North Star M165938N manual

M165938N Owner’s Manual Instructions for Installation/Set-u p, Operation, Serv icing, & Storage Portable, Outdoor Use-Only, Triple Fuel Generator 6,600 Watt Continuous (8,000 Watt Surge) Capacity Can be used t o power i ndividual appl iances plu gged directl y into the generator’s outlets, or as a back-u p connection t o a building’s powe[...]

Hazard Signal Word Definitions 2[...]

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

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 8,000 Watts of electrical power (6,600 watts continuous, 8,000 watts surge). It can supply power: 1. As a portable power source . You can plug appliances di rectly into the gener[...]

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 NorthSta r and is recommended if you will be moving the generator unassisted. Other option al accessories available from NorthStar include a vinyl cover for storage, UL-approved transf er switch[...]

Specifications – Item #165938N 6 SPECIFICATIONS Item Number #165938 Maximum Output 8000 Watts (W) Continuous Output: Gasoline Liquid Petroleum Gas (LPG) Natural Gas (NG) 6600 Watts (W) 6200 Watts (W) 5200 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency Regulation 56.5 - 63.3 Hertz (Hz) Voltage Regulation 110-129V Power [...]

Safety Label Locations – Item #165938N 7 Always make sure safety labels ar e in place and in good condition. If a safety la bel is missing or not legible, order new labe ls or unsafe operation could result. To order replacement safety labels , call NorthStar Product Support at 1-800-270-0810. On-Product Warning Labels Part numbers Description 392[...]

Machine Component Identification - Item #165938N 8 Figure 1 (Ref. 1-12) Ref. Description Ref. Description 1 Gas Cap with Gauge 11 Super Silent Muffler 2 6.5 Gallon Gas Tank 12 Air Cleaner 3 Battery Box 13 Engine Key Switch 4 Circuit Breakers 14 Fuel Valve 5 120V 15A Duplex Receptacle 15 Choke Lever 6 Fuel Selector Switch 16 Recoil 7 120V 20A Duplex[...]

Machine Component Identification - Item #165938N 9 REFERENCE GUIDE Reference 1 – Gas Cap with Gauge The gas cap is extra large, creating a large hole for refilling and a comfortable grip. You can always monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap. Reference 2 – 6.5 Gallon Gas Tank Lar[...]

Machine Component Identification - Item #165938N 10 Reference 9 – Vibration Isolation Mounts The engine and generator are mounted on rubber cylinders that absorb most of the engine vibration. This feature eliminates the tendency of the machine to “walk” which is common in engine powered equipment. Reference 10 – Oil Drain Plug Refer to your[...]

Power Load Planning & Management 11 WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DA MAGE to the generator and attached electrical devices, and m a y 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 poweri[...]

Power Load Planning & Management (cont’d) 12 Device Running Watts Device Running Watts 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 drill (3/8”) 500 Television 500 Hand drill (1/4”) 250 Toaster 10[...]

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 [...]

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 special initial hook-up requirements for natural gas and propane: WARNING:[...]

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 pre ssure in excess of 11” water column. Introduction of gas pressure into the generator [...]

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 8,000W of electrical power. It can 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 genera[...]

Installation / Initial Set-Up 17 In addition to isolating your generator f rom the utility system, the transfer switch connects your generato r to a limited set of ci rcuits in your building that have been chosen as critical to operate during a power outage. The generator cannot power your enti re home -- you must work with the installing electrici[...]

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[...]

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 operating your generator to avoid equipm ent damage and/or injury and possible de[...]

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[...]

Installation / Initial Set-Up 21 Grounding Post 10 Ga. wire Coppe r Pipe/Ro d Ground 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[...]

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 or e specific battery requirements for this generator model, such as minimum amperage[...]

Operation 23 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. 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 Generato[...]

Operation (cont’d) 24 • Malfunction during operation. Immediately turn off the generator if an y 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 m isfire o Exces[...]

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 vapor s that are present during the fueling process, resulting in serious[...]

Operation (cont’d) 26 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “Installation & Initial Set-up, Ste p 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 [...]

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 war ni ngs and instructions below. WARNING: Gasoline fire/explosion hazard Gasoline[...]

Operation (cont’d) 28 • Alway s dissipate static charge from your body before beginning the fueling process by touching a grounded m etal object at a safe distance from fuel sources. • Never fill the generator’s gas tank directly from the fuel pump – the generator’s tank is not grounde d and high velocity flow from the pump can cause st[...]

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 [...]

Operation (cont’d) 30 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 start engine if you sme ll ga[...]

Operation (cont’d) 31 5) Under long, continuous-run operating conditions, be prepared to: a) Check engine oil level every 24 operating hours, b) Change oil after the first 20 operating hours, and at least every 100 operating hours thereafter, as directed in the engine owner’s manual. WARNING: Never open oil port while engi ne is running. Hot oi[...]

Operation (cont’d) 32 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[...]

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[...]

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[...]

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[...]

Operation (cont’d) 36 Perform regular maintenance Perform pe riodic main tenance as directed in this manual to keep the generator in safe working condition. 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 fo[...]

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[...]

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 defective gasoline shu[...]

Troubleshooting 39 TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. b) Fouled spark p lug. c) Out of fuel. d) Stop switch in OFF position. e) Battery disconnected or dead. f) Fuel selector switch is OFF position. a) Fill crankcase to proper oil l ev el. b) Clean or replac e spark pl ug. c) Fill fuel[...]

Summary of Important Safety 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 ary 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 followi[...]

Summary of Important Safety Information for Operation (cont’d) 41 Installation / Initial Set-up Safety • Dry, level surface . Situate generator on a dry, firm, level surf ace. Ensure generat or sits level and will not slide or shift during operation. Block wheels if applicable. • Operate OUTSIDE only – dangero us carbon mono xide exhaust ! [...]

Summary of Important Safety Information for Operation (cont’d) 42 Personal protective equipment • Hearing prote ction . The use of ear plugs or other heari ng protection devi ce is recommended for those in close proximity to the generator while it is operating. • Loose / dang ling . Loose or dangl ing apparel can becom e entangled in movin g [...]

Summary of Important Safety Information for Operation (cont’d) 43 • Carbon monoxid e exhaust . The running engine gives off carbon monoxide, a poisonous gas th at can kill you. You CANNOT sm ell it, see it, or taste it. If you start to feel sick, dizzy , or weak while using th e generator, sh ut off the e ngine and get to fresh air RIGHT AWAY. [...]

Summary of Important Safety Information for Operation (cont’d) 44 Safety – After use • Cool engine b efore storing. Let engine cool for at least five m inutes before storing. A hot engine can be a fire hazard. • Shut off fuel supply. Make sure gasoline shut-off valve is i n the OFF position. T urn off propane tank valve or shut NG line valv[...]

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

Generator Exploded View Rev- N 46 Diag # Part # Description Qty 1 171410 Hose Clamp 5 2 777164 Positive Battery Cable 1 3 38759 Fuel Tank Assembly 1 4 30754 Leather Washer 4 5 779422 Decal 1 6 32833 Roll Cage 1 7 33482 6mm Stud and Coupler Nut 1 8 36298 Straight Hose Nipple 1 9 36297 Load Block 1 10 31770 Engine Adapter 1 11 32811 LP/NG Hose 22” [...]

Wiring Diagram Rev- N 47 Diag # Part # Description Qty 1 31086 Thermal Circuit Breaker, 30 Amp 2 2 30643 Thermal Circuit Breaker, 20 Amp 2 3 306433 Thermal Circuit Breaker, 15 Amp 1 4 30975 Control Panel Face 1 5 306429 Binding Post 1 6 306438 15 Amp, 120 Volt Receptacle (NEMA 5-15R) 1 7 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 1 8 31824 Swit[...]

Generator Head Exploded View Rev- N 48 Item # Part # Description Qty 1 779919 Mount Plate (J609B) 1 2 779556 Fan Bolts 2 3 779557 Fan 1 4 779920 Drive End Bracket 1 5 779786 Enclosing Band 1 6 777304 End Cover 1 7 38271 End Cover Plug 1 8 779787 Stator 1 9 779788 Rotor 1 10 307481 Varistor 2 11 779789 Diode 2 12 779790 Securing Stud + Nut 1 13 3827[...]