Pulsar PG6580BCO Generator

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 U.S. Agency. (EPA)

How to contact us:

To order parts, receive warranty assistance, or other service inquiries, contact Pulsar Products Inc. at: 866.591.8921, or support@pulsar-products.com

Save your original sales receipt and record the following information below for service or warranty assistance.

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.

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

The generator features various components for operation and control. These include:

• A - ON/OFF Start Switch: Controls power to the generator.
• B - 3 in 1 Hour Meter: Displays operational hours.
• C - 120 Volt 30 Amp RV Receptacle (TT-30R): For connecting RVs or high-power 120V devices.
• D - Main Breaker: Overload protection for the main circuit.
• E - 120V / 240V 30 Amp Twist Lock (L14-30R): For connecting 120V/240V devices requiring a twist-lock connection.
• F - Grounding Connection: Point for grounding the generator.
• G - Two 120 GFCI Outlets (NEMA5-20): Standard 120V outlets with Ground Fault Circuit Interrupter protection.
• H - Fuel selector switch: Allows selection between gasoline and LPG fuel.
• I - CO Sensor Light: Indicates carbon monoxide detection.
• J - Fuel Tank: Stores gasoline fuel.
• K - Fuel Tank Vapor Vent: Releases fuel tank pressure.
• L - Frame: Structural support for the generator.
• M - Choke Lever: Used for starting the engine, especially in cold weather.
• N - Fuel Valve (ON/OFF): Controls fuel flow to the engine.
• O - Air Filter: Filters air entering the engine.
• P - Recoil Starter: Manual pull-start mechanism.
• Q - Handle: For moving and transporting the generator.
• R - Support Foot: Provides stability for the generator.
• S - Oil Fill and Dipstick: For adding and checking engine oil.
• T - No Flat Tires: Durable tires for portability.

Illustration of the generator with labeled components (A-T) indicating their positions.

Assembly

Unpacking

1. Place box on a level surface.
2. Remove all items from box except the generator. Make sure all items listed on the packing list are included and not damaged.
3. Cut down the sides of box being careful to avoid hitting the generator.
4. Leave generator on box to install wheel assembly.

Packing List

Check all loose parts to the following list. Contact your dealer if any loose parts are not included.

Diagrams showing the components for Handle Assembly (handles, bolts, bushings, nuts), Wheel Assembly (wheels, axles, washers, hair pins), and Foot Assembly (support feet, bolts). Also shows a measuring cup, funnel, and engine oil bottle.

Attaching Wheels

→ See Fig 1

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

Fig 1: Illustration showing the attachment of a wheel to the generator frame using an axle, washer, and hair pin.

Installing Support Leg

→ See Fig 2

• Parts needed - Support leg & M8 Bolt (2).
• Raise the front end of the generator high enough to gain access to the bottom of the frame. Securely position props underneath to support.
• Line up holes on the support leg bracket to the holes on the front of the generator frame.
• Attach the support leg using M8 Bolt.

Fig 2: Illustration showing the attachment of the support leg to the front frame of the generator using M8 bolts.

Installing The Handles

→ See Fig 4

• Place 2 bushings on handle and slide handle in place with the pre-drilled hole on the generator frame.
• Insert bolt through the handle and frame and tighten with nut.
• Repeat on opposite side.

Fig 4: Illustration depicting the steps to install the handles onto the generator frame, showing the placement of bushings, insertion of the handle, and securing with a bolt and nut.

Adding / Checking Engine Oil

→ See Fig 5

• Place generator on a level surface.
• Insert a funnel into the crankcase dipstick hole and carefully add 4-Cycle engine oil (SAE10W-30) to empty crankcase until oil reaches the outer edge of the oil fill hole (crankcase dipstick hole).
• Be sure to replace dipstick before attempting to start the engine.
• To check oil, set generator on a level surface, wipe dipstick clean, then reinsert dipstick without rethreading.

Fig 5: Illustration showing a funnel being used to pour 10W30 oil into the engine oil fill port of the generator.

Adding Fuel

→ See Fig 6

• Set generator outdoors that is well ventilated.
• Remove fuel cap.
• Insert a funnel into the fuel tank and carefully pour gasoline into the tank until fuel level reaches 1 ½ inches below the top of the neck. Be careful not to overfill the tank to provide space for fuel expansion.

Fig 6: Illustration showing a funnel being used to pour unleaded gasoline into the generator's fuel tank.

Connecting Generator to an Electrical System

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

Operation

Grounding the Generator

→ See Fig 7

The ground terminal located on the front panel of the generator may be used for additional grounding, or when connected to a structure. Connect the ground terminal to an earthen ground rod, driven six feet into the ground, 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 undetected ground faults.

Fig 7: Illustration showing the grounding connection point on the generator.

How to Start Engine

→ See Fig 8-12

• Place generator on a level surface. All electrical loads MUST be disconnected from generator.

When Using Gasoline

• Turn the fuel selector to “GAS” position.
• Turn fuel valve to the “ON” position. (See Fig 9)
• Slide the choke lever to the “Choke” position. (See Fig 10) SKIP THIS IF THE ENGINE IS WARM OR HOT.
• Push the ON/OFF switch to the “ON” position. Pull the recoil handle (starter cord) slowly until resistance is felt, return, then pull rapidly. (See Fig 11)
• Let engine run for several seconds and then gradually, as engine warms up, slide the choke lever towards the “RUN” position until the choke is fully engaged to the “RUN” position. (See Fig 12)

When Using LPG

• Turn the fuel selector to “LPG” position
• Connect the propane hose to the intake nozzle of regulator; Open the valve on the LPG tank (See Fig 8)
• Slide the choke lever to the “Choke” position. (See Fig 10)
• Push the ON/OFF switch to the “ON” position. Pull the recoil handle (starter cord) slowly until resistance is felt, return, then pull rapidly. (See Fig 11)
• Let engine run for several seconds and then gradually, as engine warms up, slide the choke lever towards the “RUN” position until the choke is fully engaged to the “RUN” position. (See Fig 12)

Fig 8: Illustration showing the LPG tank connection. Fig 9: Illustration showing the fuel valve in the 'ON' position. Fig 10: Illustration showing the choke lever in the 'CHOKE' position. Fig 11: Illustration showing the recoil start handle being pulled. Fig 12: Illustration showing the choke lever in the 'RUN' position.

How to Stop Engine

→ See Fig 13-16

• All loads MUST be disconnected from the generator. Never start or stop the engine with electrical devices plugged in to the receptacles. (See Fig 13)

When using gasoline

1. Turn the engine ON/OFF switch to the “OFF” position. (See Fig 16)
2. Turn the fuel valve lever back to the OFF position.(See Fig 14)

When using LPG

1. Turn the engine ON/OFF switch to the “OFF” position. (See Fig 16)
2. Close supply valve on LPG bottle. (See Fig 15)

Fig 13: Illustration showing disconnected electrical devices. Fig 14: Illustration showing the fuel valve in the 'OFF' position. Fig 15: Illustration showing the LPG valve turned to the 'OFF' position. Fig 16: Illustration showing the engine ON/OFF switch in the 'OFF' position.

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.

This generator is equipped with the following receptacles:

• Two 120 GFCI Outlets (NEMA5-20).
• One 120 Volt AC, 30 Amp RV receptacle (TT-30R).
• One 120 / 240 Volt AC, 30 Amp twist lock receptacle (NEMA L14-30R).

120 Volt GFCI duplex receptacles (NEMA 5-20R)

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

120 / 240 Volt AC, 30 Amp locking receptacle

• This receptacle has a 30 Amp push-to reset circuit breaker to protect against overload.
• This receptacle is rated to operate 120 Volt, AC, single phase, 60Hz loads requiring up to 3600 watts (3.6 kW) at 30 Amps. It is also rated to operate 240 Volt AC, single phase, 60Hz loads requiring up to 7,200 watts (7.2 kW).
• Use a NEMA L14-30 plug with this receptacle.
• Use a 4-wire cord rated for 240 Volts AC, 30 Amps to the plug. You can use the same 4-wire cord to operate a 120 Volt load.

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.
• Tilt generator until it balances on wheels. Roll machine to desired location.
• If the generator must be carried, fold handle to the down position. Never lift or carry generator by its handle.

Don't Overload Generator

Make sure you can supply enough rated watts and surge watts for all electrical 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 electrical 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 electrical devices you plan to attach to the generator. To prevent overloading the generator take the following steps:

Wattage Reference Guide

(Wattages listed are just approximations. Check electronic device for actual wattage)

Hour Meter

→ See Fig 17

Use this meter along with the manual to determine when and what type of service on the unit is needed. The display will show the word “P25” at the first 25 hours of operation and again at every 100 hours of operation after.

Fig 17: Illustration showing the generator's control panel with the 3-in-1 hour meter display.

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 power requirement first and the smallest power requirement last to help prevent overloading the generator.
• Allow generator power requirement to stabilize (engine and attached devices run evenly) before plugging in the next load.

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 take the following 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 fuel valve to the open position.
4. Ensure generator is serviced according to the maintenance schedule under “Maintenance” section of manual.
5. 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.

Pre-Operation Steps

Before starting the engine, perform the following pre-operation steps:

• Check the level of the engine oil and the fuel tank level.
• 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

Changing Oil

→ See Fig 18

• Run the Generator until the Engine is warm.
• Place 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 oil drainage plug, tighten securely.
• Carefully add SAE 10W-30 to empty crankcase until the oil reaches the outer edge of the oil fill hole (Crankcase Dipstick hole).
• Replace crankcase dipstick.

Fig 18: Illustration showing the oil fill & dipstick location and the oil drainage plug on the generator.

Oil Recommendations

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

Chart showing recommended oil viscosities based on ambient temperature. SAE 30 is recommended for temperatures above 40°F (4°C), 10W-30 for temperatures between -4°F (-20°C) and 86°F (30°C), Synthetic 5W-30 for temperatures between -22°F (-30°C) and 86°F (30°C), and 5W-30 for temperatures between -22°F (-30°C) and 50°F (10°C).

Air Filter

→ See Fig 19

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.

Fig 19: Illustration showing the air filter assembly, with the cover removed and the filter element being taken out.

Checking Spark Plug

→ See Fig 20

• 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 0.7 mm - 0.8 mm (0.028 - 0.031") 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)

Fig 20: Illustration of a spark plug, indicating the electrode gap measurement of 0.7-0.8mm.

High Altitude Operation

At high altitude, the standard carburetor air/fuel mixture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude that differs from that at which this engine was certified, for extended periods of time, may increase emissions. High altitude performance can be improved by specific modifications to the carburetor. If you always operate your generator at altitudes above 5,000 feet (1,500 meters), have your dealer perform this carburetor modification. This engine, when operated at high altitude with the carburetor modifications for high altitude use, will meet each emission standard throughout its useful life. Even with carburetor modification, engine horsepower will decrease about 3.5% for each 1,000-foot (300-meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made.

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.

Storage and Transportation of the Generator:

→ See Fig 21

• 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 in an outdoor, sheltered area and use a weather-resistant cover to protect from the elements.
• The generator must be Shipped, Run and Stored in the upright position as seen in this image.

Fig 21: Illustration showing the generator in its upright position, suitable for storage and transportation.

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.

Troubleshooting

CO Sensor

The CO Sensor monitors for the accumulation of poisonous carbon monoxide gas around the generator when the engine is running. If increasing levels of CO gas are detected, the CO Sensor automatically shuts down the engine.

The CO Sensor will also detect the accumulation of carbon monoxide from other fuel burning sources used in the area of operation. For example, if the exhaust of fuel burning tools is pointed at a CO Sensor-equipped generator, a shut-off may be initiated due to rising CO levels. This is not an error. Hazardous carbon monoxide has been detected. Move and redirect any additional fuel burning sources to dissipate carbon monoxide away from personnel and occupied buildings.

Generators are intended to be used outdoors, far from occupied buildings and the exhaust pointed away from personnel and buildings. If misused and operated in a location that results in the accumulation of CO, like in a partially enclosed area, the CO Sensor shuts off the engine, notifies the user with a RED indicator light, and directs the user to read the Action Label for steps to take. The CO Sensor DOES NOT replace carbon monoxide alarms. Install battery-powered carbon monoxide alarm(s) in your home.

CO Sensor Indicator Lights

RED

Carbon monoxide accumulated around the generator. After shut-off, the RED indicator light in the CO Sensor area of the control panel will flash to provide notification that the generator was shut-off due to an accumulating CO hazard. The RED light will flash for at least five minutes after a CO shut-off.

Move the generator to an open, outdoor area far away from occupied spaces with exhaust pointed away. Once relocated to a safe area, the generator can be restarted. Introduce fresh air and ventilate the area where the generator had shut down.

YELLOW

A CO sensor system fault occurred. When a system fault occurs, the generator is automatically shut down and the YELLOW indicator light in the CO auto-shutoff area of the control panel will flash to provide notification that a fault has occurred. The YELLOW light will flash for at least five minutes after a fault. The generator can be re-started, but may continue to shutoff. A CO sensor fault can only be diagnosed and repaired by an authorized Pulsar service center.

Illustration of the CO Sentry module on the generator, showing two indicator lights: 'MAINTENANCE REQUIRED' (yellow) and 'CARBON MONOXIDE DETECTED' (red), with text indicating 'FEATURES AUTO SHUTOFF & AUTO RESET'.

Diagrams

Wiring Diagram of 120/240V Generator Set (Model: PG6580BCO)

This section contains a detailed wiring diagram for the Pulsar PG6580BCO 120/240V generator set. The diagram illustrates the electrical connections between various components, including the alternator (stator windings, sub-field/excitation winding, rotor), control panel (main breaker, 120V 30 Amp RV receptacle (TT-30R), 120V/240V 30 Amp Twist Lock (L14-30R), two 120 GFCI Outlets (NEMA5-20), grounding connection, 3-in-1 hour meter, fuel selector switch, ON/OFF engine switch, CO sensor LED), and the engine (spark plug ignition coil, low oil shutdown switch). The diagram uses standard electrical symbols and color codes for wires (Black, Brown, Orange, Blue, Light Blue, Gray, Yellow, Red, White, Green/Yellow, Black/White, Pink, Green) to show the flow of current and control signals throughout the generator system. It also indicates the grounding system where the neutral is bonded to the frame.