North Star M165955A Owner's Manual

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 at least 20 feet from the home, away from windows, vents and air intakes, to

allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. 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.

 Carbon monoxide is given off whether you are using natural gas or propane to power the generator.  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-listed 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 feet from all combustible objects.

 All fuels are flammable. Ensure there are no fuel leaks, and keep sources of sparks and flames away.  LP/NG hook-ups must be completed by a certified gas technician and comply with all federal and local requirements.  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 transfer switch and/or NG/LP hook-ups, if they will be used. See the "Installation/Initial Set-Up" section for more information about these requirements. ADD ENGINE OIL: Engine is shipped without oil. See engine manual for instructions on capacity and viscosity

recommendations.

ITEM NUMBER: 165955, 165956 SERIAL NUMBER: _____________

M165955A

Owner's Manual

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

Portable, Outdoor Use-Only, Dual Fuel Generator

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-listed transfer switch).

Any Questions, Comments, Problems, or Parts Orders

Call NorthStar Product Support 1-800-270-0810

Hazard Signal Word Definitions

Table of Contents

Hazard Signal Word Definitions ................................................................................................. 2

About Your Generator ................................................................................................................. 4

Specifications ................................................................................................................................. 6

Safety Label Locations .................................................................................................................. 7

Machine Component Identification ............................................................................................. 8

Power Load Planning & Management ........................................................................................ 10

Installation / Initial Set-Up:

1. Unpacking & Delivery Inspection .......................................................................................... 13

2. Planning the Power Load ........................................................................................................ 13

3. Gas Hook-up Installation for Natural Gas or Propane (LP) ................................................... 14

4. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ...................................... 16

5. Selecting a Suitable Site ......................................................................................................... 19

6. Grounding the Generator ........................................................................................................ 22

7. Battery Installation ................................................................................................................. 23

Operation:

1. General Safety Rules for Operation ....................................................................................... 24

2. Preparing for Operation .......................................................................................................... 25

3. Starting the Engine ................................................................................................................. 28

4. Checking Generator Output .................................................................................................... 28

5. Connecting Loads ................................................................................................................... 29

6. Stopping .................................................................................................................................. 30

7. Storage & Exercise ................................................................................................................. 30

Maintenance & Repair .................................................................................................................. 32

Troubleshooting ............................................................................................................................. 34

Summary of Important Safety Information for Operation ....................................................... 35

Generator Exploded View ............................................................................................................ 39

Generator Control Panel View ..................................................................................................... 41

Generator Head Exploded View .................................................................................................. 42

Limited Warranty ......................................................................................................................... 44

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 its rated amount of electrical power. (See specifications section of this manual for model specific ratings)

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. A licensed electrician can connect

the generator to your building's electrical system via the installation of an UL-listed transfer switch. (See the "Installation & Initial Set-up" section of this manual to learn more about specific requirements and precautions relating to wiring the generator to your building's electrical system.)

You must select a generator adequately sized for your power needs. You need to determine the power needs of all the appliances/tools you wish to power at the same time and choose a generator rated to provide at least that power level. See the "Power Load Planning & Management" section of this manual to determine your specific power load requirements and then compare them to this generator's rated capacity. You must not overload the generator. Overloading will cause damage to the generator and attached electrical devices, and may also result in fire.

You can power this generator with natural gas (NG) or liquid propane (LP) gas.

However, there are special initial hook-up requirements for natural gas and propane. See the "Specifications" section of this manual with regard to specific gas flow and pressure requirements. In addition, note the following:

 Natural gas. The standard delivery pressure provided to your building by your utility

company may not match the requirements of your generator.

a) If your standard delivery pressure is higher than allowable for this generator, you

may need to have a pressure-reducing regulator installed. (Note: The regulator supplied with this generator is NOT a pressure-reducing regulator).

b) If your standard delivery pressure is lower than allowable for this generator, you

 Liquid Propane (LP). You will need a minimum 100 lb. LP gas tank to run this generator

See the "Installation / Initial Set-Up: Step 3" section of this manual for more detailed information.

Be sure to read about site selection and grounding requirements for running this generator. More detailed information can be found in the "Installation & Initial Set-up, Steps

5 & 6 of this manual. This generator is too heavy for one person to lift without mechanical assistance. An

optional wheel kit is available from NorthStar and is recommended if you will be moving the

will need changes to your natural gas service to elevate the delivery pressure.

ALL natural gas hook-ups must be completed by trained personnel from your natural gas utility company and inspected as required by your local building code.

– the vaporization rate is insufficient with smaller tank sizes. A qualified propane gas technician must set up the valve and hose connection between the propane tank and generator in accordance with all local regulations and electric code.

About Your Generator (cont’d)

WARNING

Improper use or maintenance of this generator can result in serious injury or death from carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.

Read this manual completely before using the generator and follow all instructions and safety rules.

ATTENTION:

All Rental Companies and Private Owners who loan this

equipment to others!

All persons to whom you rent/loan this generator must have access to and read this manual. Keep this owner's manual with the generator at all times and advise all persons who will operate the machine to read it. You must also provide personal instruction on how to safely operate the generator and remain available to answer any questions a renter/borrower might have.

generator unassisted. Other optional accessories available from NorthStar include a cover for storage, UL-listed transfer switches, and extension cords.

Contact NorthStar Product Support at 1-800-270-0810

with questions about optional accessories or to order.

Read this Manual

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. For detailed engine operation and maintenance information, always refer to the engine Owner's Manual furnished with the generator.

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.

Contact NorthStar Product Support at 1-800-270-0810

for any questions about the appropriate use of this generator.

Warranty Registration

Please fill in the warranty registration information in the back of this manual and have it on hand when you call in on a warranty claim or replacement parts.

Specifications

SPECIFICATIONS

Item Number

165956

165955

Maximum Output

10,000 Watts (W)

13,000 Watts (W)

Continuous Output: Liquid Propane Gas (LP) Natural Gas (NG)

9,450 Watts (W) 8,400 Watts (W)

12,150 Watts (W) 10,800 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 Factor

1.0 p.f.

Engine

Honda GX630

Honda GX690

Engine Speed

3390 - 3798 RPM

Fuel Type

LP/NG

Pressure Range (LP, NG)

7-11 in water column, LP

4-6 oz., NG

7-11 in water column, LP

4-6 oz., NG

Min. Flow Range (LP, NG)

NG 2.3 CFM LP 1.1 CFM

NG 2.8 CFM LP 1.2 CFM

Oil Capacity

See Honda Manual

Starting Method

Electric

12V DC, 35Ah

Dimensions

Length

32.375"

Width

24.375"

Height

25.50"

Dry Weight

375 lbs.

460 lbs.

Safety Label Locations

On-Product Warning Labels

Part numbers

Description

786635

Burn Warning

782397

Battery Warning

785265

Warning

791083

LP/NG Hang Tag

ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns. NO smoking, sparks, or flames. NEVER touch both battery terminals at the same time with your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing. CONNECT cables in correct sequence: FIRST RED to POSITIVE terminal, then BLACK to NEGATIVE terminal. When disconnecting, DISCONNECT BLACK cable first, then RED. NEVER charge a visibly damaged or frozen battery. ALWAYS read and follow charger instructions.

BATTERIES:

1) contain caustic acid, 2) emit explosive gases,

3) can cause electric shock

WARNING - BATTERY HAZARDS

782397

Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result.

To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.

Machine Component Identification

Ref.

Description

Ref.

Description

Air Cleaner

Generator Head

Engine Key Switch

Fuel Inlet

Oil Drain Plug

Vibration Isolation Mount

Oil Fill Port

LP/NG Regulator Assembly Kit

Battery (not included)

Muffler

Control Panel

Machine Component Identification

REFERENCE GUIDE

Reference 1 – Air Cleaner

Refer to your Honda engine manual for air cleaner care.

Reference 2 – Engine Key Switch

The engine key switch is located on the engine. Always locate this switch and be familiar with its location before operating the generator.

Reference 3 – Oil Drain Plug

Refer to your Honda engine manual for oil change recommendations.

Reference 4 – Oil Fill Port

Refer to your Honda engine manual for oil change recommendations.

Reference 5 – Battery (not included)

Type required: 12V DC, 35Ah

Reference 6 – Control Panel

An electrical device that contains outlets and meters for controlling other electrical devices

Reference 7 – Generator Head

The electricity producing part of the generator.

Reference 8 – Fuel Inlet

A connection point to hook up the fuel supply.

Reference 9 – Vibration Isolation Mount

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 enginepowered equipment.

Reference 10 – LP/NG Regulator Assembly Kit

Includes the regulator, T-joint fitting, fuel hose and two fuel lock-off solenoids. The regulator controls the flow of LP/NG to the engine. The two fuel lock-off solenoids allow fuel while the engine is running and stops the flow of fuel when the engine is turned off or stops. This is NOT a pressure reducing regulator. Over-pressurizing this regulator will cause permanent damage.

Reference 11 – Muffler

An acoustic device installed onto the exhaust system that is designed to reduce noise.

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.

Device

Running Watts (Continuous)

Starting Watts

(Surge)

10in. Table Saw

1800

4500

7-1/4in. Circular Saw

1400

2300

8in. Bench Grinder

1400

2500

Air Conditioner - Central (24,000 BTU)

3800

4950

Air Conditioner - RV (13,500 BTU)

1500

3000

Air Conditioner - Window (10,000 BTU)

1200

2200

Battery Charger: 100 Amp with 300 Amp Boost

2400

7800

Battery Charger: 15 Amp

380

Battery Charger: 60 Amp with 250 Amp Boost

1500

5750

Belt Sander

1200

2400

Ceiling Fan

800

1200

Clock Radio

100

Clothes Dryer (electric)

1800

5750

Clothes Dryer (gas)

700

1200

Clothes Washer

1150

2300

Coffee Maker

1750

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. The sum of the running and starting wattages of the devices being powered must not exceed the continuous output rating of your generator. (The continuous output rating of your generator is listed in the "Specifications" section of this manual.) Note that:

 Devices without electric motors such as light bulbs, radios, and televisions have the same

running and starting wattage.

 Devices with electric motors such as refrigerators, compressors, and hand tools typically

require a starting wattage that is 3 to 5 times greater than the running wattage.

The running and starting wattage requirements are often listed on a device's nameplate. If wattage is not given on the device's nameplate, the wattage may be calculated by multiplying the nameplate voltage by nameplate amperage, Watts = Volts X Amps.

Example conversion to watts:

If only the running voltage is given on the nameplate for a device with an electric motor, the starting wattage can be approximated to be three to five times the running wattage.

Estimates for the running wattage requirements for common devices are listed in Table 1 below. Guidance for starting wattages is provided in the table's footnotes.

Table 1

120 Volts X 5 Amps = 600 Watts

Power Load Planning & Management (cont’d)

Device

Running Watts (Continuous)

Starting Watts

(Surge)

Deep Freezer

700

1000

Desktop Computer w/ 17" monitor

800

Dishwasher (Hot Dry)

1500

Drill: 1/2in., 5.4 Amps

600

900

Drill: 3/8in., 4 Amps

440

600

DVD/CD Player

100

Electric Fence: 25 Miles

2500

Electric Fry Pan

1300

Electric Range: 8in. Element

2100

Furnace Fan (Gas or fuel oil): 1/2 HP

875

2350

Furnace Fan (Gas or fuel oil): 1/4 HP

600

1000

Furnace Fan (Gas or fuel oil): 1/8 HP

300

500

Garage Door Opener

750

1200

Hair Dryer

1250

Hot Plate

2100

Inkjet Printer

Iron

1200

Laser Printer

950

Lights (Ten 75 Watt light bulbs)

750

Microwave Oven 1000W

1000

Milk Cooler

1100

1800

Milker (Vacuum Pump): 2 HP

1000

2300

Miter Saw - 10"

1650

2400

Oscillating Fan

200

400

Portable Heater (Kerosene, Diesel: 150,000 BTU

625

1000

Pressure Washer: 1 HP

1200

3600

Quartz Halogen Work light

1000

Reciprocating Saw

1200

2000

Refrigerator Freezer

700

1500

Security System

500

Space Heater

1800

Stereo Receiver

450

Sump Pump: 1/2 HP

1050

2150

Sump Pump: 1/3 HP

800

1300

Television 27"

500

VCR

100

Water Heater (Electric 40gal)

4000

Water Well Pump (1/3hp 220v)

1000

2000

(a) Hard-starting motors require 3-5 times the rated running watts (b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment

dealer to determine maximum wattage

Power Load Planning & Management (cont’d)

Device to be Powered

Greater of

Starting/Running Wattage

Light Bulbs (10 – 75 watt)

750 W

Refrigerator Freezer

1500 W

Microwave Oven 1000W

1000 W

Air Conditioner, Window (10,000 BTU)

2200 W

Sump pump (1/3 hp)

1300 W

Total

6750W

STAGGERING LOADS

To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps:

1. Make a list of all electrical devices you will be powering at the same time with the generator.

2. List the greater of the running or starting wattage next to each device as obtained from the

devices' nameplate or Table 1. If only the running wattage for a device with an electric motor is known, the starting wattage can be estimated to be at least 3 times the running wattage.

3. Add the wattages for all devices on your list. This total must be lower than the continuous

output rating of your generator.

Example:

In this example, the generator must have a continuous output of at least 6275 W in order to power all of the devices simultaneously.

You can increase the number of devices your generator can power by staggering the load on the generator. For example, you could alternately power your refrigerator and air conditioner for limited periods of time -- powering only one of the devices at a time and never powering both at the same time.

Installation / Initial Set-Up

Steps for Installation / Initial Set-Up

1. Unpacking & delivery inspection.

2. Planning the power load to stay within the generator's rated

capacity.

3. Gas hook-up installation for natural gas or LP gas.

4. 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.

5. Selecting a site for using the generator.

6. Grounding.

7. Battery installation.

1. Unpacking & Delivery Inspection

You should inspect the generator immediately after you receive delivery.

See the "Machine Component Identification" section of this manual for a diagram of the generator and its components.

 If you have missing components, contact Product Support at 1-800-270-0810.  If you have damaged components, contact the freight company that delivered the unit and file a

claim.

2. Planning the Power Load

Plan your power load so that you do not exceed the generator's rated capacity.

See the "Power Load Planning & Management" section of this manual to review how to plan and manage power loads for the generator.

There are a number of important steps required to set up your generator for initial use. These steps are:

Each of these steps is discussed in detail below:

Installation / Initial Set-Up

3. Gas Hook-up Installation for Natural Gas or LP

You can power this generator with natural gas (NG) or liquid propane gas (LP). However, there are special initial hook-up requirements for natural gas and propane:

WARNING:

You must have the fuel line system installed by a certified gas technician for NG or LP.

NG/LP Regulator Assembly Kit

Set Up Regulator for Intended Gas Usage (LP or NG)

Fuel selection is performed at the T-joint outlets labeled LP or NG.

1. Connect and tighten the fuel hose to the appropriate outlet on the T-joint.

Torque: 40 ~ 50 in lbs.

2. Install the cap to the outlet not being used on the T-joint.

Torque: 40 ~ 50 in lbs.

+ 32 hidden pages

North Star M165955A Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual