North Star M165955A Owner's Manual

Portable, outdoor use-only, dual fuel generator

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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Dual Fuel Generator
Can be used to power individual appliances plugged directly into the generator's outlets, or as a back-up
connection to a building's power supply (via a professionally installed UL-listed transfer switch).
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 at least 20 feet from the home, away from windows, vents and air intakes, to
allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to
fresh air RIGHT AWAY. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes,
basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These spaces can trap poisonous gases, EVEN if
you run a fan or open windows.
 Carbon monoxide is given off whether you are using natural gas or propane to power the generator.
 Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
 High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly
grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.
 NEVER plug the generator directly into a wall outlet. ANY connection to a building's electrical system MUST
ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-listed transfer switch installed by a licensed
electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.
 DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so
engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7 feet from all combustible objects.
 All fuels are flammable. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
 LP/NG hook-ups must be completed by a certified gas technician and comply with all federal and local requirements.
 ALWAYS keep a fire extinguisher rated "ABC" nearby.
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the "Power Load Planning & Management" section
of this manual to determine your power load requirements and then compare to the generator's rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the "Unpacking
& Delivery Inspection" section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of transfer switch and/or NG/LP hook-ups, if they will be used.
See the "Installation/Initial Set-Up" section for more information about these requirements.
ADD ENGINE OIL: Engine is shipped without oil. See engine manual for instructions on capacity and viscosity
recommendations.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165955A
ITEM NUMBER: 165955, 165956
SERIAL NUMBER: _____________
WARNING
CO Poisoning
Fire / Explosion
STOP!

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  • Page 1 M165955A ITEM NUMBER: 165955, 165956 SERIAL NUMBER: _____________ Owner's Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Dual Fuel Generator Can be used to power individual appliances plugged directly into the generator's outlets, or as a back-up connection to a building's power supply (via a professionally installed UL-listed transfer switch).
  • 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 ..................13 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 its rated amount of electrical power. (See specifications section of this manual for model specific ratings) It can supply power: 1.
  • Page 5: Warranty Registration

    About Your Generator (cont’d) generator unassisted. Other optional accessories available from NorthStar include a cover for storage, UL-listed transfer switches, and extension cords. Contact NorthStar Product Support at 1-800-270-0810 with questions about optional accessories or to order. Read this Manual WARNING Improper use or maintenance of this generator can result in serious injury or death from carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.
  • Page 6: Specifications

    Specifications SPECIFICATIONS Item Number 165956 165955 Maximum Output 10,000 Watts (W) 13,000 Watts (W) Continuous Output: Liquid Propane Gas (LP) 9,450 Watts (W) 12,150 Watts (W) Natural Gas (NG) 8,400 Watts (W) 10,800 Watts (W) Voltage 120 / 240 Volt (V) 120 / 240 Volt (V) Phase Single phase (4-wire)
  • Page 7: Safety Label Locations

    Safety Label Locations WARNING - BATTERY HAZARDS BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause 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.
  • Page 8: Machine Component Identification

    Machine Component Identification Ref. Description Ref. Description Air Cleaner Generator Head Engine Key Switch Fuel Inlet Oil Drain Plug Vibration Isolation Mount Oil Fill Port LP/NG Regulator Assembly Kit Battery (not included) Muffler Control Panel...
  • Page 9 Machine Component Identification REFERENCE GUIDE Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care. Reference 2 – Engine Key Switch The engine key switch is located on the engine. Always locate this switch and be familiar with its location before operating the generator.
  • 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 Watts Starting Watts Device (Continuous) (Surge) Deep Freezer 1000 Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) 1500 1500 Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles 2500 Electric Fry Pan 1300...
  • Page 12 Power Load Planning & Management (cont’d) 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.
  • Page 13: 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 14: Gas Hook-Up Installation For Natural Gas Or Propane (Lp)

    Installation / Initial Set-Up 3. Gas Hook-up Installation for Natural Gas or LP You can power this generator with natural gas (NG) or liquid propane gas (LP). However, there are special initial hook-up requirements for natural gas and propane: WARNING: You must have the fuel line system installed by a certified gas technician for NG or LP.
  • Page 15 Installation / Initial Set-Up Natural Gas (NG) Contact your gas utility company for installation of a natural gas hook- Requirement up for the generator. WARNING: Natural gas is a highly explosive gas. All natural gas hook-ups must be completed by trained personnel from your natural gas utility company and inspected as required by your local building code.
  • Page 16: Set-Up As A Portable Or Building Back-Up Power Source

    Installation / Initial Set-Up  You will need a minimum 100 lb. LP gas tank to operate the generator. This generator will not work with 20-lb gas cylinders used in gas grills and recreational equipment, or 40-lb gas cylinders used in forklifts and tractors.
  • Page 17 Installation / Initial Set-Up 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.
  • Page 18 Installation / Initial Set-Up Item # 165956 Item # 165955 1. Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet. 2.
  • Page 19: Selecting A Suitable Site

    Installation / Initial Set-Up Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga. 240V (watts) Cord Cord Cord Cord 2400 250' 150' 100' 4800 125' 7200 9600 12000 WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.
  • Page 20 Installation / Initial Set-Up  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. ...
  • Page 21 Installation / Initial Set-Up  Make sure your generator's exhaust system is at least 7 feet from all combustible materials and 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.
  • Page 22: Grounding The Generator

    Installation / Initial Set-Up 6. 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 3/4" or 1" copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –...
  • Page 23: Battery Installation

    Installation / Initial Set-Up 7. Battery Installation Your generator's engine is equipped with an electric starter, which requires the installation of a 12- volt battery. 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 with the tie plate near the engine.
  • Page 24: 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 25: Preparing For Operation

    Operation (cont’d)  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. Always discharge the capacitor before working on the generator head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on how to do this.) ...
  • Page 26 Operation (cont’d) Ground generator Make sure the generator is grounded in accordance with instruction given in "Installation & Initial Set-up, Step 6: Grounding the Generator" of this manual. WARNING: Electric shock hazard Always ensure generator is properly grounded to prevent electrical shock. Perform scheduled Make sure that any regular maintenance has been performed as maintenance as...
  • Page 27 Operation (cont’d) Inspect Fuel Inspect fuel system & check for leaks BEFORE starting generator. Do not start generator until all needed repairs have been completed. System / Check for Leaks WARNING: Fuel leak hazard LP gas (propane) and NG (natural gas) are highly explosive and fuel leaks can result in fire or explosions.
  • Page 28: 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. The following directions detail how to start the engine with either LP/NG as the fuel source: Using LP/NG To start engine using LP or Natural Gas: WARNING: DO NOT start engine if you smell gas.
  • Page 29: Connecting Loads

    Operation (cont’d) All engines have a tendency to slow down when a load is applied. When NOTE: electrical loads are connected to the generator, the engine is more heavily Slight variation in voltage/speed with loaded and as a result the speed drops slightly. changing electrical This slight decrease in speed, together with the voltage drop within the loads...
  • Page 30: Stopping

    Operation (cont’d) 6. Stopping Stop the engine using the following steps: 1. Disconnect all loads to the generator. 2. Turn engine key switch to OFF position. 3. The fuel lock-off solenoid automatically stops the flow of LP or NG to the engine. 4.
  • Page 31 Operation (cont’d) 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.
  • Page 32: 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 33 Maintenance & Repair (cont’d) Inspect fuel system / Inspect the fuel system and check for leaks on a regular basis. check for leaks 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.
  • Page 34: Troubleshooting

    Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. a) Fill crankcase to proper oil level. b) Fouled spark plug. b) Clean or replace spark plug. c) No fuel supplied. c) Check fuel supply. d) Stop switch in OFF position.
  • Page 35: 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 36 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 37 Summary of Important Safety Information for Operation (cont’d) Personal protective equipment  Hearing protection. The use of earplugs 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.
  • Page 38 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.
  • Page 39: Generator Exploded View

    Generator Exploded View Rev - A...
  • Page 40 Generator Exploded View Rev - A Ref # Part # Description Used on 791096 Decal, Side 791097 165956 Decal, End 791095 165955 790846 Roll cage 790894 165956 LP/NG Regulator Assembly Kit 790893 165955 790844 Regulator Bracket 32821 Lanyard 791083 LP/NG Hang Tag 783250 Header assembly, muffler 783260...
  • Page 41: Generator Control Panel View

    Generator Control Panel View Rev - A Ref # Part # Description Used on 783058 300V Volt Meter 783061 20 AMP Circuit Breaker 783050 NEMA L14-30 Receptacle 783053 NEMA 5-20 Receptacle (4) duplexes 783091 30 AMP Circuit Breaker 783085 NEMA L5-30 Receptacle 31953 14-50 Receptacle 165956...
  • Page 42: Generator Head Exploded View

    Generator Head Exploded View Rev - A...
  • Page 43 Generator Head Parts List Rev - A Item # Part # Description Used On MA30991 Drive End Bracket MA30994 Protection Screen MA31013 Phillips Screw MA30995 307489 Grommet 305605 Terminal Box Cover w/grommet M5 X .8, 16mm Long M5 X .8, 10mm Long, Green MA31015 M5 X .8, 10mm Long Rubber Cup...
  • Page 44: 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 45 This page left intentionally blank...
  • Page 46 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com...

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