MODEL 5500 BDG, ITEM #165913
Belt Driven Generator
M165913B
P r o v e n P e r f o r m a n c e
OWNER’S MANUAL
Any Questions, Comments, or Problems?
Call Customer Service at 1-800-270-0810
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SPECIFICATIONS
Item Number
Maximum Output
Continuous Output
Voltage
#165913
5500 Watts (W)
5000 Watts (W)
120 / 240 Volt (V)
Phase
Frequency
Power Factor
Engine
Engine Speed
120 VReceptacle
Single phase (4-wire)
59.0-62.0 Hertz (Hz)
100 %
11 hp max., 9 hp recommended
3540-3720 RPM
20 Amp (A) duplex
(NEMA 5-20R)
240 VReceptacle
20 Amp (A) Locking Device
(NEMAL6-20R)
Circuit Breaker
Dimensions
Length
Width
Height
20 Amp (A) thermal, push to reset style
16.25” (413 cm)
7.25” (184 cm)
7.75” (197 cm)
53 lb. (24.1 kg)
Gross Weight
.
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MACHINE COMPONENT IDENTIFICATION
Figure 1 (Ref. 1-4)
00041
Ref. Description
Ref. Description
1
2
3
4
Circuit Breakers
5
6
7
7/8” shaft
120V 20A Duplex Receptacle
240V 20A Locking Receptacle
Grounding screw
Mounting feet
Fan vents
Figure 2 (Ref. 5-7)
00042
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WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a
death or seri ous i nj ury.
GENERATOR FEATURES
Reference 1 - Circuit Breakers. This belt driven
single phase generator has 2, 20 amp (A) push to
reset circuit breakers to protect against electrical
overloads.
CAUTION indicates a potentially hazardous
situation, which if not avoided, may result in minor or
moderate injury. It may also be used to alert against
unsafe practices.
Receptacles
Reference 2 - 120V Receptacle. The generator
has an end cover with one duplex (two receptacles in
a common housing) receptacle and one locking device
receptacle. The duplex is a 120 volt (V) 20 amp (A)
RULES FOR SAFE OPERATIONS
straight blade
receptacle,
National
Electrical
Safety precautions are essential when operating
this generator. Respectful and cautious operation will
considerably lessen the possibilities of a personal
injury. This manual will warn of specific personal injury
potential, and these will be designated by the symbol:
Manufacturer’s Association (NEMA) number 5-20R.
This receptacle accepts NEMA plug numbers 5-15P
and 5-20P. Each receptacle on the duplex is capable
of drawing 20A.
Reference 3 - 240V Receptacle. The locking
device is a 240V 20A NEMA L6-20R receptacle. This
receptacle accepts a NEMA plug number L6-20P.
ALWAYS use grounded male plugs. The neutral
line of the generator is mechanically grounded to the
frame. Matching NEMA male plugs must always be
used.
Reference 4 - Ground Screw.
generator via the ground screw, to a copper pipe or
rod that is driven into moist soil.
Reference 5 - 7/8” diameter Shaft. The shaft is
1.50” long and has a 3/16” keyway.
WARNING This generator is equipped
with a grounding screw, located on the generator
Ground the
frame for your protection.
Always complete the
grounding path from the generator to a copper
pipe/rod that is driven into moist earth, to prevent
electrical shock.
Reference 6 - Mounting feet. Use these three
locations to bolt the generator head in place.
Reference 7 - Fan Vents. Never block the vent
sl ots or i nsert objects through the sl ots.
ALWAYS use electrical cords that are in good
condition. Worn, bare, frayed or otherwise damaged
cords can cause electric shock.
INTRODUCTION
NEVER 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.
Before attempting to mount your generator,
thoroughly study the instructions and cautions in this
manual to assure you are fully acquainted with the
operation of all components of this generator. Proper
preparation, operation and maintenance will result in
operator safety, best performance and long life of the
generator.
ALWAYS use a ground fault circuit interrupter
(GFCI) in damp or highly electrical conductive areas
and on construction job-sites to prevent electric shock.
North Star is constantly improving its products.
The specifications outlined herein are subject to
ALWAYS remove the spark plug or spark plug
wire before working on the engine or generator, this
prevents accidental starting.
change without prior notice or obligation.
The
purchaser and/or user assumes liability of any
modification and/or alterations on 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.
ALWAYS provide adequate ventilation. Do not
operate generator in any enclosed or narrow space.
Engines consume oxygen and give off deadly carbon
monoxide, a poisonous gas. Improper ventilation will
cause damage to generator and possible injury to
people.
ANSI SAFETY DEFINITIONS
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
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ALWAYS remove all oil or gasoline deposits
and accumulated dirt from generator and immediate
area. Keep generator head and engine clean.
NEVER operate the generator under the
following conditions:
A. Excessive change in engine speed, slow or
fast.
B. Overheating in load connecting devices.
C. Sparking or arcs from generator.
D. Loss of electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
H. Enclosed compartments, or confined
areas.
I. Flame or smoke.
J. Rain, snow or wet conditions.
K. Operator non-attendance.
WARNING Keep fire extinguisher
The shaft speed of the generator must be between
3540-3720 RPM. At no load the correct speed is 3720
RPM. If the engine is a 3600 RPM engine, then a
sheave diameter ratio of 1:1 should be used. This
means that the diameter of the sheave on the engine
is the same as the diameter of the sheave on the
generator. If smaller than recommended sheaves are
used, the life of the belt will be shortened. The
possibility of belt slippage also increases with a
smaller sheave.
The engine and generator should be mounted to a
plate or surface that can withstand the constant
vibration and stresses that will be produced. See figure
3 for a possible mounting configuration.
The user shall determine the proper belt
tensioning method for their specific use.
close by your generator and be familiar with how to
use it. Consult your local fire department for correct
extinguisher type.
INSTALLATION
OUTDOORS:
Choose a location where the
generator will not be exposed to rain, snow or direct
sunlight. Position the generator on secure, level
ground so it will not tip or slide down a hill. Place the
generator so that the exhaust fumes will not be
directed towards people.
The installation site must be free from water,
moisture, or dust. All electrical components should be
protected from excessive moisture or the insulation
system will deteriorate and result in grounding or
shorting out the generating system.
Foreign matters, such as dust, dirt, sand, lint, or
abrasive materials can cause damage to the generator
head and engine if allowed into its cooling system.
POWER TRANSMISSION: The recommended
method to transfer the power from the engine to the
generator is by using sheaves (pulleys) and a V-belt.
The generator shaft is 7/8” diameter X 1.50” long with
a 3/16” keyway. Use the table below to select the
correct diameter sheave. Note that a notched V-belt
requires only one sheave while the standard V-belt
requires 2 side by side sheaves and 2 V-belts. All V-
belts have a B size cross section.
To determine belt tension:
Measure L - the center
to center distance of the
two sheaves
Measure d - the
deflection of the belt.
Tighten or loosen belt
until:
d = 0.016 X L
00039
If you desire to direct couple the generator to the
engine, great care must be taken to align the shaft of
the generator and engine to within the specified
tolerances of the chosen coupler.
Single Sheave Dia. Double Sheave Dia.
Engine hp
Belt Type - Qty.
Belt Type - Qty.
5.00”
Notched V-Belt - 1
5.80”
4.60”
V-Belt - 2
5.00”
NEVER install your generator inside confined
areas. Inside installation can cause health hazards or
death.
9 hp
11 hp
Notched V-Belt - 1
V-Belt - 2
DANGER Always have proper guarding
on the V-belt and sheaves to prevent access to any
pinch points. Failure to guard the power transmission
mechanisms may result in serious injury or death.
Figure 3
00038
Note: Guards are removed to show details.
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Cooling air of sufficient amounts must be brought in
and exhausted out to ensure proper cooling of the
engine and generator.
Repulsion-Induction (RI), Capacitor (Cap), or Split-
Phase (SP) type.
The following chart shows the approximate
current required to start and run various types and
sizes of 120 volt 60 cycle electric motors under various
conditions.
DANGER Remember, exhaust fumes are
deadly carbon monoxide gas, and must be vented to
the outside where there are no people.
Starting Amps
RI type Cap type SP type
120V, 60 Hz Motors
Hp motor Running
Watts
1/6
1/4
1/3
1/2
1
1 1/2
2
3
525
700
875
1175
1925
2400
2900
4075
6750
7-11
9-15
9-18
12-23
14-29
20-40
32-64
40-80
48-96
68-136
112-224
16-22
22-32
26-35
NA
NA
NA
NA
NA
NA
LOAD APPLICATION
11-18
15-25
24-40
30-50
36-60
51-85
84-140
It is important to determine the total electrical load
before it is connected to the generator. The two major
factors in determining the life of a generator head are:
heat build up, caused by overloading the generator,
and corrosive contaminants that attack the wiring
insulation. If the generator is overloaded, the wires
become excessively hot and cause the insulation to
break down, reducing its ability to resist corrosive
contaminants. Over time the effectiveness of the
insulation is eliminated and a dead short can result.
Always compare the generator nameplate data
with that of the equipment to be used to ensure that
watts, volts, amperage, and frequency requirements
are suitable for operating equipment. The wattage
listed on the equipment nameplate is its rated output.
However, some equipment may require three to ten
times more wattage than its rating on the nameplate,
as the wattage is influenced by the equipment
efficiency, power factor and starting system. NOTE: If
wattage is not given on equipment nameplate,
approximate wattage may be determined by
5
The figures given above are for an average load
such as a blower or fan. If the electric motor is
connected to a hard starting load such as an air
compressor, it will require more starting current. If it is
connected to a light load or no load such as a power
saw, it will require less starting current. The exact
requirement will also vary with the brand or design of
the motor.
Generators respond to severe overloading
differently than the power line. When overloaded, the
engine is not able to supply enough power to bring the
electric motor up to operating speed. The generator
responds to the high initial starting current, but the
engine speed drops sharply. The overload may stall
the engine. If allowed to operate at very low speeds,
the electric motor starting winding will burn out in a
short time. The generator head winding might also be
damaged.
multiplying
amperage.
nameplate voltage by nameplate
VOLTS X AMPS = WATTS
Example: 120V X 5A
= 600W
Running the generator under these conditions may
result in damage to the generator stator as well as the
electric motor windings. Because the heavy surge of
current is required for only an instant, the generator
will not be damaged if it can bring the motor up to
speed in a few seconds. If difficulties in starting a
motor are experienced, turn off all other electrical
loads and if possible reduce the load on the electric
motor.
When connecting a resistive
load such as
incandescent lights, heaters or common electric power
tools, a capacity of up to the generator full rated
wattage output can be used.
When connecting a resistive-inductive load such
as a fluorescent or mercury light, transformers or
inductive coils, a capacity of up to 0.6 times the
generator’s full rated output can be used.
Always allow the generator to reach operating
speed before a load is applied.
EXTENSION CORDS
STARTING ELECTRIC MOTORS
When electric power is to be provided to various
loads at some distance from the generator, extension
cords can be used. These cords should be sized to
allow for distance in length and amperage so that the
voltage drop between the set and point of use is held
to a minimum.
Electric motors require much more current (amps)
to start than to run.
Some motors, particularly low cost split-phase
motors, are very hard to start and require 5 to 7 times
more current to start than to run. Capacitor motors are
easier to start and usually require 2 to 4 times as much
current to start than to run. Repulsion Induction
motors are the easiest to start and require 1.5 to 2.5
times as much to start than to run.
Most fractional motors take about the same
amount of current to run them whether they are of
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Submersible Pump (1/2 HP)
Sump Pump
Table Saw (10”)
Television
Toaster
Vacuum cleaner
VCR
Water Heater
Weed Trimmer
1500 (a)
600 (a)
2000 (a)
500
1000
250
70
3000
500
Current/Power Maximum Extension Cord Length
Amps
at
Load
(watts)
#10
Ga.
#12
Ga.
#14
Ga.
#16
Ga.
240V
Cord
Cord
Cord
Cord
10
20
30
40
50
2400
4800
7200
9600
12000
250’
125’
60’
30’
15’
150’
75’
35’
15’
*
100’
50’
25’
10’
*
75’
25’
10’
*
*
(a) Hard-starting motors require 3 to 5 times the
rated running watts.
(b) These loads may require up to 15 minutes to
restart due to its normal build up of compressor head
pressure.
*Not recommended
CAUTION: Equipment damage can result from the
low voltage caused by using an extension cord with a
sm all wi re si ze.
NOTE: For extremely hard to start loads such as
air conditioners and air compressors, consult the
equipment dealer to determine the maximum wattage.
Use this chart to estimate the total load on your
generator.
For Determining Generator Load Requirements
Device
Running Watts
1700 (a)
500
PRE-START PREPARATIONS
Air Conditioner (12,000 Btu)
Battery Charger (20 Amp)
Belt Sander (3”)
Chain Saw
Circular Saw (6-1/2”)
1000
1200
900
1000
2000 (a)
1800 (a)
1400 (a)
700
Your generator has been thoroughly tested prior to
shipment from the factory. A factory test report has
been included with this manual. However, damage
can occur during shipping, so be sure to check for
damaged parts, loose or missing nuts and bolts. If the
aforementioned problems occur, call customer service
at 1-800-270-0810.
Coffee Maker
Compressor (1 HP)
Compressor (3/4 HP)
Compressor (1/2 HP)
Curling Iron
Dishwasher
Edge Trimmer
Electric Nail Gun
Electric Range (one element)
Electric Skillet
Furnace Fan (1/3 HP)
Freezer
1200
500
1200
1500
GROUNDING - All units must be grounded. Drive
a 3/4” or 1” copper pipe or rod into the ground close to
the generator. The pipe/rod must penetrate moist
earth. Connect an approved ground clamp to the pipe.
Run a 12 gauge wire from the clamp to the generator
ground screw. Do not connect to a water pipe or a
ground used by a radio system.
1250
1200 (a)
800 (b)
1200
Hair Dryer
Hand Drill (1”)
Hand Drill (1/2”)
1100
875
OPERATING SPEED
Hand Drill (3/8”)
Hand Drill (1/4”)
Hedge Trimmer
Home Computer
Impact Wrench
Jet Pump
Lawn Mower
Light Bulb
Microwave Oven
500
250
450
150
500
800 (a)
1200
100
700
1100 (a)
300
400
225
150
4500
The generator must be run at the correct speed in
order to produce the proper electrical voltage and
frequency.
The output voltage should be checked to ensure
the generator is working properly subsequent to
connecting a load to the generator. Failure to do so
could result in damage to equipment plugged into the
unit and possible injury to the individual.
All engines have a tendency to slow down when a
load is applied. When the electrical load is 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. The slight
variation has no appreciable effect in the operation of
motors, lights and most appliances. Electronic
equipment and clocks will be affected if correct RPM is
not maintained. See Load vs. Output chart.
Milk Cooler
Oil Burner on Furnace
Oil Fired Space Htr (140,000 Btu)
Oil Fired Space Htr (85,000 Btu)
Oil Fired Space Htr (30,000 Btu)
Oven
Paint Sprayer, Airless (1/3 HP)
Paint Sprayer, Airless (hand held)
600 (a)
150
Load Requirements Continued
Radio
Refrigerator
200
600 (b)
200
Slow Cooker
Submersible Pump (1-1/2 HP)
Submersible Pump (1 HP)
2800 (a)
2000 (a)
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Load
Output
Frequency
Percent of
Generator
Output
Speed
(RPM)
Generator
voltage at 120V
Receptacle
WARNING, Stand-by Operation
(Hz)
If your generator is to be used as a standby
electric power source in case of utility failure, it must
be installed by a registered and licensed electrician
and in compliance with all applicable state and local
electrical codes. Also, local Fire Departments must be
consulted concerning proper and safe handling
procedures for gasoline. NEVER connect any
generator to any existing electrical system without an
isolating, UL approved transfer switch, installed by a
licensed electrician.
0 %
50 %
100 %
3720
3600
3540
62.0
60.0
59.0
129V
120V
115V
Output voltage should be checked periodically to
ensure continued proper operation of the generating
plant and appliances, it can be checked with a portable
meter. Frequency can be checked by using an electric
clock with a sweep second hand.
Timed against a wrist watch or a stop watch the
clock should be correct within +/- 2 seconds per
minute. All speed setting adjustments should be done
by a qualified technician.
GENERATOR CARE
The generator head is a two pole, 3600 RPM, 60
Hz, brushless, revolving field and synchronous type
with two sealed radial roller bearings.
Proper care and maintenance are necessary to
ensure a long trouble free life.
Exercising The Generator - The generator
should be operated every four weeks. Warm the
unit up by starting the engine and letting it run for 10 to
15 minutes. This will dry out any moisture that has
accumulated in the windings. If left, this moisture can
cause corrosion in the winding. Frequent operation of
the engine generator will also ensure that the set is
operating properly should it be needed in an
emergency.
Generator Maintenance - The generator head is
brushless and maintenance free. Any major generator
service including the installation or replacement of
parts should be performed only by a qualified electrical
service technician.
USE ONLY FACTORY
APPROVED REPAIR PARTS.
A. Bearing - The bearings used in this generators
are a heavy duty, sealed roller bearing. They require
no maintenance or lubrication.
B. Receptacles - Quality receptacles have been
utilized. If a receptacle should become cracked or
otherwise damaged, replace it. Using cracked or
damaged receptacles can be both dangerous to the
operator and destructive to the equipment.
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TROUBLESHOOTING
Problem
Possible Causes
Possible Remedies
Voltage too low.
a) Engine speed too slow.
a) Bring generator to a qualified
technician for adjustment.
b) Generator is overloaded.
b) Reduce the load. (See Load
Application section of this manual.)
a) Disconnect load.
Circuit breaker trips.
a) Defective load connected to generator.
b) Defective receptacle.
b) Replace receptacle.
c) Generator overloaded.
c) Reduce the load. (See Load
Application section of this manual.)
a) Bring generator to a qualified
technician for adjustment.
Voltage too high.
a) Engine speed too high.
Generator overheating. a) Generator is overloaded.
b) Insufficient ventilation.
a) Reduce the load. (See Load
Application section of this manual.)
b) Make sure there is at least 3 feet of
clearance on all sides of generator.
a) Disconnect load.
No output voltage.
a) Defective load connected to generator.
b) Broken or loose wire.
b) Bring generator to a qualified
technician for repair.
c) Defective receptacle.
d) Defective stator.
c) Replace receptacle.
d) Bring generator to a qualified
technician for repair.
e) Bring generator to a qualified
technician for repair.
e) Defective rotor.
f) Defective capacitor.
a) Generator is overloaded.
b) Dirty air filter.
f) Bring generator to a qualified
technician for repair.
a) Reduce the load. (See Load
Application section of this manual.)
b) Clean or replace air filter.
Engine lacks power.
9
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