Table of Contents
Advertisement
Quick Links
Instructions for Installation/Set-up, Operation, Servicing, and 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-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 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-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. 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 and 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
and 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
M165165A.2
ITEM NUMBER: 165165
SERIAL NUMBER: _____________
WARNING
CO Poisoning
Fire / Explosion
STOP!
Advertisement
Table of Contents
Summary of Contents for NorthStar 165165
- Page 1 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
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 and Management ..................10 Installation / Initial Set-Up: 1. Unpacking and Delivery Inspection ..................12 2. -
Page 4: About Your Generator
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 vinyl cover for storage, UL-listed transfer switches, and extension cords. -
Page 5: Warranty Registration
For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator. NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture. -
Page 6: Specifications
Specifications – Item #165165A SPECIFICATIONS Item Number 165165 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 9.4 HP Kubota OC95... -
Page 7: Safety Label Locations
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. On-Product Warning Labels... -
Page 8: Machine Component Identification
Machine Component Identification - Item #165165A Figure 1 (Ref. 1-13) Ref. Description Ref. Description Main Line Breaker Oil Fill and Dip Stick Thermal Circuit Breakers Air Cleaner Housing Voltmeter Decompression Lever 120 Volt-20 Amp GFCI Duplex Receptacles Muffler Hour Meter Ignition Fuse Engine Stop Lever Isolation Mounts... - Page 9 12 volt battery, with a minimum rating of 36 Ah (Amp-hour). battery section for sizing. Reference 18 – Generator Head Your NorthStar product is equipped with a high quality brushless generator. The generator is maintenance free and will provide years of dependable service.
-
Page 10: Power Load Planning And Management
Power Load Planning and 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 and 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...
-
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 and delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. -
Page 13: Set-Up As Either A Building Back-Up Or Portable Power Source
Installation / Initial Set-Up 3. Set-up as either 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-listed 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.
-
Page 16: Selecting A Suitable Site
Installation / Initial Set-Up 4. Selecting 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. ...
-
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) 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 ...
- Page 22 Operation (cont’d) 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. 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: ...
-
Page 23: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation and Initial Set-up, Step 4: Select a Suitable Site” generator of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. - Page 24 Operation (cont’d) ethanol-diesel (e-diesel) blends, which are more flammable than standard diesel and nearly as flammable as gasoline. Carefully follow all the instructions in this section to avoid the following conditions which could result in fuel vapor ignition: gas vapor collection inside enclosures ...
- Page 25 Operation (cont’d) because it dissipates charge to ground more readily. 5) Clean up fuel spills /splashes immediately. If possible, move the generator away from spilled fuel on the ground. Wipe up spilled fuel, and wait 5 minutes for excess fuel to evaporate before starting engine.
-
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 as shown. The fuel valve is located underneath the fuel tank. -
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: Stopping The Engine
Operation (cont’d) 6. Stopping the Engine Stop the engine using the following steps: 1. Disconnect all loads to the generator. 2. Press red stop lever on engine and hold until the engine shuts down. PUSH fig05699 3. Turn engine starting key to OFF position. 4. - Page 30 Operation (cont’d) Disconnect loads When you are finished using the generator, disconnect all loads and and turn off fuel turn off fuel supply: supply 1. Make sure all devices that were connected to the generator’s outlets are disconnected. 2. Check to be sure fuel line shut-off valve is in OFF position. Cool engine before Let engine cool for at least five minutes before storing.
-
Page 31: Maintenance And Repair
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. - Page 32 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 NorthStar 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.
-
Page 33: Troubleshooting
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Air in the line. a) Bleed the air from the fuel line. b) Out of fuel. b) Fill fuel tank. c) Battery is defective. c) Charge or replace battery. d) Fuel Filter clogged. -
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.
-
Page 38: Generator Exploded View
Generator Exploded View Rev – A.2... - Page 39 Generator Exploded View Rev – A.2 Diag # Part # Description 33321 Fuel Cap 788319 Fuel Tank Assembly 791697 Decal 791640 Cradle 31881 Heat Protective Wrap 26" 777108 Battery Cable, Black 791652 Battery Cable, Red 777352 Battery Box with Hold Down Strap 779396 Battery Warning Decal 780120...
-
Page 40: Wiring Diagram
Wiring Diagram Rev – A.2 Diag # Part # Description 791644 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 – A.2 Item # Part # Description 780228 Mount Plate (J609B) 779556 Fan Bolts 779557 781479 Drive End Bracket MA38270 Enclosing Band 788185 End Cover MA38271 End Cover Plug 780142 Stator 780229 Rotor MA307479 Diode 780143 Securing Stud + Nut MA38276... - Page 42 This page has intentionally been left blank.
-
Page 43: Limited Warranty
Transportation costs to and from service center is the responsibility of the customer. In addition to the normal warranty, NorthStar shall warrant any normal wear item from defects in material or workmanship for a period of 90 days from the date of purchase by user. - Page 44 Assembled by Northern Tool & Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.com...