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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Industrial Diesel Generator
6,120 Watt Continuous (6,500 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/buildings (battery-operated, 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.
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
Owner's Manual
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165930R
ITEM NUMBER: 165930
SERIAL NUMBER: _____________
®
WARNING
CO Poisoning
Fire / Explosion
STOP!
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Summary of Contents for North Star M165930R
- Page 1 M165930R ITEM NUMBER: 165930 SERIAL NUMBER: _____________ ® Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Industrial Diesel Generator 6,120 Watt Continuous (6,500 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...
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Page 2: Hazard Signal Word Definitions
Hazard Signal Word Definitions... -
Page 3: Table Of Contents
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. -
Page 4: About Your Generator
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 6500 Watts of electrical power (6120 watts continuous, 6500 watts surge). It can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. - Page 5 About Your Generator (cont’d) 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.
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Page 6: Specifications
Specifications – Item #165930 SPECIFICATIONS Item Number 165930 Maximum Output 6500 Watts (W) Continuous Output 6120 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 10 HP Yanmar L100 Engine Speed 3390 - 3798 RPM Fuel Type... -
Page 7: Safety Label Locations
Safety Label Locations – Item #165930 6500 DPG • Commercial-grade electric start engine • Extend run 6.5 gallon fuel tank DIESEL SERIES • Maintenance-free brushless alternator design • GENERATOR Smooth running focus mount isolation system WARNING - BATTERY HAZARDS BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock 6500 DPG ALWAYS use eye protection. -
Page 8: Machine Component Identification
Machine Component Identification - Item #165930R Figure 1 (Ref. 1-15) Ref. Description Ref. Description Main Line Breaker Oil Fill and Dip Stick Thermal Circuit Breakers Recoil Handle Voltmeter Air Cleaner Housing 120 Volt-20 Amp GFCI Duplex Receptacles Decompression Lever Hour Meter Muffler Charging Lamp Ignition Fuse... - Page 9 Machine Component Identification - Item #165930R REFERENCE GUIDE Reference 1 – Main Line Breaker The main line breaker is a two-pole thermo-magnetic circuit breaker. The circuit breaker will protect the generator from overload and short circuit conditions. To reset the circuit breaker move the toggle to the OFF position, then back to the ON position.
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Page 10: Power Load Planning & Management
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. - Page 11 Power Load Planning & Management (cont’d) Running Running Device Watts Device Watts Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1”) 1100...
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Page 12: Installation / Initial Set-Up
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. -
Page 13: Set-Up As A Portable Or Building Back-Up Power Source
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 6500W 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. - Page 14 Installation / Initial Set-Up 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.
- 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.
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Page 16: Selecting A Suitable Site
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. - Page 17 Installation / Initial Set-Up • 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. •...
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Page 18: Grounding The Generator
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 –... -
Page 19: Battery Installation
Installation / Initial Set-Up 6. Battery Installation Your generator’s engine is equipped with an electric starter, which requires the installation of a 12- volt 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. -
Page 20: Operation
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. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. - 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...
- Page 22 Operation (cont’d) Static electricity and filling the fuel tank: Static electricity can initiate from ungrounded fuel tanks or containers, from flowing fuel, and from persons carrying a static electric charge Under certain conditions, static electricity can ignite fuel vapors that are present during the fueling process, which may result in serious burns to nearby persons.
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Page 23: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in generator “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. - Page 24 Operation (cont’d) WARNING : Diesel fuel fire hazard Standard diesel fuel is a combustible liquid. High heat, sparks, and flames can ignite diesel fuel vapors. A fire could result and cause serious injury or death. Use extreme care when handling diesel fuel, especially ethanol-diesel (e-diesel) blends, which are more flammable than standard diesel and nearly as flammable as gasoline.
- Page 25 Operation (cont’d) ground to be filled. • Keep nozzle in contact with portable container while filling. Manually control the flow of fuel; do NOT use nozzle’s lock-open device. • A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily.
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Page 26: Starting The Engine
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 fuel line valve to the ON position. The fuel valve is located underneath the fuel tank. 3) Start the engine: a) Using electric start - i) Turn the engine starting key to the START position and hold it there until the engine... -
Page 27: Checking Generator Output
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. -
Page 28: Connecting Loads
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 :... -
Page 29: Storage & Exercise
Operation (cont’d) 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. - Page 30 Operation (cont’d) Prepare engine for If you will not be able to exercise the generator regularly, you must long term storage if prepare the engine for long term storage to prevent gum deposits from needed forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all fuel from the tank and carburetor...
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Page 31: Maintenance & Repair
Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the generator. - Page 32 Maintenance & Repair (cont’d) Check GFCI Once a month, test the Ground Fault Circuit Interrupter (GFCI) to (if equipped) 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.
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Page 33: Troubleshooting
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. a) Fill crankcase to proper oil level. b) Air in the line. b) Bleed the air from the fuel line. c) Out of fuel. c) Fill fuel tank. d) Battery is defective. -
Page 34: Summary Of Important Safety Information For Operation
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. WARNING Carefully read and make sure you understand the following safety information before using the generator. - 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. •...
- Page 36 Summary of Important Safety Information for Operation (cont’d) Diesel Fuel Safety Standard diesel fuel is combustible (with ethanol-diesel blends being nearly as flammable as gasoline). You can be burned or seriously injured when handling diesel fuel. Use extreme care when handling: •...
- Page 37 Summary of Important Safety Information for Operation (cont’d) • 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 condition and not worn, bare, frayed, or otherwise damaged. Use of inadequate or damaged electric cords can cause electric shock or fire.
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Page 38: Generator Exploded View
Generator Exploded View Rev – R... - Page 39 Generator Exploded View Rev – R Diag # Part # Description 33321 Fuel Cap 38761 Fuel Tank Assembly 38217 Decal 35369 Cradle 30754 Leather Washer 777108 Battery Cable, Black 32839 Battery Cable, Red 777352 Battery Box with Hold Down Strap 779396 Battery Warning Decal 780120...
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Page 40: Wiring Diagram
Wiring Diagram Rev – R Diag # Part # Description 31594 Control Panel Graphics 30644 Voltmeter 31211 Circuit Breaker Mounting Clip 31085 Thermal Circuit Breaker, 20 Amp 31005 Thermal Magnetic Circuit Breaker, 30 Amp 31344 Ground Fault Current Interrupt (GFCI) Receptacle 306423 Locking device Receptacle, 30 Amp-120 Volt 306422... -
Page 41: Generator Head Exploded View
Generator Head Exploded View Rev – R Item # Part # Description 780228 Mount Plate (J609B) 779556 Fan Bolts 779557 781479 Drive End Bracket 38270 Enclosing Band 777304 End Cover 38271 End Cover Plug 780142 Stator 780229 Rotor 307479 Diode 780143 Securing Stud + Nut 38276... - Page 42 This page has intentionally been left blank.
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Page 43: Limited Warranty
Limited Warranty Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. - Page 44 ® Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...