M165928H.1 ITEM NUMBER: 165928 SERIAL NUMBER: _____________ Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable Outdoor Use-Only, Belt-Driven Generator 9,600 Watt Continuous (10,000 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).
Hazard Signal Word Definitions 2
Table of Contents Hazard Signal Word Definitions ................................................................................................. 2 About Your Generator ................................................................................................................. 4 Specifications ................................................................................................................................. 6 Safety Label Locations ........................................................
About Your Generator Thank you for purchasing your NorthStar belt-driven generator! About Your Generator This belt-driven, portable generator is designed to provide up to 9,600 Watts of electrical power (9,600 watts continuous, 10,000 watts surge). Powered by an external engine, this generator 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.
About Your Generator (cont’d) You must follow all instructions and safety precautions presented throughout this manual. A summary of important safety information can be found at the end of the manual. Keep this manual for reference and review. Proper preparation, operation, and maintenance will result in operator safety as well as best performance and long life of the generator.
Specifications – Item #165928.1 SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Minimum Recommended Engine Engine Speed Minimum Torque 120V Receptacle 120/240V Receptacle Circuit Breaker Drive Shaft #165928 10000 Watts (W) 9600 Watts (W) 120 / 240 Volt (V) Single phase (4-wire) 59.0-62.0 Hertz (Hz) 1.0 p.f.
Safety Label Locations – Item #165928.1 WARNING DANGER HIGH VOLTAGE from generator can shock or kill. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER connect generator directly into a wall outlet. ANY connection to a building's electrical system MUST ISOLATE GENERATORFROM UTILITY POWER via a transfer switch. Be sure generator is properly grounded.
Machine Component Identification - Item #165928H.1 Figure 1 (Ref. 1-7) Ref. 1 2 3 4 5 6 Description Ref. 40A Circuit Breakers 30A Circuit Breaker 20A Circuit Breakers Voltmeter 120V 20A Duplex Receptacles 120V 30A Locking device Receptacle 7 8 9 10 11 Description 120/240V 50A Receptacle 28 mm shaft Grounding screw Mounting feet Fan vents Figure 2 (Ref.
Machine Component Identification – Item #165928H.1 (cont’d) REFERENCE GUIDE Reference 1 – Circuit Breaker Two 40 amp (A) push-to-reset circuit breaker. Reference 2 – Circuit Breaker One 30 amp (A) push-to-reset circuit breaker. Reference 3 – Circuit Breaker Two 20 amp (A) push-to-reset circuit breakers. Reference 4 – Voltmeter Voltmeter needle should be in green area during all generator load conditions. The black line in the center on the green area is 120V.
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.
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
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: 1. 2. 3. 4. 5. 6. Steps for Installation / Initial Set-Up Unpacking & delivery inspection. Planning the power load to stay within the generator’s rated capacity. Setting up for the type of power generation you need: a. portable power source, or b. connected to a building as a back-up power source. Selecting a site for using the generator.
Installation / Initial Set-Up 2. As a portable power source. You can plug appliances or tools directly into the generator’s electrical outlets. Specific requirements for each are given below. Note: Regardless of whether you use your generator as a back-up power source connected to a building or as a portable power source, you must not overload the generator. Overloading may cause serious damage to the generator and attached electrical devices.
Installation / Initial Set-Up powered simultaneously without overloading the generator. (See the previous section of this manual entitled “Power Load Planning & Management” for more information on load application and selection.) Using as a Portable Power Source When using the generator as a portable power source, you can plug electric devices and appliances directly into the generator’s electrical outlets. There are three different kinds of electrical outlets on the generator: 1.
Installation / Initial Set-Up jobsites, always use ground fault circuit interrupter (GFCI)-equipped extension cords to prevent electrical shock. Use Table 5 below to choose an adequately sized extension cord according to the amperage of the device being used and the length of the cord. Table 5 Current/Power Amps at Load 240V (watts) 10 2400 20 4800 30 7200 40 9600 50 12000 Maximum Extension Cord Length #10 Ga. #12 Ga. #14 Ga. #16 Ga.
Installation / Initial Set-Up Choose a site that meets all of the criteria specified below. Site/Location Criteria: Dry, level surface The generator should be positioned on a dry, firm, level surface. Ensure that the generator sits level and will not slide or shift during operation. Outdoors only – dangerous carbon monoxide exhaust DANGER: Carbon monoxide poisoning hazard The exhaust from the engine contains carbon monoxide (CO), a poisonous gas that can kill. You cannot smell it, see it, or taste it.
Installation / Initial Set-Up Hot engine exhaust clearance No wet conditions Do not run the generator in close proximity to other heat-generating equipment, such as another generator. The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation. Do not allow debris to accumulate and block airflow. Do not operate with a tarp, blanket, or cover surrounding the generator.
Installation / Initial Set-Up 5. Mounting & Connecting Generator and Engine You will need to supply a minimum 18 HP engine to power the generator. There are two methods to connect the generator to the engine: 1. The recommended method is to use sheaves (pulleys) and a V-belt(s). 2. An alternative method is to direct couple the generator to the engine. However this method requires great care to align the shafts of the generator and engine to within the specified tolerances of the chosen coupler.
Installation / Initial Set-Up 2. See below for a possible mounting configuration. 3. If the control box is not located on the correct side for your application, you can rotate it to the opposite side: 1) 2) 3) 4) 5) 6) Remove the fan vents. Remove the four drive-end bracket bolts. Rotate the drive-end bracket 180°. Re-torque bolts to 17 ft-lb. Reinstall the fan vents Remove the four screws at the base of the control box and rotate the control box 180°. 7) Replace screws at base of the control box.
Installation / Initial Set-Up 4. Bolt the generator to the mounting base using three, 7/16” grade 8 bolts. below. See Mounting Holes Note: In order to access two of the mounting holes, you will need to remove the louvered, fan vent panels on both sides. ALWAYS replace panels before starting the generator. If mounting to a concrete slab, use the optional mounting kit, NorthStar item #165935 (available from Northern Tool & Equipment catalog or by calling Product Support @ 1-800-270-0810).
Installation / Initial Set-Up Engine Speed (RPM) 3600 RPM = Generator Sheave Diameter Engine Sheave Diameter If smaller than recommended sheaves are used, the life of the belt(s) will be shortened and the possibility of belt slippage increases. Note about direct coupling: We recommend you use belts & sheaves to transmit power from the engine to the generator.
Installation / Initial Set-Up DANGER: All parts of the power transmission assembly must be equipped with a guard that prevents access to rotating parts. Clothing or hair can become rapidly entangled in unguarded rotating parts, resulting in serious injury or death. Guard requirements. The guard must: 1) Prevent contact with all rotating shafts, pulleys, belts, and couplings. 2) Allow for adequate cooling ventilation and hot exhaust clearance, as described in the previous section “4. Select a Suitable Site”.
Installation / Initial Set-Up 6. Ground 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. 2) Connect an approved ground clamp to the pipe.
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. Operation Procedures General Safety Rules for Operation Preparing for Operation (Pre-start checklist) Starting the Generator Connecting Loads Stopping Storage & Exercise 7. Each of these procedures is discussed in detail below: 1.
Operation (cont’d) Adjusting / repairing. Before working on the generator or engine, always turn off engine and remove spark plug(s) or spark plug wire(s) to prevent accidental starting. Always discharge the capacitor before working on the generator head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on how to do this.) Carbon monoxide poisoning. The running engine gives off carbon monoxide, a poisonous gas that can kill you.
Operation (cont’d) 2. Preparing for Operation (Pre-start checklist) Mount generator & engine Check that the generator and engine are mounted and connected in accordance with the instructions given earlier in this manual in the “Installation / Initial Set-up” section, “Step 5: Mount & Connect Generator and Engine”.
Operation (cont’d) Check/fill fuel tank Check the engine fuel level. If needed, fill tank with fresh fuel from a portable container after first reading the following instructions and warnings: 1) Allow engine to cool for at least two minutes before removing gas cap. Note: A running or still-hot engine is hot enough to ignite fuel. 2) When adding fuel: - Use only a UL-approved portable fuel container to transfer fuel. Follow the safety warning and instructions below for avoiding static electric sparking.
Operation (cont’d) Personal Protection Always dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources. Never fill the generator’s fuel tank directly from the pump – the generator’s tank is not grounded and high velocity flow from the pump can cause static electricity build-up. Use an approved portable container to transfer gas to the generator’s tank.
Operation (cont’d) 3. Starting the Generator After you have completed the pre-start checklist procedures, you are ready to start the generator. Start engine Start the engine with the guard in place. Check output voltage without load Before starting, confirm there are no loads connected to the generator’s outlets. Follow the instructions provided in your engine manual for starting the engine. Check output voltage before connecting loads to the generator.
Operation (cont’d) 4. 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.
Operation (cont’d) Note: Expect slight variations in voltage/speed with changing electrical loads. All engines have a tendency to slow down when a load is applied. When electrical loads are connected to the generator, the engine is more heavily loaded and as a result the speed drops slightly. This slight decrease in speed, together with the voltage drop within the generator itself, results in a slightly lower voltage when the generator is loaded to its full capacity than when it is running with no load.
Operation (cont’d) 6. Storage & Exercise When you are finished using the generator, you must: o Make sure all loads to the generator are disconnected and fuel supply is shut off (if possible) o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below. Disconnect loads & shut off fuel supply When you are finished using the generator, disconnect all loads and turn off fuel supply: 1.
Operation (cont’d) o Removing all fuel from the tank and carburetor OR o Adding fuel stabilizer to the fuel (following manufacturer’s instructions) Fuel stabilizer steps: 1. Ensure fuel tank is full. 2. Add fuel stabilizer to fuel tank. 3. Run engine at least 10 minutes after adding stabilizer to allow it to enter the fuel system. 4. Shut off engine 5. Disconnect spark plug wire and remove spark plug 6. Add one teaspoon oil through spark plug hole 7.
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 engine’s 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.
Maintenance & Repair (cont’d) Check mounting, belts and couplings Check generator mounting, belts, and couplings on a periodic basis: 1. Make sure that the mounting bolts are tight and secure. 2. Check belt (if applicable) and pulleys for looseness or signs of wear. Adjust or replace as necessary. 3. Check coupling (if applicable) for signs of wear or misalignment. Replace/realign as needed. Perform engine maintenance Perform engine maintenance as specified in the engine owner’s manual.
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Voltage too low. a) Engine speed too slow. a) Bring generator to a qualified technician for adjustment. b) Reduce the load. (See Power Load Planning & Mgt. section of this manual.) c) Tighten belt(s). (Or tighten coupler) a) Disconnect load. b) Replace receptacle. c) Reduce the load. (See Power Load Planning & Mgt. section of this manual.) a) Bring generator to a qualified technician for adjustment. a) Reduce the load.
Summary of Important Safety Information 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.
Summary of Important Safety Information (cont’d) barns, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows. Cooling ventilation. The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head so it does not overheat and possibly cause fire. Situate so there is adequate clearance around generator to allow for cooling airflow. Do not allow debris to accumulate and block airflow.
Summary of Important Safety Information (cont’d) Sparks/Smoking. Never smoke or work near sparks or other sources of ignition. Electric shock. Never touch both battery terminals at the same time with your hand or any non-insulated tools. Connection/disconnection sequence. ALWAYS connect and disconnect cables to the correct battery terminals in the proper sequence: o When CONNECTING the battery, connect the RED cable to the POSITIVE terminal FIRST.
Summary of Important Safety Information (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 parts.
Generator Exploded View – Rev H.
Generator Exploded View – Rev H.
Wiring Diagram – Rev H.
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Limited Warranty Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O.
