NorthStar 165165 Product manual

Manual is about: Portable, Outdoor Use-Only, Industrial Diesel Generator 6,120 Watt Continuous (6,500 Watt Surge) Capacity 1 / 44

Summary of 165165

  • Page 1

    M165165a.2 owner’s manual 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 ...

  • Page 2

    Hazard signal word definitions 2.

  • Page 3

    Table of contents 3 hazard signal word definitions ................................................................................................. 2 about your generator ................................................................................................................. 4 specificatio...

  • Page 4: About Your Generator

    About your generator 4 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. Yo...

  • Page 5: Warranty Registration

    About your generator (cont’d) 5 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...

  • Page 6: Specifications

    Specifications – item #165165a 6 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 engine speed 3600 rpm fuel type di...

  • Page 7

    Safety label locations – item #165165a 7 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...

  • Page 8

    Machine component identification - item #165165a 8 figure 1 (ref. 1-13) ref. Description ref. Description 1 main line breaker 11 oil fill and dip stick 2 thermal circuit breakers 12 air cleaner housing 3 voltmeter 13 decompression lever 4 120 volt-20 amp gfci duplex receptacles 14 muffler 5 hour met...

  • Page 9: Reference Guide

    Machine component identification - item #165165a 9 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 tog...

  • Page 10

    Power load planning and management 10 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 (surg...

  • Page 11

    Power load planning and management (cont’d) 11 device running watts device running 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 sump pump 600 (a) hand ...

  • Page 12

    Installation / initial set-up 12 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. 3. Settin...

  • Page 13

    Installation / initial set-up 13 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 ...

  • Page 14

    Installation / initial set-up 14 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 with...

  • Page 15

    Installation / initial set-up 15 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 am...

  • Page 16

    Installation / initial set-up 16 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 a...

  • Page 17

    Installation / initial set-up 17 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 a...

  • Page 18

    Installation / initial set-up 18 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...

  • Page 19

    Installation / initial set-up 19 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 g...

  • Page 20

    Operation 20 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. Starting the engine 4. C...

  • Page 21

    Operation (cont’d) 21 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 tur...

  • Page 22

    Operation (cont’d) 22 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 ...

  • Page 23

    Operation (cont’d) 23 2. Preparing for operation position generator position generator in accordance with the instructions given in “installation and initial set-up, step 4: select a suitable site” of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. Wa...

  • Page 24

    Operation (cont’d) 24 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 en...

  • Page 25

    Operation (cont’d) 25 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. Fuel soaked ra...

  • Page 26

    Operation (cont’d) 26 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 th...

  • Page 27

    Operation (cont’d) 27 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...

  • Page 28

    Operation (cont’d) 28 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 g...

  • Page 29: Push

    Operation (cont’d) 29 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. 3. Turn engine starting key to off position. 4. Turn fuel line shut-off valve to off position as s...

  • Page 30

    Operation (cont’d) 30 disconnect loads and turn off fuel supply 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 are disconnected. 2. Check to be sure fuel line shut-off valve is in off p...

  • Page 31

    Maintenance and repair 31 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 clean...

  • Page 32

    Maintenance and repair (cont’d) 32 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 t...

  • Page 33: Troubleshooting

    Troubleshooting 33 troubleshooting problem possible causes possible remedies engine will not start. A) air in the line. B) out of fuel. C) battery is defective. D) fuel filter clogged. E) fuel shut off valve is in the off position. F) engine fuse is blown. A) bleed the air from the fuel line. B) fil...

  • Page 34

    Summary of important safety information for operation 34 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 carefu...

  • Page 35

    Summary of important safety information for operation (cont’d) 35 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 – dan...

  • Page 36

    Summary of important safety information for operation (cont’d) 36 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: fuel outdoors...

  • Page 37

    Summary of important safety information for operation (cont’d) 37 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 da...

  • Page 38

    Generator exploded view rev – a.2 38.

  • Page 39

    Generator exploded view rev – a.2 39 diag # part # description qty 1 33321 fuel cap 1 2 788319 fuel tank assembly 1 3 791697 decal 1 4 791640 cradle 1 5 31881 heat protective wrap 26" 6 777108 battery cable, black 1 7 791652 battery cable, red 1 8 777352 battery box with hold down strap 1 9 779396 b...

  • Page 40

    Wiring diagram rev – a.2 40 diag # part # description qty 1 791644 control panel graphics 1 2 30644 voltmeter 1 3 31211 circuit breaker mounting clip 4 4 31085 thermal circuit breaker, 20 amp 2 5 31005 thermal magnetic circuit breaker, 30 amp 1 6 31344 ground fault current interrupt (gfci) receptacl...

  • Page 41

    Generator head exploded view rev – a.2 41 item # part # description qty 1 780228 mount plate (j609b) 1 2 779556 fan bolts 2 3 779557 fan 1 4 781479 drive end bracket 1 5 ma38270 enclosing band 1 6 788185 end cover 1 7 ma38271 end cover plug 1 8 780142 stator 1 9 780229 rotor 1 10 ma307479 diode 2 11...

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    42 this page has intentionally been left blank..

  • Page 43: Limited Warranty

    Limited warranty 43 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 al...

  • Page 44

    44 assembled by northern tool & equipment co., inc. Burnsville, mn 55306 northerntool.Com.