North Star M165957K User Manual

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Page 1

M165957K

ITEM NUMBER: 165957

Owner’s Manual

SERIAL NUMBER: _____________

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

Portable, Outdoor Use-Only, Gasoline Generator

6600 Watt Continuous (8000 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.

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:

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/buildin gs (bat t er y -o perat ed , or plug-in with battery backup).

• 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.

• 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.

WARNING

CO Poisoning

Electric shock / Electrocution

Fire / Explosion

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

Page 2

Hazard Signal Word Definitions

Page 3

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..........................................................................................12

2. Planning the Power Load........................................................................................................12

3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ......................................13

4. Selecting a Suitable Site.........................................................................................................16

5. Grounding the Generator........................................................................................................18

6. Battery Installation .................................................................................................................19

Operation:

1. General Safety Rules for Operation .......................................................................................20

2. Preparing for Operation..........................................................................................................23

3. Starting the Engine.................................................................................................................26

4. Checking Generator Output....................................................................................................27

5. Connecting Loads...................................................................................................................28

6. Stopping the Engine ...............................................................................................................28

7. Storage & Exercise.................................................................................................................29

Maintenance & Repair..................................................................................................................31

Troubleshooting.............................................................................................................................33

Summary of Important Safety Information for Operation.......................................................34

Generator Exploded View............................................................................................................38

Wiring Diagram.............................................................................................................................40

Generator Head Exploded View..................................................................................................41

Page 4

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 8000 Watts of electrical power (6600 watts continuous, 8000 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. A licensed electrician can connect the generator to your building’s electrical system via the installation of an UL-approved 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.

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 generator unassisted. Other optional accessories available from NorthStar include a cover for storage, UL-approved 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

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.

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.

WARNING

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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.

Contact NorthStar Product Support at 1-800-270-0810 for any questions about the appropriate use of this generator.

Warranty Registration

Please fill out and submit the warranty registration card so that we have your contact information for any future product literature or replacement parts you may need.

ATTENTION:

All Rental Companies and Private Owners who loan this

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.

equipment to others!

Page 6

Specifications – Item #165957K

SPECIFICATIONS

Item Number #165957 Maximum Output 8000 Watts (W) Continuous Output 6600 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency 56.5-63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 13 HP Honda GX390 Engine Speed 3390-3800 RPM Fuel Type Unleaded gasoline Fuel Capacity 6.5 gallons (24.6 L) Oil Capacity 1.16 US quarts (1.1 L) Starting Method Electric / Recoil 120 V Receptacle 15 Amp (A) duplex

(NEMA 5-15R) & 20 Amp (A) duplex

(NEMA 5-20R)

120/240 V Receptacle 30 Amp (A) locking device

(NEMA L14-30R)

Circuit Breakers 30 Amp (A), Qty. 2; 20 Amp (A), Qty. 2;

15 Amp (A), Qty. 1; thermal,

push to reset style Grounding Post Receives 12 Ga. wire or fork terminal Battery (not included) 12 Volt, Group size U1

350 CCA, 33 amp/hr

Dimensions

Length 31.75” (80.6 cm) Width 23.63” (60.0 cm) Height 22.25” (56.5 cm) Dry Weight 220 lb. (100 kg) Gross Weight 250 lb. (114 kg)

Page 7

Safety Label Locations – Item #165957K

WARNING

BURN HAZARD

Do not touch hot muffler.

PN 39260

• Commercial-grade electric start engine

• Extend run 6.5 gallon fuel tank

• Maintenance-free brushless alternator design

• Smooth running focus mount isolation system

BATTERIES:

1) contain caustic acid, 2) emit explosive gases, 3) can c ause electric shock

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 con tacts eyes, skin, or clothing.

CONNECT cables in correct sequence: FIRST RED to POSITIVE terminal, then BLACK to NEGATIVE

terminal. When disconnecting, DISCONNECT BLAC K cable first, then RED. NEVER charge a visibly damaged or frozen battery. ALWAYS read and follow charger instructions.

IF GENERATOR IS TO BE STORED LONGER THAN 2 MONTHS,

charge battery with a trickle charger that is rated for 3 amps maximum.

WARNING - BATTERY HAZARDS

ATTENTION

A charged battery ensures reliable engine starting.

PN 779396

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.

• Commercial-grade electric start engine

• Extend run 6.5 gallon fuel tank

• Maintenance-free brushless alternator design

• Smooth running focus mount isolation system

On-Product Warning Labels

Part numbers Description

39260 Burn Warning

779422 NorthStar 779423 Warning 779396 Battery Warning

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Machine Component Identification - Item #165957K

Figure 1 (Ref. 1-8) 00591

Ref. Description Ref. Description

1 Circuit Breakers 10 Gas Cap with Gauge 2 120/240V 30A

Locking device Receptacle 3 Grounding Post 12 Generator Head 4 120V 20A Duplex Receptacle 13 Battery Box 5 120V 15A Duplex Receptacle 14 Vibration Isolation Mount 6 Oil Drain Plug 15 Recoil 7 Air Cleaner 16 Fuel Valve Lever 8 Super Silent Muffler 17 Choke Lever

18 Engine Key Switch

Figure 2 (Ref. 10-18) 01804

11 6.5 Gallon G as Tank

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Machine Component Identification - Item #165957K

REFERENCE GUIDE

Reference 1 – Circuit Breakers This portable single phase generator has 1, 15 amp (A)

2, 20A, and 2, 30A push to reset circuit breakers to protect against electrical overloads.

Reference 2 – 120/240V Receptacle

Reference 3 – Grounding Post Ground the generator via the grounding post, to a copper Reference 4 – 120V Receptacle The duplex is a 120V 20A straight blade receptacle,

Reference 5 – 120V Receptacle The duplex is a 120 volt (V) 15 amp (A) straight blade

Reference 6 – Oil Drain Plug Refer to your Honda engine manual for oil change Reference 7 – Air Cleaner Refer to your Honda engine manual for air cleaner care.

Reference 8 – Super Silent Muffler Reference 10 – Gas Cap with Gauge

Reference 11 – 6.5 Gallon Gas Tank

Reference 12 – Generator Head The electricity producing part of the generator. Reference 13 – Battery Box The battery box provides protection for the battery and will

Reference 14 – Vibration Isolation Mounts

Reference 15 – Recoil Grasp firmly when starting engine. Consult engine Reference 16 – Fuel Valve Lever The engine has an ON-OFF valve mounted on the front

Reference 17 – Choke Lever Used during cold starts. Refer to the starting/stopping

Reference 18 – Engine Key Switch

The locking device is a 120/240V 30A NEMA L14-30R receptacle. This receptacle accepts a NEMA plug number L14-30P. Use this receptacle if installing a transfer switch.

pipe or rod that is driven into moist soil. National Electrical Manufacturer’s Association (NEMA)

number 5-20R. This receptacle accepts NEMA plug numbers 5-15P and 5-20P. Each receptacle on this duplex is capable of drawing 20A.

receptacle, National Electrical Manufacturer’s Association (NEMA) number 5-15R. This receptacle accepts NEMA plug number 5-15P. The duplex is capable of drawing 15A out of either receptacle or a combination of both.

recommendations. 4 dB less than Honda’s standard muffler. The gas cap is extra large, creating a large hole for

refilling and a comfortable grip. You can monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap. Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full.

accept a standard lawn tractor size battery (Group U1-7). See battery section for sizing. 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.

manual for further instruction. of the engine. Always keep this valve closed when the

generator is not in use. instructions and the Honda engine owner’s manual for

further instruction. The engine key is located on the engine. Always locate this switch and be familiar with its location before operating the generator. Consult the Honda engine owner’s manual for further instructions.

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Power Load Planning & Management

NEVER exceed the rated wattage capacity of your generator.

WARNING

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. 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:

120 Volts X 5 Amps = 600 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

Device

Air conditioner (12.000 BTU) 1700 (a,b) Jet pump 800 (a) Battery charger (20 Amp) 500 Lawn mower 1200 Belt sander (3”) 1000 Light bulb (100 Watt) 100 Chain saw 1200 Microwave oven 700 Circular saw (6½”) 2000 (a,b) Milk cooler 1100 (a) Coffee maker 1800 (a,b) Oil burner on furnace 300 Compressor (1 HP) 1400 (a,b) Oil-fired space heater (140,000 Btu) 400 Compressor (3/4 HP) 1800 (a) Oil-fired space heater (85,000 Btu) 225 Compressor (1/2 HP) 1400 (a) Oil-fired space heater (30,000 Btu) 150 Curling iron 700 Oven 4500 Dishwasher 1200 Paint sprayer, Airless (1/3 HP) 600 (a) Edge trimmer 500 Paint sprayer, Airless (handheld) 150 Electric nail gun 1200 Radio 200 Electric range (1 element) 1500 Refrigerator 600 (b) Electric skillet 1250 Slow cooker 200

Running

Watts Device

Running

Watts

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Power Load Planning & Management (cont’d)

Device

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 drill (3/8”) 500 Television 500 Hand drill (1/4”) 250 Toaster 1000 Hedge trimmer 450 Vacuum cleaner 250 Home computer 150 VCR 70 Impact wrench 500 Water Heater 3000 Weed trimmer 500

(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

Running

Watts Device

Running

Watts

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:

Device to be Powered

Starting/Running Wattage

Greater of

Light Bulb 75 W Refrigerator – 18 Cu. Ft. 1600 W Microwave 700 W Window AC 1800 W Sump pump (1/3 hp) 2100 W

Total 6275W

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

STAGGERING LOADS

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.

Page 12

Installation / Initial Set-Up

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:

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. Battery installation (electric start models only).

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.

Page 13

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 8000W 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. The transfer switch must be installed in accordance with building electrical code and guidelines supplied by your power company.

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.

Using as a Back-up Power Source for a Building

Contact a licensed electrician to install a UL-approved transfer switch if

you want to use your generator as a back-up power source for a building. What does a transfer switch do? It:

a) Safely connects the generator to your building’s electrical system by

isolating your generator from your utility company’s power lines, AND

b) Connects your generator to a critical subset of your building’s circuits

that are needed for emergency power needs.

If your generator will be connected to your building’s electrical system, it MUST ALWAYS be isolated from the utility power grid with a UL-approved transfer switch installed by a licensed electrician in compliance with all applicable building and electrical codes, and in accordance with guidelines supplied by your power company.

DANGER:

A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise:

♦

When your generator is running, it’s output will back feed into the utility power line and transformer that are normally used to provide you with power. The transformer will step up the current to the normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated line could be electrocuted.

♦ If your generator is connected (running or not) when utility

power is restored, your generator will be destroyed. It could also explode or cause fire.

In addition to isolating your generator from the utility system, the transfer switch connects

our generator to a limited set of circuits in your building

Page 14

Using as a Portable Power Source

Installation / Initial Set-Up

that have been chosen as critical to operate during a power outage. 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.

(See the previous section of this manual entitled “Power Load Planning &

Management” for more information on load application and selection.) 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. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R locking receptacle compatible with L14-30P mating plug).

2. One 120 Volt, 20 Amp duplex straight-blade receptacle (NEMA 520R duplex receptacle compatible with NEMA 5-20P or 5-15P mating plugs).

3. One 120 Volt, 15 Amp duplex straight-blade receptacle (NEMA 5-

♦ Make sure you plug each electrical device/appliance into the correct

15R receptacle compatible with NEMA 5-15P mating plug)

NEMA

5-20

Duplex

EMA

L14-30R

GROUNDING POST

NEMA

5-15

Please read your owner's manual before operating, if you do not have

a manual or have questions, call customer service at 1-800-270-0810

FIG02679

(See more technical detail about these receptacles and their associated circuit breakers in the “Machine Component Identification” section of this manual.)

generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet.

Page 15

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 240V

10 2400 250’ 150’ 100’ 75’ 20 4800 125’ 75’ 50’ 25’ 30 7200 60’ 35’ 25’ 10’ 40 9600 30’ 15’ 10’ * 50 12000 15’ * * *

WARNING:

Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.

♦ All extension and appliance cords must be in good condition and not worn,

bare, frayed, or otherwise damaged.

WARNING:

Use of damaged electric cords can cause electric shock or fire.

Note: If an extension cord becomes hot to the touch, it is overloaded or damaged and must be replaced.

Northern Tool is NOT responsible for damage or injury resulting from customer use of inadequate extension cords.

Load (watts)

#10 Ga. Cord

#12 Ga. Cord

#14 Ga. Cord

#16 Ga. Cord

Page 16

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.

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. If applicable, block the generator’s wheels to prevent sliding and shifting.

Outdoors only – dangerous carbon monoxide exhaust

WARNING: Carbon monoxide poisoning hazard

The exhaust from your generator contains carbon monoxide (CO), a poisonous gas that can kill. You cannot smell it, see it, or taste it.

Carbon monoxide exhaust is given off whether you are using gasoline, natural gas, or propane as the fuel source to power the generator.

Follow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning.

The location you choose to operate the generator must be OUTDOORS and away from all air intakes:

• Never run the generator inside any closed or semi-enclosed spaces (even if outdoors), including homes, garages, basements, sheds, or boxes. These spaces can trap poisonous gases, even if you run a fan or open windows.

• Place the generator so that the exhaust fumes will not be directed towards people or building air intakes.

• Ensure that working, battery-operated or battery back-up carbon monoxide alarms are used in any dwelling/structure that is in close proximity to the running generator.

• Note that this generator is NOT designed or approved for use in vehicles or marine applications. Never run the generator inside RVs or other vehicles, on boats, or on pick-up truck beds.

WARNING:

Never attempt to attach ductwork to the muffler system to allow for installation inside an enclosure. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator.

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.

Page 17

Installation / Initial Set-Up

• Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.

• Never place the generator 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 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.

No wet conditions Choose a location where the generator will NOT be exposed to rain,

snow, or direct sunlight. Exposure to water can cause electric shock.

You may operate the generator under an outdoor, canopy-like structure of heat-resistant material that is open on all sides. Make sure that all parts of canopy are at least 7’ from exhaust, and allow for adequate clearance above generator so that heat does not build up.

Hot exhaust clearance

Away from dust/dirt Hearing protection

The exhaust gas from your generator is extremely hot and can cause combustible materials to catch on fire.

• Make sure your generator’s exhaust system is at least 7 feet from all combustible materials and buildings/structures.

• Equip the engine with a spark arrestor if the generator will be used near any ignitable forest, brush, or grassy land. (See the “Specifications” section of this manual to determine if your generator is already equipped.) Make sure you comply with applicable local, state, and federal codes.

• Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged and be familiar with its use.

Do not use the generator in extremely dusty or dirty conditions. Excessive dust and dirt can cause premature failure of the machine.

Generators can produce noise levels of up to 95 dB in close proximity, which can be dangerous to human hearing with prolonged exposure.

Hearing protection may be required for persons working within 15-20 feet of the running generator for an extended period of time.

WARNING:

Never attempt to attach ductwork to the muffler system to lower noise levels. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator.

Page 18

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.

2) Connect an approved ground clamp to the pipe.

3) Run a 10 gauge wire from the clamp to the generator grounding post located on the rear of the generator head.

4) Do not connect the generator grounding post to a water pipe or a ground used by a radio system.

10 Ga. wire

Coppe

Pipe/Ro

Grounding

Post

Groun

If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a back-up power system, grounding may alternatively be completed through the building’s grounding system. Ask your electrician. If the generator is not grounded through your building’s electrical system, follow the procedure above.

WARNING:

Operating the generator when it is not properly grounded can result in electrical shock.

Page 19

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. Follow the instructions detailed below for connecting and disconnecting the battery.

WARNING: Battery hazards

Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause electric shock. Caution must be exercised when making connections to a battery to avoid shock and contact with the acid, and to prevent any sparking that could lead to an explosion. ALWAYS follow the general battery safety rules and instructions listed below.

General Battery Safety Rules

Connecting the battery

Disconnecting the battery

• ALWAYS use eye protection when handling batteries.

• NEVER smoke or work near sparks or other sources of ignition.

• NEVER touch both battery terminals at the same time with your hand or

any non-insulated tools.

• If battery acid contacts skin or clothing, flush immediately with water and neutralize with baking soda.

Always connect the cables in the following sequence to avoid possible shock:

1. Find the battery cables located inside the battery box.

2. Connect the red cable to the positive(+) terminal of the battery.

3. Then connect the black cable to the negative(-) terminal of the battery.

Always disconnect cables in the following sequence to avoid possible shock.

1. First, disconnect the black cable from the negative(-) terminal of the

battery.

2. Next, disconnect the red cable from the positive(+) terminal of the

battery.

Page 20

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.

Each of these procedures is discussed in detail below:

Operation Procedures

1. General Safety Rules for Operation

2. Preparing for Operation

3. Starting the Engine

4. Checking Generator Output

5. Connecting Electrical Loads (Portable Power Generation)

6. Stopping

7. Storage & Exercise of Generator

1. General safety rules for operation

Before starting the generator, review the following general safety rules for operation:

WARNING:

Failure to follow safety rules may result in serious injury or death to the operator or bystanders.

• Know proper use/how to stop. Be thoroughly familiar with proper use of the equipment and all

generator controls, output receptacles, and connections. Know how to stop the generator quickly if needed (see “Operation, Step 6 - Stopping the Engine”).

• Instruct ope rators. The generator owner must instruct all operators in safe generator set-up and

operation. Only trained adults should set up and operate the generator – Do not let children operate.

• Intended use . Carefully read about and understand the intended use of this generator. Do not use for

other purposes, as unforeseen hazards or equipment damage may result.

• Under the influence. Never operate, or let anyone else operate, the generator while under the influence

of alcohol, drugs, or medication.

• Safety equipment / controls. Do not operate the generator unless all safety covers, guards, and barriers

are in place and in good working order, and all controls are properly adjusted for safe operation.

• Damaged. Do not operate the generator with damaged, missing, or broken parts.

• Modifications. Do not modify the generator in any way. Modifications can create serious safety hazards

and will also void the warranty.

• Engine spee d . Never attempt to modify the engine speed setting. The engine speed is preset at 3600 RPM

for safe and optimal performance of the generator. If speed needs adjusting, it must be done by factoryauthorized 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 elevation will cause gasoline to leak from carburetor during operation. Fire or explosion could result.

Page 21

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. Always turn off generator and remove spark plug(s) or spark plug wire(s) before

working on the generator to prevent accidental starting. 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. You CANNOT smell it, see it, or taste it. Follow all instructions for site selection and positioning the generator, and avoid inhaling the exhaust. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

• Other exhaust dangers. This product contains or emits chemicals known to the State of California to

cause cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust.

• Wet conditions. Do not operate the generator or handle any electrical equipment while standing in water,

while barefoot, while hands are wet or while in the rain or snow. Electric shock may result.

• Ground fault circuit interrupter. Always use a ground fault circuit interrupter (GFCI) protected

extension cord (or outlet, if generator is equipped) in damp or highly electrical conductive areas and on construction jobsites to prevent electrical shock.

• Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running.

• 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.

• Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or

flames.

• Hot muffler. Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine

parts can be very hot and will burn you.

• Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never

remove any drive belt or fan guard while the unit is operating.

Always discharge the capacitor before working

Page 22

Operation (cont’d)

Static electricity and filling the gasoline tank:

Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and

Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons. To avoid static electricity while fueling, certain steps must be followed before and during the fueling process in order to minimize and safely dissipate static charge build-up:

• Touch a grounded metal object before starting. Always dissipate static charg e from your body

before beginning the fueling process by touching a grounded metal object at a safe distance away from fuel sources.

• Use a portable container to fill tank. Never fill the generator’s gas tank directly from the fuel pump –

the generator’s tank is not grounded and the high velocity flow of gasoline from a fuel pump can cause static electric build-up. Use an approved portable container to transfer gasoline to the generator’s tank.

• Fill container on the ground. Never fill the portable gas container while it is sitting inside a vehicle,

trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled.

• Keep nozzle in contact with container. Keep nozzle in contact with the portable container at all times

while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device.

• Use a portable container made of metal or conductive plastic. It will dissipate charge to ground more

readily.

About static electricity and fueling Many common objects can accumulate and retain a static electric charge. Objects made of non-conductive materials (e.g. plastics) easily accumulate and retain static electric charge, as can objects made of conductive material (e.g. metal, water) if they are not electrically grounded. The static electric charge on an object, such as a human body or plastic fuel tank/container, can reach as high as several thousand volts!

A static electric spark can be generated if the static electric charge stored on an object “jumps” to another, less charged object. Such a spark can ignite invisible gasoline vapors that are present during fueling situations.

Typical sources of static electric hazards during fueling The following objects can accumulate a static electric charge and cause an ignition spark in typical fueling situations:

1) Ungrounded tanks/containers. Any ungrounded fuel tank or container can accumulate a static electric charge as a result of contact with other objects or friction during transportation. This static electricity can discharge as a spark to the grounded gasoline dispenser nozzle, as the nozzle is first brought close to the tank/container at the beginning of the fueling process.

2) Flowing gasoline. Most people are not aware that gasoline accumulates static electric charge while flowing through a hose or pipe. This charge then transfers to and accumulates in the gas tank or container that is being filled. The total amount of charge accumulation depends on the amount of gas pumped into the container, the speed with which it is pumped, and whether or not the tank/container is grounded. If sufficient static electric charge accumulates in the fuel tank or container during the fueling process, the tank/container may discharge a spark to the grounded gasoline dispenser nozzle.

3) Persons resulting from contact with their car seat or electronics. The static electricity can discharge as a spark between that person’s hand and either the grounded dispenser nozzle or the fuel tank opening.

. A person dispensing the gasoline can carry a static electric charge on their body, typically

from persons carrying a static electric charge

Page 23

Operation (cont’d)

2. Preparing for Operation

Position generator

Ground generator

Perform scheduled maintenance as needed

Check/add oil Check the oil level using the dipstick and add oil as needed.

Check/fill gasoline tank

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. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.

Carbon monoxide exhaust is given off whether you are using gasoline, natural gas, or propane to power the generator.

Make sure the generator is grounded in accordance with instruction given in

“Installation & Initial Set-up, Step 5: Grounding the Generator” of

this manual.

WARNING: Electric shock hazard

Always ensure generator is properly grounded to prevent electrical shock.

Make sure that any regular maintenance has been performed as prescribed in this manual in the “Maintenance & Repair” section.

1. Refer to the engine owner’s manual for engine maintenance instructions.

2. Make sure battery is charged. Charge as needed according to your battery manufacturer’s instructions.

Using a funnel, add oil up to the FULL mark on the dip stick with the recommended oil type for your engine and expected ambient conditions. (See engine Owner’s Manual for oil type and capacity, and more detailed oil check/fill instructions.)

WARNING: Burn hazard

Never open oil port while engine is running. Hot oil can spray over face and body.

Notes: o Low oil shutdown feature prevents the generator from starting without

sufficient oil.

o Engine is shipped without

oil. You must add oil before first use.

IMPORTANT: Under long, continuous-run operating conditions, be prepared to:

• Check engine oil level every time you refuel the engine.

• Change oil after the first 20 operating hours, and at least every 100

operating hours thereafter, or as directed in engine owner’s manual.

Check the gasoline level in the generator’s tank. If needed, fill tank with fresh unleaded gasoline from a portable container, after first reading the

warnings and instructions below.

Page 24

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. Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition:

• gas vapor collection inside enclosures

• static electric sparks

• sparks from electric wiring, batteries, or running engines

• sources of heat (such as a hot engine or exhaust)

• open flames, including pilot lights

1) Before starting, review the following general safety precautions for fueling: a) Never pump gasoline directly into the generator’s gas tank at a gas station –

high velocity flow from the pump could result in a static electric build-up in the generator’s tank. Always use a portable container to fill the tank.

See warning box about static electric spark hazards below.

b) Fill gasoline tank OUTDOORS – never indoors. c) Stay away from all sources of heat, sparks, and flames. Do not smoke.

2) Turn generator engine off and allow to cool for at least two minutes before removing gas cap.

Note: A running or still-hot engine is hot enough to ignite fuel.

3) Remove generator gasoline cap.

4) Add gasoline through the fill opening:

- Use only a UL-approved portable gasoline container to transfer the gasoline

to the generator’s tank. Follow the safety warning and instructions below for avoiding static electric sparking.

- Do NOT overfill the gasoline tank. Allow at least 1/2” of empty space

below the fill neck to allow for fuel expansion.

WARNING: Static electric spark hazard

A static electric spark can explosively ignite gasoline vapor, resulting in a flash fire that could cause serious injury or death.

To avoid static electric sparking while filling the gasoline tank, the

following steps must be followed to minimize and safely dissipate static electric charge build-up before and during the fueling process

• 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 gas tank directly from the fuel 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.

• Never fill the portable gas container while it is sitting inside a vehicle,

trunk, or pick-up truck bed. ALWAYS place container on the

trailer

Page 25

Inspect Fuel System / Check for Leaks

Personal Protection

Operation (cont’d)

ground to be filled.

• 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.

• Wipe up spilled gasoline, and wait 5 minutes for excess gasoline to

evaporate before starting engine.

• Gasoline soaked rags are flammable and should be disposed of properly.

• If gasoline is spilled on your skin or clothes, change clothes and wash skin

6) Replace gasoline cap securely before starting engine.

7) Store extra gasoline in a cool, dry place in an UL-approved, tightly sealed

IMPORTANT: For continuous operation, be prepared to check and refuel the engine on a

Inspect fuel system & check for leaks BEFORE starting generator.

Do not start generator until all needed repairs have been completed.

Inspect the entire fuel system. Look for:

1) Hearing can be damaged from prolonged, close-range exposure to the type of

2) Loose or dangling apparel can become entangled in moving parts. Metal

immediately.

container.

regular basis. A tank of gasoline should last about 4 hours under 100% load, and about 8 hours under 50% load.

WARNING: Fuel leak hazard

Standard diesel fuel is combustible (with ethanol-diesel blends being nearly as flammable as gasoline). Fuel leaks can result in fire. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

• signs of leaks or deterioration,

• chafed or spongy fuel hose,

• loose connections,

• loose or missing fuel hose clamps,

• a damaged gasoline tank, or

• a defective gasoline shut-off valve.

noise produced by this generator. The use of ear plugs or other hearing protection device is recommended for persons working within 15-20 feet of

the running generator for an extended period of time.

jewelry can conduct electricity. Never wear jewelry or loose-fitting

clothing when starting or operating the generator.

Page 26

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) Using electric start –

i) Turn the engine key switch to the START position and hold it there until the engine starts.

NOTE: If the engine fails to start after 5 seconds, release key and wait 10 seconds

before attempting to start again. Cranking the electric starter for more than 5 seconds continuously can overheat and damage the starter motor.

5) When engine starts, move choke lever to RUN position.

6) Under long, continuous-run operating conditions, be prepared to:

ii) Release the key when the engine starts.

b) Using recoil start –

i) Turn the engine key switch to the ON position. ii) Pull the starter grip lightly until you feel resistance, then pull the starter cord out briskly

and rapidly.

iii) Allow starter cord to return slowly.

a) Check and refuel the engine on a regular basis. A tank of gas should last about 4 hours under

100% load, and about 8 hours under 50% load. See engine owner’s manual for more detail.

WARNING:

A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if engine is running or still hot. Let cool at least 2 minutes.

b) Check engine oil level each time you refuel. c) 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 engine is running. Hot oil can spray over face and body.

Page 27

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. Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual.

Output voltage should be checked with a portable voltage meter:

1. Start engine and allow to warm up for five minutes. Do not connect any loads.

2. Use voltage meter to check output voltage at the generator’s outlets/receptacles.

3. Measured voltage should be within the following ranges:

a. 120V +/- 10% at 120V receptacles. b. 240V +/- 10% at 240V receptacles.

4. If measured voltage is not within the specified range, have generator adjusted by factory authorized personnel. Do not attempt to adjust the engine speed yourself.

NOTE: Slight variation 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. Additionally, there may be small brief surges and drops in voltage as motors connected to the generator cycle on or off.

The slight variation has no appreciable effect in the operation of motors, lights, and most appliances.

Page 28

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. Make sure that combined starting and running loads do not exceed rated capacity of generator. Overloading the generator can cause damage to the generator and attached electrical devices, and may result in fire.

Using as a Portable Power Source

Using as a Back-up Power Source for a Building

Stop the engine using the following steps:

1. Disconnect all loads to the generator.

Connect electrical loads one at a time according to the following instructions:

1. Allow engine to reach operating speed by allowing it to warm up for approximately 5 minutes before connecting electrical devices.

2. After engine is warmed up, begin by connecting the items that require the highest wattage first. The recommended sequence is as follows:

a. Connect items with motors such as refrigerators, freezers, air

conditioners, or small hand tools, one at a time. Let each motor

stabilize before connecting the next device. b. Connect any lights you are planning on powering. c. Connect voltage sensitive equipment such as electronics via surge

protectors. Plug devices such as TV’s, computers, and microwaves

into a UL listed voltage surge protector, then plug the surge

protector into the generator.

Each transfer switch installation will be unique. Proper instructions for how to safely bring the generator online with the

building’s electrical system should be provided by the installing electrician, who should also provide personal instruction to the owner/operator.

Failure to follow the proper procedure as provided by the electrician could expose persons to the hazards noted above.

6. Stopping

2. Turn engine key switch to OFF position.

3. Turn gasoline line shut-off valve to OFF position.

4. Remove key from starter to prevent accidental starting of engine.

Page 29

Operation (cont’d)

7. Storage & Exercise

When you are finished using 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 off fuel supply

Cool engine before storing Choose a storage location

Prevent accidental starting

Exercise generator every 4 weeks

Perform regular maintenance

When you are finished using the generator, disconnect all loads and turn off fuel supply:

1. Make sure all devices that were connected to the generator’s outlets have been disconnected.

2. Check to be sure gasoline line shut-off valve is in OFF position.

Let engine cool for at least five minutes before storing. A hot engine can be a fire hazard.

Store the generator in a location that is:

o Clean and dry o Away from sources of heat, open flames, sparks, or pilot lights, even

if the generator’s fuel tank is empty. Residual fuel in the tank could ignite.

o Away from extreme high or low temperatures.

Note: Do not store with battery charger always connected. Batteries that are over-charged can boil themselves dry and produce excessive amounts of hydrogen, an explosive gas.

Remove key from starter (for electric start engines) and secure key in a safe location, or remove spark plug(s) in order to ensure the generator

cannot be started accidentally in a storage location or by untrained persons.

The generator should be exercised regularly.

At least every four weeks, start the engine and let it run for 10 to 15 minutes with a small load plugged in, such as a lamp or fan.

Monthly exercising of the generator will:

o Dry out any moisture that has accumulated in the windings. If left,

this moisture can cause corrosion in the winding.

o Ensure that the unit is operating properly should it be needed in an

emergency.

Perform periodic maintenance as directed in this manual to keep the generator in safe working condition.

Page 30

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

o Adding fuel stabilizer to the gasoline (following manufacturer’s

instructions)

Fuel stabilizer steps:

1. Ensure gasoline 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. Place rag over spark plug hole and turn starter (or pull the recoil) a few times to lubricate the combustion chamber.

8. Replace spark plug, but do not reconnect the spark plug wire.

Page 31

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.

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. The bearing is a heavy-duty sealed ball bearing which requires no maintenance or lubrication.

Maintenance & Repair

Follow safety rules Read and follow these safety rules whenever you will be servicing the

generator:

• Turn off generator. Always turn off generator and remove spark plug(s) or

spark plug wire(s) before working on the engine or generator to prevent accidental starting.

• Discharge capacitor. When the generator is shut down, the capacitor may

maintain a charge. Always discharge the capacitor before working on the generator head to prevent electrical shock. Discharge using a screwdriver with an insulated handle. While wearing safety glasses, touch opposite terminals of the capacitor together with the tip of the screwdriver. If there is stored charge in the capacitor, a spark will be generated thereby discharging the capacitor.

• Replace guards. Make sure all guards and shields are replaced after servicing

the generator.

• Repair. Major service, including the installation or replacement of parts, should

be performed only by a qualified electrical service technician. Obtain factory approved parts from NorthStar Product Support at 1-800-270-0810.

• Replacement parts. If a part needs replacement, only use factory approved

repair parts. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator and will void the warranty.

Perform engine maintenance

Check receptacles Check receptacles before each use to make sure they are not cracked or

Inspect fuel system / check for leaks

Perform engine maintenance as specified in the engine owner’s manual.

Engine maintenance items include:

1. Changing oil and oil filter

2. Air filter check/replacement

3. Spark plug cleaning and replacement

4. Fuel filter check/replacement

5. Fuel tank cleaning.

broken.

If a receptacle is cracked or otherwise damaged, do not use until replaced with an authorized factory part. Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment.

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 connections, loose or missing fuel hose clamps, damaged gasoline tank, or defective gasoline shut-off valve.

WARNING

Page 32

Maintenance & Repair (cont’d)

Check GFCI (if equipped)

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. If the RESET button does not extend, contact Northern Tool for replacement parts.

2. Restore power to the GFCI by firmly pressing the RESET button back into the receptacle until an audible click is heard.

Clean & inspect spark arrestor (if equipped)

Clean and inspect the spark arrestor muffler. (Only for those models

equipped with a spark arrestor – See the “Specifications” section.) If the engine is equipped with a spark arrester muffler, clean and inspect it

regularly (follow manufacturer’s service instructions). Replace if damaged.

Keep generator clean

Keep generator clean.

If dust or debris accumulates on the generator, clean the generator with a damp cloth or soft bristle brush. Do not allow air intakes to become blocked.

Note: Do not spray generator with a garden hose or pressure washer. Water may enter the generator and cause damage to the rotor, stator, or internal windings.

Recharge and maintain battery (if electric start)

Inspect, recharge, and maintain your battery according to your battery manufacturer’s instructions. (Only for those models equipped with electric

start.) Do not store with battery charger always connected. Batteries that are over-

charged can boil themselves dry and produce excessive amounts of hydrogen, an explosive gas.

IMPORTANT:

If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator.

Contact NorthStar Product Support at 1-800-270-0810 for any questions,

problems, or parts orders.

Page 33

Troubleshooting

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 is not charged.

Voltage too low. a) Engine speed too slow.

b) Generator is overloaded.

Circuit breaker trips. a) Defective load connected to generator.

b) Defective receptacle.

c) Generator overloaded. Voltage too high. a) Engine speed too high. a) Bring ge nerator to a qualified Generator overheating. a) Generator is overloaded.

b) Insufficient ventilation. No output voltage. a) Defective load connected to generator.

b) Broken or loose wire.

c) Defective receptacle.

d) Defective stator.

e) Defective rotor.

f) Defective capacitor. Engine lacks power. a) Generator is overloaded.

b) Dirty air filter. Engine shuts down during operation.

a) Out of fuel.

b) Low oil level.

a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) Fill fuel tank. d) Place switch in ON position. e) Charge Battery. If battery will not hold a charge, replace with new battery (part # 31868). a) Bring generator to a qualified technician for adjustment. b) Reduce the load. (See Power Load Planning & Mgt. section of this manual.) a) Disconnect load. b) Replace receptacle. c) Reduce the load. (See Power Load Planning & Mgt. section of this manual.)

technician for adjustment. a) Reduce the load. (See Power Load Planning & Mgt. section of this manual.) b) Make sure there is at least 3 feet of clearance on all sides of generator. a) Disconnect load. b) Bring generator to a qualified technician for repair. c) Replace receptacle. d) Bring generator to a qualified technician for repair. e) Bring generator to a qualified technician for repair. f) Bring generator to a qualified technician for repair. a) Reduce the load. (See Power Load Planning & Mgt. section of this manual.) b) Clean or replace air filter. a) Fill fuel tank. b) Fill crankcase to proper oil level.

Page 34

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.

Carefully read and make sure you understand the following safety information before using the generator. Improper use or maintenance of the generator can result in

death

from carbon monoxide poisoning, electric shock, fire/explosion, or burns.

• Read manual. Read this Owner’s Manual and the engine Owner’s Manual completely before attempting to

set-up and use the generator. Serious injury or death can result if safety instructions are not followed.

• Instruct operators. The generator owner must instruct all operators in safe generator set-up and operation.

Do not allow anyone to operate the generator who has not read the Owner’s Manual and been instructed on its safe use.

• Adults only. Only trained adults should set up and operate the generator. Do not let children operate.

• Under the influence. Never operate, or let anyone else operate, the generator while under the influence of

alcohol, drugs, or medication.

• Intended use. Carefully read about and understand the intended use of this generator. Do not use for other

purposes, as unforeseen hazards or equipment damage may result.

Prohibition Against Modifications

Never modify or alter the generator in any way. Modifications can create serious safety hazards and will also void the warranty.

• Engine speed. Never attempt to modify the engine speed setting. The engine speed is preset at 3600 RPM for

safe and optimal performance of the generator. If speed needs adjusting, it must be done by factoryauthorized personnel.

• Fuel/exhaust system. Never modify the exhaust system, fuel tanks, or fuel lines. Carbon monoxide

poisoning, fire, or explosion could result.

• Guards. Do not operate generator unless all guards and cover shields, which prevent access to moving parts and pinch points, are in place. Failure to guard the power transmission mechanisms may result in serious injury or death.

WARNING

serious injury or

General

Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause electric shock.

Caution must be exercised when making connections to a battery to avoid shock and contact with the acid, and to prevent any sparking that could lead to an explosion. Follow safety rules carefully when connecting battery to generator:

• Eye/skin protection. Always wear eye protection and protective clothing when connecting or disconnecting battery.

• 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. 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 with baking soda.

Safety – Installation & Set-up

Battery Safety

Page 35

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. ONLY run generator OUTDOORS and away from building air intakes. NEVER run generator inside homes, garages, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows. Carbon monoxide is given off whether you are using gasoline, natural gas, or propane to powe r the generator.

• No vehicle/marine use. This generato r is N OT desi gned or approved for use in vehicles or marine applications. Never run the generator inside RVs or other vehicles, on boats, or on pick-up truck beds.

• Cooling ventilation. The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head. Situate so there is adequate clearance around generator to allow for cooling airflow. Do not allow debris to accumulate and block airflow.

• Grounding. Always ensure generator is properly grounded to prevent electrical shock. This generator is equipped with a grounding post. Always complete the grounding path from the generator to a copper pipe/rod driven into moist earth to a sufficient depth. Check with an electrician for local grounding requirements. If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a standby power system, grounding will be complete through the building’s grounding system.

• Isolate connection to building’s electrical circuit. 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 an UL-approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes. If the generator is not isolated from the utility power system by such means, generator output will backfeed into the utility power grid. This may result in injury or death to utility power workers or others who contact the lines during a power outage. It may also cause the generator to explode or cause fires when utility power is restored.

• Wet conditions. Water conducts electricity. Do not operate generator where it is wet. Operate on a dry surface under an open, canopy-like structure.

• CO alarms. Ensure that working, battery-operated or battery back-up carbon monoxide alarms are used in any dwelling/structure that is in close proximity to the running generator.

• Hot exhaust - fires. Exhaust from engine can be extremely hot and cause fire. Position muffler at least 7’ from combustible objects during operation.

• Spark arrestor. Equip engine with a spark arrestor if generator will be used near any ignitable forest, brush, or grassy land. See the “Specifications” section of this manual to determine if your generator is already equipped. Make sure you comply with applicable local, state and federal codes.

• Fire extinguisher. Keep a fire extinguisher rated “ABC” by the National Fire Protection Association nearby. Keep it properly charged and be familiar with its use.

Safety – Before Use

Know how to operate

• Review safety rules. Before each use of this generator, review the “Rules for Safe Operation.” Failure to follow these rules may result in serious injury or death.

• Know how to operate . Be thoroughly familiar with all controls and with the proper use of the equipment. Know how to stop the generator quickly if needed.

Personal protective equipment

• Hearing protection. The use of ear plugs or other hearing protection device is recommended for those in close proximity to the generator while it is operating.

• Loose / dangling. Loose or dangling apparel can become entangled in moving parts. Metal jewelry can conduct electricity. Never wear jewelry or loose-fitting clothing when operating the generator.

Page 36

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. Use an UL approved fuel container to transfer gas to the engine.

• Running / hot engine. A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if engine is running or still hot. Stop the engine and allow to cool at least two minutes before adding fuel.

• Heat / flames / sparks. Stay away from sources of heat, flame, or sparks while adding fuel.

• Don’t overfill . DO NOT overfill the gas tank. Allow at least 1/2” of empty space below the fill neck to allow

for fuel expansion.

• Replace cap. Replace gas cap securely before starting engine.

• Spills. Clean up fuel spills immediately. Move generator away from spilled fuel on the ground. Wipe fuel off

engine and wait 5 minutes for excess fuel to evaporate before starting engine. Gas soaked rags should be disposed of properly.

• On skin / clothes. If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately.

• Inspect fuel system. Check fuel system on a regular basis. Look for signs of leaks, deterioration, chafed or

spongy fuel hose, loose or missing fuel hose clamps, damaged fuel tank, or a defective fuel shut-off valve. Do not start generator until needed repairs have been completed.

• Gasoline storage. Store gasoline in a cool, dry place in an UL-approved, tightly sealed container.

Safety – During Use

• Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation.

• Know how to stop. Be thoroughly familiar with proper use of the equipment and all generator controls, output receptacles, and connections. Know how to stop the generator quickly if needed.

• Damaged. Do not operate the generator with damaged, missing, or broken parts.

• Carbon monoxide exhaust. The running engine gives off carbon monoxide, a poisonous gas that can kill

you. You CANNOT smell it, see it, or taste it. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

• Other exhaust dangers. This product contains or emits chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust.

• Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or flames.

• Check output voltage. Check output voltage to ensure the generator is working properly before connecting loads to the generator. Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual. Do not adjust output speed of engine to change voltage. If voltage is not within specified range, have generator repaired by fact ory aut h ori zed personnel.

• Stabilize before connecting loads. Start generator and let engine stabilize before connecting electrical loads.

• Do not overload. Do not overload the generator. Make sure that combined starting and running loads do not

exceed rated capacity of generator or damage will result.

• Protect sensitive electronics. Some electronic equipment, such as computers and audio/video equipment, can be damaged by small fluctuations in the flow of power. Use a surge suppressor for any voltage-sensitive electronic equipment you will be powering with the generator.

• Wet conditions. Do not operate the generator or handle any electrical equipment while standing in water, while barefoot, while hands are wet or while in the rain or snow. Electric shock may result.

• Ground fault circuit interrupter. Always use a ground fault circuit interrupter (GFCI) protected extension cord (or outlet, if generator is equipped) in damp or highly electrical conductive areas and on construction jobsites to prevent electrical shock.

• Electrical cords. Use only UL-listed, outdoor-rated, three prong extension cords of the proper size. All extension and appliance cords must be in good condit ion and not worn, bare, frayed, or otherwise dama ged . Use of inadequate or damaged electric cords can cause electric shock or fire.

Page 37

Summary of Important Safety Information for Operation (cont’d)

• Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running.

• 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. Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine parts can be very hot and will burn you.

• Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never remove any drive belt or fan guard while the unit is operating.

• Refueling. DO NOT refuel the engine until it has cooled at least two minutes.

• Malfunction during operation. Immediately turn off the generator if any of the following conditions arise

during operation:

• Adjusting / repairing. Always turn off generator and rem ove spark plug(s) or spark plug wire(s) befor e working on the generator to prevent accidental starting.

Safety – After use

• Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine can be a fire hazard.

• Shut off fuel supply. Make sure gasoline shut-off valve is in the OFF position.

• Prevent accidental starting. When generator is not in use, remove key from starter (key start engines) and

secure in a safe location, or remove spark plug(s) in order to ensure that generator cannot be started in a storage location or by untrained persons.

• Storage location. Store the generator in a dry location away from sources of heat, open flames, sparks or pilot lights – such as water heaters, space heaters, furnaces, clothes dryers, or other gas appliances – EVEN IF the generator’s gas tank is empty. Residual gasoline could ignite.

• Exercise regularly. Exercise generator every four weeks to dry out moisture that accumulates in the windings. If generator cannot be exercised on a regular basis, prepare generator for long term storage.

• Periodic maintenance. Perform periodic maintenance as directed in this manual to keep the generator in safe working condition.

Safety - Inspection/Maintenance

Inspect and maintain your generator on a regular basis and repair as needed to keep it in safe working condition:

• Turn off generator. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the engine or generator to prevent accidental starting.

• Discharge capacitor. When the generator is shut down, the capacitor may maintain a charge. Always discharge the capacitor before working on the generator head to prevent electrical shock.

• Replace guards / shields. Make sure all guards and shields are replaced after servicing the generator.

• Replacement parts. If a part needs replacement, only use parts that meet the manufacturer’s specifications.

Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator and will void the warranty.

Page 38

Generator Exploded View Rev - K

Page 39

Generator Exploded View Rev - K

Ref # Part # Description Qty

1 38759 Fuel Tank Assembly 1 2 33321 Fuel Cap 1 3 777352 Battery Box 1 4 30754 Leather Washer 4 5 779422 Decal 1 6 777834 Hose Clamp 3 7 779423 Warning Decal 1 8 32833 Roll Cage 1

9 39260 Hot Muffler Sticker 1 10 31335 Honda GX390 Engine, 13 HP 1 11 778530A Generator Head 1 12 777304 Generator Cover 1 13 306459 Engine Ground Wire 1 14 777621 Generator Bracket 1 15 777108 Battery Cable, Negative 1 16 34172 Isolation Mount 4 17 32844 Bottom Bracket 4 18 778483 Generator Base 1 19 82018 Bolt, 5/16-18 X 2” 4 20 82067 Clip Nut, #10-32 4 21 82007 Screw, #10-32 X .75 4 22 777164 Positive Battery Cable 1 23 777620 Control Panel Face Assembly 1 24 38180 Control Panel Housing 1 25 306579 Grommet 1 26 32848 Top Bracket 4 27 34176 Nameplate 1 28 30755 Fuel Filter 1 29 777345 1/4” Fuel Line 33” 30 38184 Engine Cover 1 31 779396 Battery Warning Decal 1 32 30753 Protective Sleeve 1.38ft

Page 40

Wiring Diagram Rev - K

Diag # Part # Description Qty

1 306438 15 Amp, 120 Volt Receptacle (NEMA 5-15R) 1 2 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 1 3 306422 30 Amp, 120/240 Volt Locking Receptacle

(NEMA L14-30R) 4 306429 Grounding Post 1 5 306433 Thermal Circuit Breaker, 15 Amp 1 6 38191 Wiring Harness

(Connects generator to Control Panel) 7 82004 #8-32 X ½ Button Head Cap Screw 6 8 82005 #8-32 Lock Nut 6 9 30643 Thermal Circuit Breaker, 20 Amp 2

10 31086 Thermal Circuit Breaker, 30 Amp 2 11 31107 Wire Assembly (B25, B27) 1 12 306604 Wire Assembly (W23, W24, G22, G23, G24) 1 13 30975 Control Panel Face 1 14 82085 ¼ USS Flat Washer 2

15 82155 Cable Tie 1 B23 31106 Black Terminated Wire 1 B24 31108 Black Terminated Wire 1 B26 31109 Black Terminated Wire 1 B28 306599 Black Terminated Wire 1 B29 30660 Black Terminated Wire 1 B31 306601 Black Terminated Wire 1

G22 306603 Green Terminated Wire 1

W25 30977 White Terminated Wire 1

Page 41

Generator Head Exploded View Rev - K

Item # Part # Description Qty

1 38266 Mount Plate (J609B) 1 2 38267 Fan Bolts 2 3 38268 Fan 1 4 38269 Drive End Bracket 1 5 38270 Enclosing Band 1 6 777304 End Cover 1 7 38271 End Cover Plug 1 8 38272 Stator 1

9 38273 Rotor 1 10 307479 Diode 2 11 38275 Securing Stud 1 12 38276 Bearing 1 13 38277 Nut 1 14 38278 Non Drive End Bracket 1 15 38279 Capacitor 1 16 38280 Bracket Securing Stud 4 17 307481 Varistor 2