.
• Each socket is rated for 120 Volt, AC, single phase, 60Hz loads up to 2400 watts (2.4 kW) at 20 Amps.
• Use extension cords with a minimum rating of 125 Volts AC, 20 Amps.

❗ CAUTION! Do not connect 3-phase loads to the generator.

⚠️ WARNING! 12 Volt 8.3 Amp Output is for charging batteries only!

Extension Cord Selection

Use the table below to select the appropriate extension cord for your load. Using an inadequate cable can cause voltage drop, damaging the device and cord.

Ground Fault Circuit Interrupter

Receptacles are protected by a Ground Fault Circuit Interrupter (GFCI) to prevent electrocution from moisture or faulty devices. GFCI receptacles do not protect against short circuits, overloads, or shocks. To test, press the TEST button; the RESET button should pop out. To restore power, press the RESET button. Test GFCI receptacles before each use.

Moving the Generator

• Disconnect electronic devices and turn the generator off.
• Turn the fuel valve to the “OFF” position.
• Tilt the generator until it balances on its wheels and roll it to the desired location.
• If the generator must be carried, fold the handle down. Never lift or carry the generator by its handle.

❗ CAUTION! This product is heavy and requires several people to lift. Lift and lower with your legs by bending at the knees, not your back, to avoid injury.

Don't Overload Generator

Ensure you supply enough rated watts and surge watts for all connected electronic devices. Rated watts are needed to keep a device running, while surge watts are required to start it (typically 2-3 seconds). Account for this surge when selecting devices.

To prevent overloading:

1. Add up the total rated wattage of all electronic devices to be connected simultaneously.
2. Estimate surge watts by adding the highest output item (it's not necessary to calculate surge for all devices if connected one at a time).
3. Add the Surge Watts to the total Rated Watts from step 1. Keep the total load within the generator's power capacity.

Wattage Reference Guide

Check electronic devices for actual wattage, as these are approximations.

⚠️ WARNING! 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.

Cold Weather Operation

Under humid conditions where temperatures drop to 40°F (4°C), the carburetor and/or crankcase breather system may begin to freeze. To prevent icing, follow these steps:

1. Replace any old fuel with clean, fresh fuel.
2. Use synthetic 5W-30 or SAE 5W-30 engine oil. Check oil daily or after every 8 hours of use.
3. Turn the fuel valve to the open position.
4. Ensure the generator is serviced according to the maintenance schedule in the “Maintenance” section.
5. Shelter the unit from the elements.

Maintenance

Regular maintenance will extend the life and improve the performance of this generator. The warranty does not cover items resulting from operator negligence, misuse, or abuse. To receive full warranty value, maintain the generator as instructed, including proper storage.

⚠️ WARNING! Before inspecting or servicing this machine, ensure 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 these steps:

• Check the engine oil and fuel tank levels.
• Ensure the air filter is clean.
• Remove any debris from the generator, muffler, and controls using a vacuum cleaner or a soft bristle brush for caked-on dirt.
• Inspect the work area for hazards.

After Each Use

• Shut off the engine.
• Charge electric starter (refer to Battery Charger section).
• Store the unit in a clean and dry area.

Maintenance Schedule

Changing Oil (See Fig 14)

• Run the generator until the engine is warm.
• Place the generator on a level surface.
• Remove the crankcase dipstick.
• Place an oil pan underneath the oil drainage bolt to collect used oil.
• Remove the oil drainage plug and allow oil to drain completely.
• Reinstall the oil drainage plug, tightening it securely.
• Carefully add SAE 10W-30 oil until it reaches the outer edge of the oil fill hole.
• Replace the crankcase dipstick.

Oil Recommendations

• Do not use special additives.
• Outdoor temperatures determine the proper oil viscosity. Use the chart to select the best viscosity for the expected temperature range.

❗ CAUTION! Used oil should be disposed of at an approved disposal site. See your local oil retailer for more information.

Oil Viscosity Chart:

• Below 40°F (4°C): Use SAE 30 (may result in hard starting).
• 40°F (4°C) to 80°F (27°C): Use 10W-30.
• Above 80°F (27°C): Use Synthetic 5W-30 (may cause increased oil consumption; check oil level more frequently).

Air Filter (See Fig 15)

A dirty air filter reduces engine life, makes starting difficult, and lowers performance. To clean:

• Remove the air filter cover.
• Carefully pull the air filter out by lifting up along the edges.
• Remove dirt by tapping or blowing it out. Replace with a new filter annually.
• Reinstall the air filter, ensuring a seal, and replace the air filter cover.

Checking Spark Plug (See Fig 16)

• 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 adjust to 0.762 mm - 0.80 mm (.030 - .031") if necessary.
• Reinstall the spark plug and tighten to 22.0 – 26.9 Nm (16-20 ft-lb).
• Reconnect the spark plug wire.
• If the spark plug is worn, replace it with an equivalent part (e.g., BOSCH F7TC, NGK BP6ES, CHAMPION N9YC). Replace annually.

Spark Arrestor (See Fig 17)

• Inspect the spark arrestor for breaks or holes. Replace if necessary. Contact PULSAR customer service for replacements.
• Use a brush to remove carbon deposits from the spark arrestor screen.
• To remove: While the muffler is cool, loosen the locking clamp and slide the spark arrestor out. Reverse to install.

Cooling System

The cooling system should only be serviced by an authorized dealer.

Carburetor Adjustment

The carburetor is low emission and has a non-adjustable idle mixture valve. Contact an authorized dealer for adjustments.

Replacing Fuel Filter (See Fig 18)

Occasionally, the fuel filter may become clogged and need replacing. Contact PULSAR customer service or a local small engine repair shop.

• Turn the fuel valve to the “OFF” position.
• Remove the fuel line from both sides of the filter by squeezing the retaining clip ends with pliers.
• Slide the fuel line off.
• Replace with a new fuel filter.
• Reinstall fuel lines to the new fuel filter.
• Turn the fuel valve to the “ON” position.

❗ CAUTION! Fuel tank must be empty before replacing fuel filter. Run unit until tank is empty, if needed, or inspect filter prior to fill-up.

Draining Fuel Tank and Carburetor

To prevent gum deposits, drain fuel from the tank and carburetor before storing the unit for long periods. This prevents starting problems. Stale or gummy fuel is not covered by warranty.

Draining the fuel tank

• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Push the fuel valve knob through the valve holder bracket to access the petcock.
• Remove the fuel line leading to the carburetor from the petcock by squeezing hose clamp ends and sliding the line off.
• If needed, attach a fuel hose to a suitable container to catch drained fuel.
• Turn the fuel valve to the ON position.
• When the tank is drained, close the fuel valve and reinstall the fuel line securely on the petcock.
• Reinstall the fuel valve knob in the bracket, pushing forward until it snaps securely.

Draining the carburetor

• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Position a container under the carburetor drain screw; loosen the screw.
• Allow fuel to drain completely into the container.
• Retighten the drain screw.

❗ CAUTION! Consult your local hazardous waste management for proper disposal of used fuel.

Storage

• Remove any debris from the generator, muffler, and controls using a vacuum cleaner or soft bristle brush.
• Inspect air cooling slots for obstructions and clear them.
• Disconnect the negative battery cable.
• For short-term storage, start the generator once every 7 days.
• For long-term storage, add fuel stabilizer to prevent stale fuel from causing deposits in the fuel system and carburetor.
• Store indoors and use a protective cover to protect from dust.

Troubleshooting

Diagrams

The generator includes a wiring diagram illustrating the electrical connections for the 120V generator set. It shows the engine's spark plug ignition coil, oil sensor, control panel, and the alternator's sub-field winding and rotor. Key components like the engine switch, DC coil, and AVR (Automatic Voltage Regulator) are depicted, with connections indicated by color-coded wires (Red, White, Black, Blue, Orange, Yellow/Green) and labels for terminals and components.

Warranty

Pulsar Products Inc. Limited 2 Year Warranty:

Pulsar Products Inc. warrants to the original purchaser that each portable generator sold shall be free from defects in material and workmanship for the specified time period. Pulsar Products Inc. will, at its discretion, repair or replace any defective part found upon examination by an authorized service dealer. The warranty period is not extended by repairs or replacements. The consumer is responsible for all transportation costs to and from the factory or warehouse. Proof of purchase is required for warranty service.

Length of Warranty:

• Personal use: Two (2) years or 500 hours, whichever comes first. Proof of purchase and maintenance required.
• Year 1: Limited coverage on generator engine and alternator components (parts and labor).
• Year 2: Limited coverage on generator engine components (parts only).

"Personal use" refers to residential or recreational use. "Commercial use" includes commercial, construction, or income-producing purposes, and such use voids the warranty. Rental equipment or use as primary utility power is also not covered.

Consumer Responsibilities:

• Read and follow all instructions in the owner's manual. Products damaged due to misuse or abuse are not covered.
• Pay all transportation costs to an authorized Pulsar Products Inc. Service Center. Expedited shipments may incur additional charges.
• Pay labor costs for warranted repairs within the first twelve (12) months after purchase. Labor rates are based on normal working hours.
• Maintain the generator as specified in the manual. Documentation of maintenance may be required.
• Present any problems to an authorized Pulsar Products Inc. Service Center promptly. Warranted repairs will be completed within 30 days.

What this Warranty Does Not Cover:

• Normal wear: Filters, spark plugs, gaskets, O-rings, adapter cord sets, wheels, starting batteries.
• Maintenance: Tune-ups, routine maintenance, or adjustments/repairs not performed by an authorized facility.
• Misuse: Abuse, neglect, incorrect fuels/lubricants, overloading, overspeeding, improper maintenance/storage, unapproved modifications, or operation contrary to the manual.
• Adverse conditions: Freezing, accident, or natural disasters.
• Product shipment: Damage from shipping, handling, or warehousing. Claims must be filed with the freighter.
• Other exclusions: Products sold "as is," with removed serial numbers, refurbished, used, demonstration, or floor models.

Where Warranty is Valid:

Warranty is valid for products purchased from an authorized Pulsar Products Inc. dealer in the United States, Canada, or Mexico. It extends only to the original purchaser. Refurbished, used, demonstration, floor models, and products purchased from online auction sites (e.g., eBay) are not covered. Commercial use is also excluded.

How to Obtain Warranty Service:

Take the original receipt and product to the place of purchase, or mail them to the address found on the website if purchased online. You can also locate the nearest Pulsar Products Inc. dealer for service or warranty questions by calling 1-866-591-8921. Pulsar Products Inc. recommends retaining all receipts for purchase and maintenance, but will not deny coverage if proof of purchase or service can be obtained.

Pulsar Products Inc.'s obligation is limited to product repair or replacement and is not liable for incidental or consequential damages (e.g., delivery costs, property loss, lost revenue, telephone charges, inconvenience). Some states/provinces may not allow these limitations.

Image of products may slightly differ due to continued improvement of product.