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North Star M165939J manual

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  • Page 1

    M165939J Owner’s Manual Instructions for Installation/S et-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Triple Fuel Generator 10,500 Watt Continuous (13,000 Watt Surge) Capacity Can be used to power individual ap pliances plugged direc tly into the generato r’s outlets, or as a back-up connection to a building’s power s[...]

  • Page 2

    Hazard Signal Word Definitions 2[...]

  • Page 3

    Table of Contents 3 Hazard Signal Word Definitions ................................................................................................. 2 About Your Generator ................................................................................................................. 4 Specifications ...............................................[...]

  • Page 4

    About Your Generator 4 Thank you for purchasing your NorthStar portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to 8000 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 di rectly into the gene[...]

  • Page 5

    About Your Generator (cont’d) 5 This generator is too heavy for one person to lift without mechanical assistance. An optional wheel kit is available from NorthStar and is recomm ended if you will be moving the generator unassisted. Other optional accessories available fro m NorthStar include a vinyl cover for storage, UL-approved transf er switch[...]

  • Page 6

    Specifications – Item #165939J 6 SPECIFICATIONS Item Number #165939 Maximum Output 13500 Watts (W) Continuous Output: Gasoline Liquid Petroleum Gas (LPG) Natural Gas (NG) 10500 Watts (W) 9600 Watts (W) 8400 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency Regulation 56.5 - 63.3 Hertz (Hz) Voltage Regulation 218 - 258 V P[...]

  • Page 7

    Safety Label Locations – Item #165939J 7 BATTERIES: 1) contain c austic acid, 2) em it explosive g ases, 3) can cause electric shock ALWAY S use eye protection. Cau stic ac id and ex plos ive gas es can cause blindness or sev ere burns. NO smok ing, sparks, or flames. NEVER tou ch bot h ba tter y ter mina ls a t th e same t ime wit h y our hand o[...]

  • Page 8

    Machine Component Identification - Item #165939J 8 Figure 1 (Ref. 1-19) Ref. Description Ref. Description 1 Air Cleaner 15 Hour Meter 2 Gas Cap with Gauge 16 Oil Drain Area 3 10.0 Gallon Gas Tank 17 Demand Regulator Assembly 4 Battery Box 18 Engine Oil Drain Plug 5 LPG/NG-3/4” NP T Gas Inlet 19 Oil Level Dip Stick 6 120/240V, 50A, Circuit Breaker[...]

  • Page 9

    Machine Component Identification - Item #165939J 9 REFERENCE GUIDE Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care. Reference 2 – Gas Cap with Gauge The gas cap is extra large, creating a large hole for refueling and a comfortable grip. You can always monitor the fuel level without removing the cap by using the [...]

  • Page 10

    Machine Component Identification - Item #165939J 10 and press the extended button back into the circuit breaker housing. Reference 13 - 120V, 20A, Duplex Receptacle The generator has a control panel with two duplex (two receptacles in a common housing) receptacles. This duplex is a 120-volt (V) 20 amp (A) straight blade receptacle, National Electri[...]

  • Page 11

    Power Load Planning & Management 11 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 PROP ERLY to provide both the running and starting (surge) wattage of the devices you will be powering.[...]

  • Page 12

    Power Load Planning & Management (cont’d) 12 Device Running Watts Device Running Watts Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1”) 1100 Sump pump 600 (a) Hand drill (1/2”) 875 Table saw 2000 (a) Hand d[...]

  • Page 13

    Installation / Initial Set-Up 13 There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / In itial Se t-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. 3. Getting gas hook-ups installed if natu ral gas or [...]

  • Page 14

    Installation / Initial Set-Up 14 3. Gas Hook-up Installation fo r Natural Gas or LPG (if needed) You can power this generator with gasoline, natural gas (NG), or propane (LP) gas. The generator is designed so that it is easy to switch between fuel sources. However, there are specia l initial hook-up requirements for natural gas and propane: WARNING[...]

  • Page 15

    Installation / Initial Set-Up 15 ♦ This product is designed to operate at an LPG gas pressure range of 7” to 11” of water column and requires a minimum LPG gas flow rate of 9.33 lb/hr, 2.2 Gal/hr, or 201,718 BTU/hr. Note : All gas cylinders produce gas pressure in excess of 11 ” water column. Introduction of gas pressure into the generator [...]

  • Page 16

    Installation / Initial Set-Up 16 4. 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 ca n supply electricity in two ways: 1. As a back-up, standby power source for a building. For this applicatio n, you must arrange for a licensed electrician to connect the gene[...]

  • Page 17

    Installation / Initial Set-Up 17 The generator cannot power your enti re home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electr ician can help you determine which circuits and devices can be powered simultaneously without overloading the generator. (See the previous[...]

  • Page 18

    Installation / Initial Set-Up 18 ♦ Extension cords may be used to pow er devices that are located at a distance from the generator. Howe ver, 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 leng[...]

  • Page 19

    Installation / Initial Set-Up 19 5. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet al l of the criteria listed below. WARNING: You must choose a suitable site for oper ating your generator to avoid equipment damage and/or injury and possible de[...]

  • Page 20

    Installation / Initial Set-Up 20 • Never place the generato r immediately adjacent to a building or other structure – allow at least a 7’ clearance. • Do not run the generator in close proximity to other heat-generating equipment, such as another generato r. The combined heat that is generated may raise air temperature in the imm ediate are[...]

  • Page 21

    Installation / Initial Set-Up 21 6. Grounding the generator Always ensure the generator is properly grou nded to prevent electrical shock. You must always ground the generator by the fo llowing 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 pip[...]

  • Page 22

    Installation / Initial Set-Up 22 7. Battery Installation Your generator’s engine is equipp ed with an electric starter which require s the installation of a 12- volt lawn tractor size battery (Gr oup U1). See the “Specifications” section of this manual for m ore specific battery requirements for this generator model, such as minimum amperage [...]

  • Page 23

    Operation 23 Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessa ry for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. Starting the Engine: a) Using LP/NG b) Using Gasoline 4. Checking Generat[...]

  • Page 24

    Operation (cont’d) 24 be done by factory-authorized personnel. • External fuel sources . Never attempt to connect external gasoline/diesel sources in order to increase engine run time. Larger tank at pressure or higher elev ation will cause ga soline to le ak from carburetor during operation. Fi re or explosion could result. • Malfunction dur[...]

  • Page 25

    Operation (cont’d) 25 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 pr esent during the fu eling process, resulting in seriou[...]

  • Page 26

    Operation (cont’d) 26 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 5: Select a Suitable Site” of this manual. Operate outside only, on dry, level gr ound with adequate clearance and ventilation. WARNING: Carbon monoxide poisoning hazard G[...]

  • Page 27

    Operation (cont’d) 27 Fill gasoline tank (if using gasoline) Check the gasoline level in the generator’s tank if you will be operating the generator on gasoline. If needed, fill tank with fresh unleaded gasoline from a portable container, after first reading the warni ngs and instructions below. WARNING: Gasoline fire/explosion hazard Gasoline [...]

  • Page 28

    Operation (cont’d) 28 the generator’s tank is not grounded and high velocity flow from the pump can cause static electric ity build-up. U se an approved portable container to transfer gas to the generator’s tank. • Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pi ck-up truck bed. ALWAYS place[...]

  • Page 29

    Operation (cont’d) 29 Inspect Fuel System / Check for Leaks Inspect fuel system & check for le aks BEFORE starting generator. Do not start generator until all neede d repairs have been completed. WARNING: Fuel leak hazard Gasoline, LP gas (propane) and NG (natural gas) are highly explosive and fuel leaks can result in fire or explosions. You [...]

  • Page 30

    Operation (cont’d) 30 A djustmen t Screw Lock Nut 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. The following directions detail how to sta rt the engi ne with either LP/NG or Gasoline as the fuel source: Using LP/NG To start engine using LP or Natural Gas: WARNING : DO NOT s[...]

  • Page 31

    Operation (cont’d) 31 WARNING: Never open oil port while engine is running. Hot oil c an spray over face and body. Using Gasoline To start engine using gasoline: 1) Disconnect all load s to the generator. 2) Flip the fuel selector switch to the GASOLINE position. 3) Turn the gasoline line valve to the ON positio n. 4) For cold engine, move choke [...]

  • Page 32

    Operation (cont’d) 32 4. Checking Genera tor Outpu t 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 mus[...]

  • Page 33

    Operation (cont’d) 33 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 prov ided below for connecting loads wh en you are using the generator: o As a portable power source o Conne[...]

  • Page 34

    Operation (cont’d) 34 6. Switching Fuels (during operation) You can switch fuel sources (from gasoline to LP /NG, or from LP/NG to gasoline) while the generator is running. Follow the instructions below: Switching from LP/NG to Gasoline 1. Disconnect all loads to the genera tor. Leave the engine running. 2. Turn the gasoline line shut-off valve t[...]

  • Page 35

    Operation (cont’d) 35 8. Storage & Exercise When you are finished usin g the generator, you must: o Disconnect all loads o Shut off fuel supply 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 & turn o[...]

  • Page 36

    Operation (cont’d) 36 Prepare engine for long term storage if needed If you will not be able to exercis e the generato r 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 carbure[...]

  • Page 37

    Maintenance & Repair 37 Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety ru les and recom mended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the ge nerator. M[...]

  • Page 38

    Maintenance & Repair (cont’d) 38 Inspect fuel system / check for leaks Inspect the fuel system and check for leaks on a regular basis. 1) Inspect the entire fuel system. Look for: signs of leaks or deterioration, chafed or spongy fuel hose, loose co nnections, loose or missing fuel hose clamps, damaged gasoline tank, or de fective gasoline sh[...]

  • Page 39

    Troubleshooting 39 TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Stop switch in OFF position. e) Battery disconnected or dead. f) Fuel selector switch is set to the incorrect fuel. a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) F[...]

  • Page 40

    Summary of Importation Information for Operation 40 This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summ a ry 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 s[...]

  • Page 41

    Summary of Importation Information for Operation cont’d 41 o When CONNECTING the battery, connect the RED cable to the POSITIVE terminal FIRST. o When DISCONNECTING the battery, disconnect the BLACK cable from the NEGATIVE terminal FIRST • Acid/skin contact. If battery acid contacts skin or clothing, flush immediately with water and neutralize [...]

  • Page 42

    Summary of Importation Information for Operation cont’d 42 • Spark arrestor . Equip engine with a spark a rrestor if generator will be us ed near any igni table forest, brush, or grassy land. See the “Specifications” sec tion of this manual to dete rmine if your generator is already equipped. Make sure you comply with applicable local, stat[...]

  • Page 43

    Summary of Importation Information for Operation cont’d 43 • Smell for gas before starting the generator: • Natural gas . Natural gas is lighter than air and tends to collect in high areas. After opening NG line supply, smell for gas BEFORE starting engine. • LP gas (propane) . LP gas is heavier than air and tends to settle in low areas. Af[...]

  • Page 44

    Summary of Importation Information for Operation cont’d 44 contact with victim. Use a nonconducting im plement, su ch as a dry rope or board, to free the victim from the live conductor. Apply first aid and get im mediate medical help. • Hot muffler . Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine parts[...]

  • Page 45

    Generator Exploded View Rev - J 45[...]

  • Page 46

    Generator Exploded View Rev - J 46 Fig # Part # Description Qty 1 777149 Fuel Cap, With Gauge 1 2 38760 Fuel Tank Assembly 1 3 171410 Fuel Clamp 2 4 30754 Leather Washer 4 5 779429 Decal, Control Panel Side 1 6 779464 Decal, Gas Valve Side 1 7 35298 Cradle Weldment 1 8 35844 Nameplate 1 9 31007 Spark Arrester 1 10 778553 Generator Head 1 11 34857 G[...]

  • Page 47

    Wiring Diagram Rev - J 47[...]

  • Page 48

    Wiring Diagram Rev - J 48 Diag # Part # Description Qty 1 306422 Twist Lock Receptacle, NEMA L14-30R 1 2 306426 Receptacle, 120 Volt, 20 Amp, NEMA 5-20R 2 3 30643 Circuit Breaker, 20 Amp 2 4 306434 Circuit Breaker, 30 Amp 1 5 306423 Receptacle, 120 Volt, 30 Amp, NEMA L5-30R 1 6 31953 Receptacle, 120/240 Volt, 50 Amp, NEMA 14-50R 1 7 31211 Circuit B[...]

  • Page 49

    Fuel Delivery System Rev - J 49 Diag # Part # Description Qty 1 82187 M6-1.0 X 65mm Socket Head Cap Screw, w/ thread locking patch 2 2 35846 Venturi 1 3 35847 Adapter 1 4 32808 Elbow 1 5 777119 Hose Clamp 2 6 37748 Regulator Wire Harne ss 1 7 35488 Oil Pressure Switch Wire Harness 1 8 777239 Protective Sleeve 13.2” 9 32811 Gas Hose 16.6” 10 362[...]

  • Page 50

    Generator Head Exploded View Rev - J 50 Ref # Part # Description Qty 1 30991 Drive End Bracket 1 2 30994 Protection Screen 2 3 31013 Phillips Screw 10 4 30995 Fan 1 5 307489 Grommet 1 6 305605 Terminal Box Cover 1 7 31014 M5 X .8, 16mm Long 2 8 31018 M5 X .8, 10mm Long, Green 2 9 31015 M5 X .8, 10mm Long 4 10 307484 Rubber Cup 2 11 306403 Rear Bear[...]