Gasoline Generator Owner's Manual

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M165923V.1

Owner’s Manual

Instructions for Installation/Set-up, Operation, Servicing, & Storage

Portable, Outdoor Use-Only, Gasoline Generator

10,500 Watt Continuous (13,000 Watt Surge) Capacity

Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-

up connection to a building’s power supply (via a professionally installed UL-approved transfer

switch).

WARNING

READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up,

operate, and maintain this generator could result in serious injury or death from carbon monoxide poisoning,

electric shock, fire/explosion, or burns. In particular, be aware of the following hazards:

CO Poisoning

Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.

• ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or

semi-enclosed spaces, including homes, basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These

spaces can trap poisonous gases, EVEN if you run a fan or open windows.

• Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).

Electric shock / Electrocution

• High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly

grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.

• NEVER plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST

ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed

electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.

Fire / Explosion

• DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so

engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7’ from all combustible objects.

• All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use

approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.

• ALWAYS keep a fire extinguisher rated “ABC” nearby.

STOP!

CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power load Planning & Management” section

of this manual to determine your power load requirements and then compare to the generator’s rated capacity.

INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking

& Delivery Inspection” section for instructions on whom to contact to report missing or damaged parts.

ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to

your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this

requirement.

Any Questions, Comments, Problems, or Parts Orders

Call NorthStar Product Support 1-800-270-0810

ITEM NUMBER: 165923

SERIAL NUMBER: _____________

Summary of content (42 pages)

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M165923V.1 ITEM NUMBER: 165923 SERIAL NUMBER: _____________ TM Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 10,500 Watt Continuous (13,000 Watt Surge) Capacity Can be used to power individual appliances plugged directly into the generator’s outlets, or as a backup connection to a building’s power supply (via a professionally installed UL-approved transfer switch).
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Hazard Signal Word Definitions 2
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Table of Contents Hazard Signal Word Definitions .................................................................................................2 About Your Generator .................................................................................................................4 Specifications .................................................................................................................................6 Safety Label Locations............................................................
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About Your Generator Thank you for purchasing your NorthStar portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to 13,000 Watts of electrical power (10,500 watts continuous, 13,000 watts surge). It can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. 2. As a back-up, standby power source for a building.
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About Your Generator (cont’d) NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture. Before using, the user shall determine the suitability of this product for its intended use and assumes liability therein.
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Specifications – Item #165923 SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Total Harmonic Distortion Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method 120V Receptacles 120/240V Receptacles Circuit Breakers Battery (not included) 165923 13000 Watts (W) 10500 Watts (W) 120/240 Volt (V) Single phase (4-wire) 56.5-63.3 Hertz (Hz) 1.0 p.f. less than 5% 20 HP Honda 3390 - 3798 RPM Unleaded gasoline 10 gallons (38.
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Safety Label Locations – Item #165923V.1 DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. • Commercial-grade electric start engine NEVER use inside a home or garage. EVEN IF doors and windows are open. • Extend run 10 gallon fuel tank • Maintenance-free brushless alternator design • Smooth running focus mount isolation system Only use OUTSIDE and far away from windows, doors, and vents.
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Machine Component Identification - Item #165923V.1 Figure 1 (Ref. 1-10) Ref. 1 2 3 4 5 6 7 8 9 10 Description Ref. Air Cleaner Optional Wheel Kit (#165919) Circuit Breakers 120/240V, 50A Receptacle 120/240V, 30A Locking Receptacle 120V, 30A Locking Receptacle 120V, 20A Duplex Receptacle Oil Drain Plug Vibration Isolation Mount Oil Filler Cap Figure 2 (Ref. 11-19) 8 Description 11 12 13 14 15 10.
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Machine Component Identification - Item #165923V.1 REFERENCE GUIDE Reference 1 – Air Cleaner Reference 2 – Optional Wheel Kit Reference 3 – Circuit Breakers Reference 4 – 120/240V, 50A Receptacle Reference 5 – 120/240V, 30A Locking Device Receptacle Reference 6 – 120V, 30A Locking Device Receptacle Reference 7 – 120V, 20A Duplex Receptacle Reference 8 – Oil Drain Plug Reference 9 – Vibration Isolation Mount Reference 10 – Oil Filler Cap Reference 11 - 10.
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Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously.
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Power Load Planning & Management (cont’d) Device Furnace fan (1/3 HP) Freezer Hair dryer Hand drill (1”) Hand drill (1/2”) Hand drill (3/8”) Hand drill (1/4”) Hedge trimmer Home computer Impact wrench Running Watts 1200 (a) 800 (b) 1200 1100 875 500 250 450 150 500 Device Submersible pump (1-1/2 HP) Submersible pump (1 HP) Submersible pump (1/2 HP) Sump pump Table saw Television Toaster Vacuum cleaner VCR Water Heater Weed trimmer Running Watts 2800 (a) 2000 (a) 1500 (a) 600 (a) 2000 (a) 500 1000 250 70
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Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. 3. Setting up generator for the type of power generation you need: a. portable power source, or b. connected to a building as a back-up power source. 4. Selecting a site for using the generator. 5. Grounding. 6.
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Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 13,000W of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch.
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Installation / Initial Set-Up The generator cannot power your entire home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator. Using as a Portable Power Source (See the previous section of this manual entitled “Power Load Planning & Management” for more information on load application and selection.
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Installation / Initial Set-Up ♦ Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoor-rated, grounded extension cords of the proper size. Use Table 2 below to choose an adequately sized extension cord according to the amperage of the device being used and the length of the cord. Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga.
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Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet all of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. Choose a site that meets all of the criteria specified.
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Installation / Initial Set-Up Adequate cooling ventilation The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. No wet conditions Hot exhaust clearance • Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.
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Installation / Initial Set-Up 5. Grounding the generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth – the depth required will be dictated by local soil conditions. Consult with an electrician.
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Installation / Initial Set-Up 6. Battery Installation Your generator’s engine is equipped with an electric starter which requires the installation of a 12volt lawn tractor size battery (Group U1). See the “Specifications” section of this manual for more specific battery requirements for this generator model, such as minimum amperage or CCA rating. The battery is to be supplied by the customer and should be installed in the protective battery box located near the engine.
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Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. 1. 2. 3. 4. 5. 6. 7. Operation Procedures General Safety Rules for Operation Preparing for Operation Starting the Engine Checking Generator Output Connecting Electrical Loads (Portable Power Generation) Stopping Storage & Exercise of Generator Each of these procedures is discussed in detail below: 1.
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Operation (cont’d) • Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire o Excessive vibration o Flame or smoke o Abnormal noise • Adjusting / repairing.
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Operation (cont’d) Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
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Operation (cont’d) 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from air intakes.
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Operation (cont’d) WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite gasoline vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Use extreme care when handling gasoline.
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Operation (cont’d) • • Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device. A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily. 5) Clean up gasoline spills /splashes immediately. • • If possible, move the generator away from spilled gasoline on the ground. • • Gasoline soaked rags are flammable and should be disposed of properly.
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Operation (cont’d) 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position. To restart a warm engine, move choke lever to half choke or to RUN position. 4) Start the engine: a) Turn the engine key switch to the START position and hold it there until the engine starts.
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Operation (cont’d) 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency.
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Operation (cont’d) 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING: Do not overload generator.
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Operation (cont’d) 7. Storage & Exercise When you are finished using the generator, you must: Disconnect all loads Shut off fuel supply Store the generator properly Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below.
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Operation (cont’d) Prepare engine for long term storage if needed If you will not be able to exercise the generator regularly, you must prepare the engine for long term storage to prevent gum deposits from forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carburetor OR o Adding fuel stabilizer to the gasoline (following manufacturer’s instructions) Fuel stabilizer steps: 1. Ensure gasoline tank is full. 2.
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Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using. Note: The generator head is brushless and maintenance free.
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Maintenance & Repair (cont’d) Check GFCI (if equipped) Clean & inspect spark arrestor (if equipped) Keep generator clean Recharge and maintain battery (if electric start) Once a month, test the Ground Fault Circuit Interrupter (GFCI) to protect against electrical shock due to failure of the GFCI. (Only for those models equipped with GFCI – See the “Specifications” section.) To test the GFCI: 1. Depress the TEST button. The RESET button should extend from the receptacle.
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Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) b) c) d) e) Voltage too low. a) Engine speed too slow. a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) Fill fuel tank. d) Place switch in ON position. e) Battery has low electrolyte and/or needs to be charged or replaced. a) Bring generator to a qualified technician for adjustment. b) Reduce the load. (See Power Load Planning & Mgt. section of this manual.
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Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator.
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Summary of Important Safety Information for Operation (cont’d) Installation / Initial Set-up Safety • Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. • Operate OUTSIDE only – dangerous carbon monoxide exhaust! Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it.
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Summary of Important Safety Information for Operation (cont’d) Gasoline Safety Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use extreme care when handling: • Fuel outdoors. Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. • Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel.
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Summary of Important Safety Information for Operation (cont’d) • Electric shock accident. If an electric shock accident occurs, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. Avoid direct contact with victim. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. Apply first aid and get immediate medical help. • Hot muffler.
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Generator Exploded View Rev- V.
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Generator Exploded View Rev- V.
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Wiring Diagram Rev – V.
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Wiring Diagram Rev – V.
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Generator Head Exploded View Rev- V.1 Ref # Part # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 30991 30994 31013 30995 307489 305605 31014 31018 31015 307484 306403 306416 30997 31065 30999 30992 307479 307481 9910303129 39256 31017 31011 307478 31022 Description Drive End Bracket Protection Screen Phillips Screw Fan Grommet Terminal Box Cover M5 X .8, 16mm Long M5 X .8, 10mm Long, Green M5 X .