North Star Portable Generator M165938N User Manual

M165938N  
ITEM NUMBER: 165938  
SERIAL NUMBER: _____________  
TM  
Owner’s Manual  
Instructions for Installation/Set-up, Operation, Servicing, & Storage  
Portable, Outdoor Use-Only, Triple Fuel Generator  
6,600 Watt Continuous (8,000 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.  
WARNING  
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:  
CO Poisoning  
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.  
Carbon monoxide is given off whether you are using gasoline, natural gas, or propane to power the generator.  
Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).  
Electric shock / Electrocution  
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.  
Fire / Explosion  
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.  
LPG/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.  
STOP!  
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/LPG hook-ups, if they will be used.  
See the “Installation/Initial Set-Up” section for more information about these requirements.  
Any Questions, Comments, Problems, or Parts Orders  
Call NorthStar Product Support 1-800-270-0810  
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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........................................................................................11  
Installation / Initial Set-Up:  
1. Unpacking & Delivery Inspection..........................................................................................13  
2. Planning the Power Load........................................................................................................13  
3. Gas Hook-up Installation for Natural Gas or Propane (LPG) – if using................................14  
4. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ......................................16  
5. Selecting a Suitable Site .........................................................................................................19  
6. Grounding the Generator........................................................................................................21  
7. Battery Installation .................................................................................................................22  
Operation:  
1. General Safety Rules for Operation .......................................................................................23  
2. Preparing for Operation..........................................................................................................26  
3. Starting the Engine .................................................................................................................30  
4. Checking Generator Output....................................................................................................32  
5. Connecting Loads...................................................................................................................33  
6. Switching Fuels (during operation)........................................................................................34  
7. Stopping the Engine ...............................................................................................................34  
8. Storage & Exercise.................................................................................................................35  
Maintenance & Repair..................................................................................................................37  
Troubleshooting.............................................................................................................................39  
Summary of Important Safety Information for Operation.......................................................40  
Generator Exploded View ............................................................................................................45  
Wiring Diagram.............................................................................................................................47  
Generator Head Exploded View ..................................................................................................48  
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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 8,000 Watts of  
electrical power (6,600 watts continuous, 8,000 watts surge).  
It can supply power:  
1. As a portable power source. You can plug appliances directly into the generator’s  
electrical outlets.  
2. As a back-up, standby power source for a building. A licensed electrician can connect  
the generator to your building’s electrical system via the installation of an UL-approved  
transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn  
more about specific requirements and precautions relating to wiring the generator to your  
building’s electrical system.)  
You must select a generator adequately sized for your power needs. You need to  
determine the power needs of all the appliances/tools you wish to power at the same time and  
choose a generator rated to provide at least that power level. See the “Power Load Planning &  
Management” section of this manual to determine your specific power load requirements and  
then compare them to this generator’s rated capacity. You must not overload the generator.  
Overloading will cause damage to the generator and attached electrical devices, and may also  
result in fire.  
You can power this generator with gasoline, natural gas (NG), or propane (LP) gas. The  
generator is designed so that it is easy to switch between fuel sources. However, there are  
special initial hook-up requirements for natural gas and propane. See the “Specifications”  
section of this manual with regard to specific gas flow and pressure requirements. In addition,  
note the following:  
Natural gas. The standard delivery pressure provided to your building by your utility  
company may not match the requirements of your generator.  
a) If your standard delivery pressure is higher than allowable for this generator, you  
may need to have a pressure-reducing regulator installed. (Note: The regulator  
supplied with this generator is NOT a pressure-reducing regulator).  
b) If your standard delivery pressure is lower than allowable for this generator, you  
will need changes to your natural gas service to elevate the delivery pressure.  
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.  
Propane (LP). You will need a minimum 100 lb. LPG gas tank to run this generator – the  
vaporization rate is insufficient with smaller tank sizes. A qualified propane gas  
technician must set up the valve and hose connection between the propane tank and  
generator in accordance with all local regulations and electric code.  
See the “Installation / Initial Set-Up: Step 3” section of this manual for more detailed  
information.  
Be sure to read about site selection and grounding requirements for running this  
generator. More detailed information can be found in the “Installation & Initial Set-up, Steps  
5 & 6” of this manual.  
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About Your Generator (cont’d)  
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-approved 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.  
Read this manual completely before using the generator and follow all instructions and  
safety rules.  
You must follow all instructions and safety precautions presented throughout this manual. A  
summary of important safety information can be found at the end of the manual. Keep this  
manual for reference and review.  
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. 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.  
Before using, the user shall determine the suitability of this product for its intended use and  
assumes liability therein.  
Contact NorthStar Product Support at 1-800-270-0810  
for any questions about the appropriate use of this generator.  
Warranty Registration  
Please fill out and submit the warranty registration card so that we have your contact  
information for any future product literature or replacement parts you may need.  
ATTENTION:  
All Rental Companies and Private Owners who loan this  
equipment to others!  
All persons to whom you rent/loan this generator must have access to and read this manual.  
Keep this owner’s manual with the generator at all times and advise all persons who will  
operate the machine to read it. You must also provide personal instruction on how to safely  
operate the generator and remain available to answer any questions a renter/borrower might  
have.  
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Specifications – Item #165938N  
SPECIFICATIONS  
Item Number  
#165938  
Maximum Output  
8000 Watts (W)  
Continuous Output: Gasoline  
Liquid Petroleum Gas (LPG)  
Natural Gas (NG)  
Voltage  
6600 Watts (W)  
6200 Watts (W)  
5200 Watts (W)  
120 / 240 Volt (V)  
Phase  
Single phase (4-wire)  
56.5 - 63.3 Hertz (Hz)  
110-129V  
Frequency Regulation  
Voltage Regulation  
Power Factor  
1.0 p.f.  
Engine  
13 HP Honda  
Engine Speed  
3390 - 3798 RPM  
Fuel Type  
Unleaded gasoline/LPG/NG  
(7-11 in H2O, 4-6 oz.)  
(5.7 lb/hr-LPG, 2.0 CFM-NG)  
6.5 gallons (24.6 L)  
Pressure Range (LPG, NG)  
Min. Flow Range (LPG, NG)  
Fuel Capacity  
Oil Capacity  
Starting Method  
120V Receptacle  
1.16 US quarts (1.1 L)  
Electric/Recoil  
15 Amp (A) duplex (NEMA 5-15R)  
20 Amp (A) duplex (NEMA 5-20R)  
30 Amp (A) locking device  
(NEMA L14-30R)  
(1) 15 Amp (A) thermal, push to reset  
(2) 20 Amp (A) thermal, push to reset  
(2) 30 Amp (A) thermal, push to reset  
Receives 10 Ga. wire or fork terminal  
12 Volt, 18 Amp-Hour minimum,  
Group size U1  
120/240V Receptacle  
Circuit Breaker  
Grounding Post  
Battery (not included)  
Dimensions  
Length  
31.75” (80.6 cm)  
23.63” (60.0 cm)  
22.25” (56.5 cm)  
225 lb. (102 kg)  
250 lb. (114 kg)  
Width  
Height  
Dry Weight  
Gross Weight  
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Safety Label Locations – Item #165938N  
WARNING  
BURN HAZARD  
Do not touch  
hot muffler.  
Commercial-grade electric start engine  
Extend run 6.5 gallon fuel tank  
Maintenance-free brushless alternator design  
Smooth running focus mount isolation system  
©2005 NT+E 1-800-270-0810  
PN 39260  
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.  
FLUSH immediately with water if battery acid contacts eyes, skin, or clothing.  
CONNECT cables in correct sequence: FIRST RED to POSITIVE terminal, then BLACK to NEGATIVE  
terminal. When disconnecting, DISCONNECT BLACK cable first, then RED.  
NEVER charge  
a
visibly damaged or frozen battery. ALWAYS read and follow charger instructions.  
ATTENTION  
IF GENERATOR IS TO BE STORED LONGER THAN 2 MONTHS,  
charge battery with a trickle charger that is rated for 3 amps maximum.  
A charged battery ensures reliable engine starting.  
©2007 NT+E 1-800-270-0810  
PN 779396  
Starting Instructions LP/NG  
-
1. Connect regulator hose to LP/NG inlet  
2. Set fuel selector switch to LP/NG  
3. Start engine  
Starting Instructions Gasoline  
-
1. Set fuel selector switch to Gasoline  
2. Start engine  
Switching Fuels on the Fly  
LP/NG to Gasoline:  
1. Change fuel selector switch to Gasoline  
Gasoline to LP/NG:  
1. Change fuel selector switch to None  
2. Wait for engine to start sputtering  
3. Change fuel selector switch to LP/NG  
See Owner's manual for more details  
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  
Part numbers  
Description  
Burn Warning  
Battery Warning  
NorthStar  
39260  
779396  
779422  
779424  
Warning  
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Machine Component Identification - Item #165938N  
Figure 1 (Ref. 1-12)  
Ref. Description  
Ref. Description  
1
2
3
4
5
6
7
8
9
Gas Cap with Gauge  
6.5 Gallon Gas Tank  
Battery Box  
11  
12  
13  
14  
15  
16  
17  
18  
19  
Super Silent Muffler  
Air Cleaner  
Engine Key Switch  
Fuel Valve  
Choke Lever  
Circuit Breakers  
120V 15A Duplex Receptacle  
Fuel Selector Switch  
120V 20A Duplex Receptacle  
120/240V 30A Locking Receptacle  
Vibration Isolation Mounts  
Oil Drain Plug  
Recoil  
LPG / NG - 3/4” NPT Inlet  
Demand Regulator  
Generator Head  
10  
Figure 2 (Ref. 13-19)  
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Machine Component Identification - Item #165938N  
REFERENCE GUIDE  
Reference 1 – Gas Cap with  
Gauge  
The gas cap is extra large, creating a large hole for  
refilling and a comfortable grip. You can always  
monitor the fuel level without removing the cap by  
using the fuel level indicator built into the gas cap.  
Large tank allows for extended run capabilities.  
Always allow room for gasoline expansion by not  
filling the gas tank completely full.  
Reference 2 – 6.5 Gallon Gas  
Tank  
Reference 3 – Battery Box  
The battery box provides protection for the battery and  
will accept a standard lawn tractor size battery (Group  
U1-7). The engine requires a 12 volts d.c. battery, with  
a minimum rating of 18Ah (Amp-Hour). See battery  
section for sizing.  
Reference 4 – Circuit Breakers  
This portable single phase generator has 1-15 amp  
(A), 2-20 amp (A), and 2-30 amp (A) push to reset  
circuit breakers to protect against electrical overloads.  
The generator has a control panel with two duplex (two  
receptacles in a common housing) receptacles. This  
duplex is a 120 volt (V) 15 amp (A) straight blade  
Reference 5 – 120V 15A Duplex  
Receptacle  
receptacle,  
National  
Electrical  
Manufacturer’s  
Association (NEMA) number 5-15R. This receptacle  
accepts NEMA plug number 5-15P. The duplex is  
capable of drawing 15A out of either receptacle or a  
combination of both.  
Reference 6 – Fuel Selector  
Switch  
Switching from LP or NG to gasoline:  
1. Disconnect all loads to generator.  
2. Turn the gas line valve to ON position.  
3. Flip the fuel selection switch to the GASOLINE  
position.  
Switching from gasoline to LP or NG:  
1. Disconnect all loads to generator.  
2. Make sure LP or NG fuel is being supplied.  
3. Flip the fuel selection switch to the NONE position.  
4. Wait for the engine to begin sputtering, this  
indicates the engine is being starved of  
gasoline. Do not choke the engine when  
switching to LP/NG fuel.  
5. Flip the fuel selection switch to the LP/NG  
position.  
6. Momentary sputtering is common. If engine  
stops running, turn the ignition key to restart  
the engine.  
7. Turn gasoline line valve to OFF position.  
Reference 7 – 120V 20A Duplex  
Receptacle  
The second duplex is a 120V 20A straight blade  
receptacle,  
National  
Electrical  
Manufacturer’s  
Association (NEMA) number 5-20R. This receptacle  
accepts NEMA plug numbers 5-15P and 5-20P. Each  
receptacle on this duplex is capable of drawing 20A.  
The locking device is a 120/240V 30A NEMA L14-30R  
receptacle. This receptacle accepts a NEMA plug  
number L14-30P.  
Reference 8 – 120/240V 30A  
Locking Receptacle  
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Machine Component Identification - Item #165938N  
Reference 9 – Vibration  
Isolation Mounts  
The engine and generator are mounted on rubber  
cylinders that absorb most of the engine vibration.  
This feature eliminates the tendency of the machine to  
“walk” which is common in engine powered equipment.  
Refer to your Honda engine manual for oil change  
recommendations.  
Reference 10 – Oil Drain Plug  
Reference 11 – Super Silent  
Muffler  
Noise level is 8 dB less than Honda’s standard muffler.  
Reference 12 – Air Cleaner  
Refer to your Honda engine manual for air cleaner  
care.  
Reference 13 – Engine Key  
Switch  
The engine key is located on the engine. Always  
locate this switch and be familiar with its location  
before operating the generator. Consult the Honda  
engine owner’s manual for further instructions.  
The engine has an ON-OFF valve mounted on the  
front of the engine. Always keep this valve closed  
when the generator is not in use.  
Used during cold starts. The choke is only used with  
gasoline fuel. Refer to Honda engine manual for  
usage.  
Reference 14 – Fuel Valve  
Reference 15 – Choke Lever  
Reference 16 – Recoil  
Reference 17 – LPG / NG – ¾”  
NPT Inlet  
Grasp firmly when starting engine.  
Before you start engine, smell next to floor for gas, if  
you do smell gas:  
DO NOT start engine.  
DO NOT light a match.  
DO NOT flip on an electrical switch.  
Exit area immediately and call gas supplier or  
fire department.  
Minimum flow range required: NG - 2.0 CFM,  
LPG - 5.7 lb/hr.  
Pressure Range: 4-6 ounces, OR 7-11 inches of water  
column. NEVER over pressurize.  
Reference 18 – Demand  
Regulator  
Supplies the engine LP or NG fuel only if the engine is  
running.  
Reference 19 – Generator Head  
The electricity producing part of the generator.  
10  
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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. Before using your generator, determine the running  
and starting wattage requirements of all the electrical devices you will be powering simultaneously.  
The sum of the running and starting wattages of the devices being powered must not exceed the  
continuous output rating of your generator. (The continuous output rating of your generator is listed  
in the “Specifications” section of this manual.) Note that:  
Devices without electric motors such as light bulbs, radios, and televisions have the same  
running and starting wattage.  
Devices with electric motors such as refrigerators, compressors, and hand tools typically  
require a starting wattage that is 3 to 5 times greater than the running wattage.  
The running and starting wattage requirements are often listed on a device’s nameplate. If wattage  
is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate  
voltage by nameplate amperage, Watts = Volts X Amps.  
Example conversion to watts:  
120 Volts X 5 Amps = 600 Watts  
If only the running voltage is given on the nameplate for a device with an electric motor, the starting  
wattage can be approximated to be three to five times the running wattage.  
Estimates for the running wattage requirements for common devices are listed in Table 1 below.  
Guidance for starting wattages is provided in the table’s footnotes.  
Table 1  
Running  
Watts  
1700 (a,b) Jet pump  
Running  
Watts  
800 (a)  
1200  
100  
Device  
Device  
Air conditioner (12.000 BTU)  
Battery charger (20 Amp)  
Belt sander (3”)  
500  
1000  
1200  
Lawn mower  
Light bulb (100 Watt)  
Microwave oven  
Chain saw  
700  
Circular saw (6½”)  
Coffee maker  
2000 (a,b) Milk cooler  
1800 (a,b) Oil burner on furnace  
1100 (a)  
300  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling iron  
Dishwasher  
Edge trimmer  
Electric nail gun  
Electric range (1 element)  
Electric skillet  
1400 (a,b) Oil-fired space heater (140,000 Btu)  
1800 (a) Oil-fired space heater (85,000 Btu)  
1400 (a) Oil-fired space heater (30,000 Btu)  
400  
225  
150  
4500  
600 (a)  
150  
200  
600 (b)  
200  
700  
1200  
500  
1200  
1500  
1250  
Oven  
Paint sprayer, Airless (1/3 HP)  
Paint sprayer, Airless (handheld)  
Radio  
Refrigerator  
Slow cooker  
Furnace fan (1/3 HP)  
1200 (a) Submersible pump (1-1/2 HP)  
2800 (a)  
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Power Load Planning & Management (cont’d)  
Running  
Running  
Watts  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
Device  
Freezer  
Hair dryer  
Watts  
800 (b)  
1200  
1100  
875  
Device  
Submersible pump (1 HP)  
Submersible pump (1/2 HP)  
Sump pump  
Table saw  
Television  
Hand drill (1”)  
Hand drill (1/2”)  
Hand drill (3/8”)  
Hand drill (1/4”)  
Hedge trimmer  
Home computer  
Impact wrench  
500  
250  
450  
150  
500  
Toaster  
Vacuum cleaner  
VCR  
Water Heater  
Weed trimmer  
1000  
250  
70  
3000  
500  
(a) Hard-starting motors require 3-5 times the rated running watts  
(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment  
dealer to determine maximum wattage  
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. List the greater of the running or starting wattage next to each device as obtained from the  
devices’ nameplate or Table 1. If only the running wattage for a device with an electric  
motor is known, the starting wattage can be estimated to be at least 3 times the running  
wattage.  
3. Add the wattages for all devices on your list. This total must be lower than the continuous  
output rating of your generator.  
Example:  
Greater of Starting/Running  
Device to be Powered  
Light Bulb  
Wattage  
75 W  
Refrigerator – 18 Cu. Ft.  
Microwave  
1600 W  
700 W  
Window AC  
Sump pump (1/3 hp)  
Total  
1800 W  
2100 W  
6275W  
In this example, the generator must have a continuous output of at least 6275 W in order to power all  
of the devices simultaneously.  
STAGGERING LOADS  
You can increase the number of devices your generator can power by staggering the load on the  
generator. For example, you could alternately power your refrigerator and air conditioner for  
limited periods of time -- powering only one of the devices at a time and never powering both at the  
same time.  
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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.  
3. Getting gas hook-ups installed if natural gas or LP gas will be used as  
a fuel source.  
4. Setting up generator for the type of power generation you need:  
a. portable power source, or  
b. connected to a building as a back-up power source.  
5. Selecting a site for using the generator.  
6. Grounding.  
7. Battery installation (electric start models only).  
Each of these steps is discussed in detail below:  
1. Unpacking & Delivery Inspection  
You should inspect the generator immediately after you receive delivery.  
See the “Machine Component Identification” section of this manual for a  
diagram of the generator and its components.  
If you have missing components, contact Product Support at 1-800-270-0810.  
If you have damaged components, contact the freight company that delivered the unit and file a  
claim.  
2. Planning the Power Load  
Plan your power load so that you do not exceed the generator’s rated capacity.  
See the “Power Load Planning & Management” section of this manual to review how to plan and  
manage power loads for the generator.  
13  
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Installation / Initial Set-Up  
3. Gas Hook-up Installation for Natural Gas or LPG (if needed)  
You can power this generator with gasoline, natural gas (NG), or propane (LP) gas. The generator  
is designed so that it is easy to switch between fuel sources. However, there are special initial  
hook-up requirements for natural gas and propane:  
WARNING:  
If you choose to operate the generator on NG or LPG, you must have the fuel line system  
installed by a certified gas technician.  
Specific requirements for each type of hook-up are given below:  
Natural Gas (NG) Contact your gas utility company for installation of a natural gas hook-  
Hook-up  
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.  
This product is designed to operate on NG at a gas pressure range of 4 to  
6 ounces per square inch (7”-11” of water column) and requires a  
minimum NG flow rate of 3.25 CFM.  
The standard gas pressure normally delivered to your building by your  
utility company may be higher or lower than the required 4-6 ounces per  
square inch (7”-11” of water column):  
o If your standard delivery pressure exceeds 4-6 ounces per square  
inch (7”-11” water column), you will need a pressure-reducing  
regulator installed. Excessive gas pressure will permanently  
damage this product and void the warranty if the generator is not  
installed correctly with a pressure-reducing regulator as needed.  
Note: The regulator supplied with this product is NOT a  
pressure-reducing regulator, but one can be supplied  
and installed by your gas utility technician at the time  
of fuel system hook-up.  
o If your standard delivery pressure is lower than 4-6 ounces per  
square inch (7”-11” water column), you will need changes to your  
natural gas service to provide elevated delivery pressure. In  
addition you will need to have a pressure-reducing devices installed  
for your other natural gas appliances.  
Propane (LPG)  
Hook-up  
Contact your local propane supplier to install a propane fuel system for  
the generator.  
WARNING:  
LPG is a highly explosive gas. A qualified propane technician must  
make the valve and hose connection between the propane tank and  
generator in accordance with all local regulations and electrical codes.  
All LPG hook-ups should be completed by trained personnel from  
propane supplier and inspected as required by your local building  
code.  
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Installation / Initial Set-Up  
This product is designed to operate at an LPG gas pressure range of 7” to  
11” of water column and requires a minimum LPG gas flow rate of 9.33  
lb/hr, 2.2 Gal/hr, or 201,718 BTU/hr.  
Note: All gas cylinders produce gas pressure in excess of 11” water  
column. Introduction of gas pressure into the generator in  
excess of 11” water column will permanently damage this  
product and void the warranty. You will need a pressure-  
reducing regulator installed as part of your LP gas fuel system.  
You will need a minimum 100 lb. LPG 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. These smaller gas tanks do not have a sufficient vaporization  
rate to run the generator.  
Some installations may require tanks even larger than 100-lb as a result  
of low surrounding air temperature and other appliances drawing fuel  
from the same tank.  
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Installation / Initial Set-Up  
4. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source  
This generator is designed to provide up to 8,000W 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. The transfer switch must be installed in  
accordance with building electrical code and guidelines supplied by your power company.  
2. As a portable power source. You can plug appliances or tools directly into the generator’s  
electrical outlets.  
Specific requirements for each are given below.  
Note: Regardless of whether you use your generator as a back-up power source connected to a  
building or as a portable power source, you must not overload the generator. Overloading  
may cause serious damage to the generator and attached electrical devices.  
Using as a  
Contact a licensed electrician to install a UL-approved transfer switch if  
Back-up Power  
Source for a  
Building  
you want to use your generator as a back-up power source for a building.  
What does a transfer switch do? It:  
a) Safely connects the generator to your building’s electrical system by  
isolating your generator from your utility company’s power lines,  
AND  
b) Connects your generator to a critical subset of your building’s circuits  
that are needed for emergency power needs.  
If your generator will be connected to your building’s electrical system, it  
MUST ALWAYS be isolated from the utility power grid with a UL-approved  
transfer switch installed by a licensed electrician in compliance with all  
applicable building and electrical codes, and in accordance with guidelines  
supplied by your power company.  
DANGER:  
A transfer switch must be installed in order to isolate your  
generator from the utility power grid. If your generator is  
NOT properly isolated from the utility system, serious  
hazards will arise:  
When your generator is running, it’s output will back feed  
into the utility power line and transformer that are  
normally used to provide you with power. The  
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.  
It could also explode or cause fire.  
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Installation / Initial Set-Up  
In addition to isolating your generator from the utility system, the transfer  
switch connects your generator to a limited set of circuits in your building  
that have been chosen as critical to operate during a power outage.  
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.  
(See the previous section of this manual entitled Power Load Planning &  
Management” for more information on load application and selection.)  
When using the generator as a portable power source, you can plug  
electric devices and appliances directly into the generator’s electrical  
outlets.  
Using as a  
Portable Power  
Source  
There are three different kinds of electrical outlets on the generator:  
1. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R  
locking receptacle compatible with L14-30P mating plug).  
2. One 120 Volt, 20 Amp duplex straight-blade receptacle (NEMA 5-  
20R duplex receptacle compatible with NEMA 5-20P or 5-15P  
mating plugs).  
3. One 120 Volt, 15 Amp duplex straight-blade receptacle (NEMA 5-  
15R receptacle compatible with NEMA 5-15P mating plug)/  
NEMA  
5-20R  
NEMA  
L14-30R  
NEMA  
5-15R  
FIG02683  
(See more technical detail about these receptacles and their associated  
circuit breakers in the “Machine Component Identification” section of this  
manual.)  
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.  
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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.  
Table 2  
Current/Power  
Maximum Extension Cord Length  
Amps at  
240V  
10  
Load  
#10 Ga. #12 Ga. #14 Ga. #16 Ga.  
(watts)  
2400  
4800  
7200  
9600  
12000  
Cord  
250'  
125'  
60'  
Cord  
150'  
75'  
35'  
15'  
*
Cord  
100'  
50'  
25'  
10'  
*
Cord  
75'  
25'  
10'  
*
20  
30  
40  
30'  
50  
15'  
*
WARNING:  
Use of under sized extension cords can cause electric shock,  
fire, or damage to connected devices.  
All extension and appliance cords must be in good condition and not worn,  
bare, frayed, or otherwise damaged.  
WARNING:  
Use of damaged electric cords can cause electric shock or fire.  
Note: If an extension cord becomes hot to the touch, it is overloaded or  
damaged and must be replaced.  
Northern Tool is NOT responsible for damage or injury resulting from  
customer use of inadequate extension cords.  
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Installation / Initial Set-Up  
5. 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.  
Choose a site that meets all of the criteria specified.  
Dry, level surface The generator should be positioned on a dry, firm, level surface.  
Ensure that the generator sits level and will not slide or shift during operation.  
If applicable, block the generator’s wheels to prevent sliding and shifting.  
Outdoors only –  
dangerous carbon  
monoxide exhaust  
WARNING: Carbon monoxide poisoning hazard  
The exhaust from your generator contains carbon monoxide (CO), a  
poisonous gas that can kill. You cannot smell it, see it, or taste it.  
Carbon monoxide exhaust is given off whether you are using gasoline,  
natural gas, or propane as the fuel source to power the generator.  
Follow the directions below for choosing a location to operate your  
generator in order to avoid carbon monoxide poisoning.  
The location you choose to operate the generator must be OUTDOORS  
and away from all air intakes:  
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.  
Place the generator so that the exhaust fumes will not be directed towards  
people or building air intakes.  
Ensure that working, battery-operated or battery back-up carbon monoxide  
alarms are used in any dwelling/structure that is in close proximity to the  
running generator.  
Note that this generator is NOT designed or approved for use in vehicles  
or marine applications. Never run the generator inside RVs or other  
vehicles, on boats, or on pick-up truck beds.  
WARNING:  
Never attempt to attach ductwork to the muffler system to allow for  
installation inside an enclosure. This could cause hot air deflection,  
heat build-up, and increased exhaust back-pressure, resulting in  
possible exhaust leakage or damage to the generator.  
Adequate cooling The generator needs adequate, unobstructed flow of air to allow for  
ventilation  
proper cooling of engine and generator head.  
WARNING:  
Heat build-up from inadequate ventilation can result in fire,  
posing a serious risk to nearby persons and structures.  
Situate so there is adequate clearance around generator to allow for  
cooling airflow so that heat does not build up.  
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Installation / Initial Set-Up  
Never place the generator immediately adjacent to a building or other  
structure – allow at least a 7’ clearance.  
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 accumulate and block airflow.  
Do not operate with a tarp, blanket, or cover surrounding the generator.  
No wet conditions Choose a location where the generator will NOT be exposed to rain,  
snow, or direct sunlight. Exposure to water can cause electric shock.  
You may operate the generator under an outdoor, canopy-like structure of  
heat-resistant material that is open on all sides. Make sure that all parts of  
canopy are at least 7’ from exhaust, and allow for adequate clearance above  
generator so that heat does not build up.  
Hot exhaust  
clearance  
The exhaust gas from your generator is extremely hot and can cause  
combustible materials to catch on fire.  
Make sure your generator’s exhaust system is at least 7 feet from all  
combustible materials and buildings/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.  
Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged  
and be familiar with its use.  
Away from  
dust/dirt  
Do not use the generator in extremely dusty or dirty conditions.  
Excessive dust and dirt can cause premature failure of the machine.  
Hearing  
protection  
Generators can produce noise levels of up to 95 dB in close proximity,  
which can be dangerous to human hearing with prolonged exposure.  
Hearing protection may be required for persons working within 15-20 feet of  
the running generator for an extended period of time.  
WARNING:  
Never attempt to attach ductwork to the muffler system to lower noise  
levels. This could cause hot air deflection, heat build-up, and  
increased exhaust back-pressure, resulting in possible exhaust leakage  
or damage to the generator.  
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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 ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod  
must penetrate moist earth – the depth required will be dictated by local soil conditions.  
Consult with an electrician.  
2) Connect an approved ground clamp to the pipe.  
3) Run a 10 gauge wire from the clamp to the generator grounding post located on the rear of  
the generator head.  
4) Do not connect the generator grounding post to a water pipe or a ground used by a radio  
system.  
10 Ga. wire  
Copper  
Pipe/Rod  
Grounding Post  
Ground  
If a licensed electrician installs the generator with a connection to your building’s electrical circuit  
for use as a back-up power system, grounding may alternatively be completed through the  
building’s grounding system. Ask your electrician. If the generator is not grounded through your  
building’s electrical system, follow the procedure above.  
WARNING:  
Operating the generator when it is not properly grounded can result in electrical shock.  
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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 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. Follow the instructions detailed below for connecting and disconnecting  
the battery.  
WARNING: Battery hazards  
Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can  
cause electric shock. Caution must be exercised when making connections to a battery to  
avoid shock and contact with the acid, and to prevent any sparking that could lead to an  
explosion.  
ALWAYS follow the general battery safety rules and instructions listed below.  
General Battery  
Safety Rules  
ALWAYS use eye protection when handling batteries.  
NEVER smoke or work near sparks or other sources of ignition.  
NEVER touch both battery terminals at the same time with your hand or  
any non-insulated tools.  
If battery acid contacts skin or clothing, flush immediately with water and  
neutralize with baking soda.  
Connecting the  
battery  
Always connect the cables in the following sequence to avoid possible shock:  
1. Find the battery cables located inside the battery box.  
2. Connect the red cable to the positive(+) terminal of the battery.  
3. Then connect the black cable to the negative(-) terminal of the battery.  
Disconnecting the Always disconnect cables in the following sequence to avoid possible shock.  
battery  
1. First, disconnect the black cable from the negative(-) terminal of the  
battery.  
2. Next, disconnect the red cable from the positive(+) terminal of the  
battery.  
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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. Starting the Engine:  
a)  
b)  
Using LP/NG  
Using Gasoline  
4. Checking Generator Output  
5. Connecting Electrical Loads (Portable Power Generation)  
6. Switching Fuels:  
a)  
b)  
From LP/NG to Gasoline  
From Gasoline to LP/NG  
7. Stopping  
8. Storage & Exercise of Generator  
Each of these procedures is discussed in detail below:  
1. General safety rules for operation  
Before starting the generator, review the following general safety rules for operation:  
WARNING:  
Failure to follow safety rules may result in serious injury or death to the operator or  
bystanders.  
Know proper use/how to stop. Be thoroughly familiar with proper use of the equipment and all  
generator controls, output receptacles, and connections. Know how to stop the generator quickly if  
needed (see “Operation, Step 7 - Stopping the Engine”).  
Instruct operators. The generator owner must instruct all operators in safe generator set-up and  
operation. Only trained adults should set up and operate the generator – Do not let children operate.  
Intended use. Carefully read about and understand the intended use of this generator. Do not use for  
other purposes, as unforeseen hazards or equipment damage may result.  
Under the influence. Never operate, or let anyone else operate, the generator while under the influence  
of alcohol, drugs, or medication.  
Safety equipment / controls. Do not operate the generator unless all safety covers, guards, and barriers  
are in place and in good working order, and all controls are properly adjusted for safe operation.  
Damaged. Do not operate the generator with damaged, missing, or broken parts.  
Modifications. Do not modify the generator in any way. Modifications can create serious safety hazards  
and will also void the warranty.  
Engine speed. Never attempt to modify the engine speed setting. The engine speed is preset at 3600 RPM  
for safe and optimal performance of the generator. If speed needs adjusting, it must be done by factory-  
authorized personnel.  
External fuel sources. Never attempt to connect external gasoline/diesel sources in order to increase  
engine run time. Larger tank at pressure or higher elevation will cause gasoline to leak from carburetor  
during operation. Fire or explosion could result.  
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Operation (cont’d)  
Malfunction during operation. Immediately turn off the generator if any of the following conditions  
arise during operation:  
o
o
o
o
o
o
o
o
o
Excessive change in engine speed, slow or fast  
Overheating in load connecting devices  
Sparking or arcs from generator  
Loss of electrical output  
Receptacle damage  
Engine misfire  
Excessive vibration  
Flame or smoke  
Abnormal noise  
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.)  
Carbon monoxide poisoning. The running engine gives off carbon monoxide, a poisonous gas that can  
kill you. You CANNOT smell it, see it, or taste it. Follow all instructions for site selection and  
positioning the generator, and avoid inhaling the exhaust. If you start to feel sick, dizzy, or weak while  
using the generator, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have  
carbon monoxide poisoning.  
Other exhaust dangers. This product contains or emits chemicals known to the State of California to  
cause cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust.  
Wet conditions. Do not 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.  
Ground fault circuit interrupter. Always use a ground fault circuit interrupter (GFCI) protected  
extension cord (or outlet, if generator is equipped) in damp or highly electrical conductive areas and on  
construction jobsites to prevent electrical shock.  
Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running.  
Electric shock accident. If an electric shock accident occurs, immediately shut down the source of  
electrical power. If this is not possible, attempt to free the victim from the live conductor. Avoid direct  
contact with victim. Use a nonconducting implement, such as a dry rope or board, to free the victim from  
the live conductor. Apply first aid and get immediate medical help.  
Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or  
flames.  
Hot muffler. Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine  
parts can be very hot and will burn you.  
Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never  
remove any drive belt or fan guard while the unit is operating.  
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Operation (cont’d)  
Static electricity and filling the gasoline tank:  
Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing  
gasoline, and from persons carrying a static electric charge  
Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting  
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:  
Touch a grounded metal object before starting. Always dissipate static charge from your body  
before beginning the fueling process by touching a grounded metal object at a safe distance away from  
fuel sources.  
Use a portable container to fill tank. Never fill the generator’s gas tank directly from the fuel pump –  
the generator’s tank is not grounded and the high velocity flow of gasoline from a fuel pump can cause  
static electric build-up. Use an approved portable container to transfer gasoline to the generator’s  
tank.  
Fill container on the ground. Never fill the portable gas container while it is sitting inside a vehicle,  
trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled.  
Keep nozzle in contact with container. Keep nozzle in contact with the portable container at all times  
while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device.  
Use a portable container made of metal or conductive plastic. It will dissipate charge to ground more  
readily.  
About static electricity and fueling  
Many common objects can accumulate and retain a static electric charge. Objects made of non-conductive  
materials (e.g. plastics) easily accumulate and retain static electric charge, as can objects made of conductive  
material (e.g. metal, water) if they are not electrically grounded. The static electric charge on an object, such  
as a human body or plastic fuel tank/container, can reach as high as several thousand volts!  
A static electric spark can be generated if the static electric charge stored on an object “jumps” to another,  
less charged object. Such a spark can ignite invisible gasoline vapors that are present during fueling  
situations.  
Typical sources of static electric hazards during fueling  
The following objects can accumulate a static electric charge and cause an ignition spark in typical fueling  
situations:  
1) Ungrounded tanks/containers. Any ungrounded fuel tank or container can accumulate a static electric  
charge as a result of contact with other objects or friction during transportation. This static electricity  
can discharge as a spark to the grounded gasoline dispenser nozzle, as the nozzle is first brought close to  
the tank/container at the beginning of the fueling process.  
2) Flowing gasoline. Most people are not aware that gasoline accumulates static electric charge while  
flowing through a hose or pipe. This charge then transfers to and accumulates in the gas tank or container  
that is being filled. The total amount of charge accumulation depends on the amount of gas pumped into  
the container, the speed with which it is pumped, and whether or not the tank/container is grounded. If  
sufficient static electric charge accumulates in the fuel tank or container during the fueling process, the  
tank/container may discharge a spark to the grounded gasoline dispenser nozzle.  
3) Persons. A person dispensing the gasoline can carry a static electric charge on their body, typically  
resulting from contact with their car seat or electronics. The static electricity can discharge as a spark  
between that person’s hand and either the grounded dispenser nozzle or the fuel tank opening.  
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Operation (cont’d)  
2. Preparing for Operation  
Position generator in accordance with the instructions given in  
“Installation & Initial Set-up, Step 5: Select a Suitable Site” of this  
manual.  
Position generator  
Operate outside only, on dry, level ground with adequate clearance and  
ventilation.  
WARNING: Carbon monoxide poisoning hazard  
Generators give off carbon monoxide exhaust, a poisonous gas that  
can kill. You CANNOT smell it, see it, or taste it. ONLY run  
generator OUTDOORS and away from air intakes. NEVER run  
generator inside any enclosed or semi-enclosed spaces, including  
homes, garages, basements, sheds, boxes, pick-up truck beds, RVs,  
or boats. These spaces can trap poisonous gases, EVEN if you run a  
fan or open windows. Carbon monoxide exhaust is given off whether  
you are using gasoline, natural gas, or propane to power the  
generator.  
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  
needed  
prescribed in this manual in the “Maintenance & Repair” section.  
1. Refer to the engine owner’s manual for engine maintenance  
instructions.  
2. Make sure battery is charged. Charge as needed according to your  
battery manufacturer’s instructions.  
Check/add oil  
Check the oil level using the dipstick and add oil as needed.  
Using a funnel, add oil up to the FULL mark on the dip stick with the  
recommended oil type for your engine and expected ambient conditions.  
(See engine Owner’s Manual for oil type and capacity, and more detailed oil  
check/fill instructions.)  
WARNING: Burn hazard  
Never open oil port while engine is running. Hot oil can spray over  
face and body.  
Notes:  
o Low oil shutdown feature prevents the generator from starting without  
sufficient oil.  
o Engine is shipped without oil. You must add oil before first use.  
IMPORTANT:  
Under long, continuous-run operating conditions, be prepared to:  
Check engine oil level every time you refuel the engine if using  
gasoline, or every 24 operating hours if using NG/LPG.  
Change oil after the first 20 operating hours, and at least every 100  
operating hours thereafter, or as directed in engine owner’s manual.  
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Operation (cont’d)  
Fill gasoline tank  
(if using gasoline)  
Check the gasoline level in the generator’s tank if you will be operating  
the generator on gasoline.  
If needed, fill tank with fresh unleaded gasoline from a portable  
container, after first reading the warnings and instructions below.  
WARNING: Gasoline fire/explosion hazard  
Gasoline is highly flammable and explosive. Heat, sparks, and  
flames can ignite gasoline vapors, which can become widespread  
during fueling. A flash fire and/or explosion could result and cause  
serious injury or death. Use extreme care when handling gasoline.  
Carefully follow all the instructions in this section to avoid the  
following conditions which could result in gasoline ignition:  
gas vapor collection inside enclosures  
static electric sparks  
sparks from electric wiring, batteries, or running engines  
sources of heat (such as a hot engine or exhaust)  
open flames, including pilot lights  
1) Before starting, review the following general safety precautions for  
fueling:  
a) Never pump gasoline directly into the generator’s gas tank at a gas  
station – high velocity flow from the pump could result in a static  
electric build-up in the generator’s tank. Always use a portable  
container to fill the tank. See warning box about static electric spark  
hazards below.  
b) Fill gasoline tank OUTDOORS – never indoors.  
c) Stay away from all sources of heat, sparks, and flames. Do not smoke.  
2) Turn generator engine off and allow to cool for at least two minutes  
before removing gas cap.  
Note: A running or still-hot engine is hot enough to ignite fuel.  
3) Remove generator gasoline cap.  
4) Add gasoline through the fill opening:  
- Use only a UL-approved portable gasoline container to transfer the  
gasoline to the generator’s tank. Follow the safety warning and  
instructions below for avoiding static electric sparking.  
- Do NOT overfill the gasoline tank. Allow at least 1/2” of empty space  
below the fill neck to allow for fuel expansion.  
WARNING: Static electric spark hazard  
A static electric spark can explosively ignite gasoline vapor,  
resulting in a flash fire that could cause serious injury or death.  
To avoid static electric sparking while filling the gasoline tank,  
the following steps must be followed to minimize and safely  
dissipate static electric charge build-up before and during  
the fueling process:  
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Operation (cont’d)  
Always dissipate static charge from your body before beginning  
the fueling process by touching a grounded metal object at a safe  
distance from fuel sources.  
Never fill the generator’s gas tank directly from the fuel pump –  
the generator’s tank is not grounded and high velocity flow from  
the pump can cause static electricity build-up. Use an approved  
portable container to transfer gas to the generator’s tank.  
Never fill the portable gas container while it is sitting inside a  
vehicle, trailer, trunk, or pick-up truck bed. ALWAYS place  
container on the ground to be filled.  
Keep nozzle in contact with portable container while filling.  
Manually control the flow of gasoline; 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.  
5) Clean up gasoline spills /splashes immediately.  
If possible, move the generator away from spilled gasoline on the  
ground.  
Wipe up spilled gasoline, and wait 5 minutes for excess gasoline to  
evaporate before starting engine.  
Gasoline soaked rags are flammable and should be disposed of  
properly.  
If gasoline is spilled on your skin or clothes, change clothes and  
wash skin immediately.  
6) Replace gasoline cap securely before starting engine.  
7) Store extra gasoline in a cool, dry place in an UL-approved, tightly sealed  
container.  
IMPORTANT:  
For continuous operation, be prepared to check and refuel the engine on  
a regular basis. A tank of gasoline should last about 4 hours under  
100% load, and about 8 hours under 50% load.  
Propane (LPG):  
1) Make sure the fuel hose is securely connected to the propane tank  
regulator on one end, and the ¾” NPT gas inlet on the generator base on  
the other end.  
Start LPG/NG  
supply  
(if using)  
2) Open the propane tank main valve.  
3) Check ¾” NPT gas inlet connection for leaks each time you connect. Use  
the leak test method described below.  
Natural Gas:  
1) Make sure the gas line is securely connected to the ¾” inlet on the  
generator base.  
2) Open line valve, if gas line is so equipped.  
3) Check ¾” NPT gas inlet connection for leaks each time you connect.  
Use the leak test method described below.  
28  
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Operation (cont’d)  
Inspect Fuel  
Inspect fuel system & check for leaks BEFORE starting generator.  
System / Check for Do not start generator until all needed repairs have been completed.  
Leaks  
WARNING: Fuel leak hazard  
Gasoline, LP gas (propane) and NG (natural gas) are highly  
explosive and fuel leaks can result in fire or explosions. You can be  
burned and seriously injured if the fuel system is not properly  
hooked up or there is a fuel leak when you start the engine.  
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, a damaged gasoline tank, or a defective gasoline shut-off valve.  
2) If you are using LPG or NG, check for leaks after opening supply valve:  
a) Leak test method. Test for leaks on a regular basis by applying a  
soap and water solution over pipes, hoses, and connections. Soap  
bubbles will form if there is a leak. Use this method to test after each  
reconnection to NG/LPG supply (for example, after moving the  
generator), and on a regular basis thereafter. This method will help  
you detect small leaks.  
b) Also beware of gas odor. Both LP and NG have an odorant added  
(rotten egg/sulfur smell) that will aid in the detection of more  
dangerous quantities of leaking gas. Note:  
Natural gas. Natural gas is lighter than air and tends to collect in  
high areas.  
LP gas (propane). LP gas is heavier than air and tends to settle in  
low areas. Smell next to floor for gas.  
If you smell gas, DO NOT start engine! DO NOT light a match. DO NOT  
flip on an electrical switch. If possible, shut off LPG or NG  
supply. Exit area immediately and call gas supplier or fire department.  
Personal Protection 1) Hearing can be damaged from prolonged, close-range exposure to the  
type of noise produced by this generator. The use of ear plugs or other  
hearing protection device is recommended for persons working within  
15-20 feet of the running generator for an extended period of time.  
2) Loose or dangling apparel can become entangled in moving parts. Metal  
jewelry can conduct electricity. Never wear jewelry or loose-fitting  
clothing when starting or operating the generator.  
29  
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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 or Gasoline as the fuel  
source:  
Using LP/NG  
To start engine using LP or Natural Gas:  
WARNING:  
DO NOT start engine if you smell gas. Exit area immediately  
and call gas supplier or fire department. If possible, shut off  
gas supply.  
1) Disconnect all loads to the generator.  
2) Flip fuel selector switch to the LP/NG position.  
3) Start the engine:  
a) Using electric start -  
Turn the engine key switch to the START position and hold it there until  
the engine starts. When the engine starts, release the key, allowing it to  
return to the ON position.  
b) Using recoil start –  
Turn the engine key switch to the ON position. Pull the starter grip lightly  
until you feel resistance, then pull the starter cord out briskly and rapidly.  
Allow starter cord to return slowly.  
Note: You must have the battery hooked up for recoil starting when  
using LP/NG. The LP/NG fuel system requires a battery to function.  
4) It may be necessary to momentarily depress the primer button while  
starting the engine, especially for cold starts.  
NOTE: If you have trouble starting the engine with LP/NG, you may  
need to adjust the load block:  
a. Loosen the lock nut, then turn the adjustment screw clockwise until  
resistance is felt. At this point the load block is completely shut-off.  
Adjustment  
Screw  
Lock Nut  
b. While LP or NG is being supplied to the generator, turn the ignition  
key to the start position and slowly turn the adjustment screw  
counterclockwise until the engine starts. (Depress the primer button  
when cold starting the engine.)  
c. Once the engine is running, turn the adjustment screw very slowly to  
smooth out engine performance.  
d. Once the proper setting is achieved turn the brass lock nut to secure  
the adjustment screw.  
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Operation (cont’d)  
5) Under long, continuous-run operating conditions, be prepared to:  
a) Check engine oil level every 24 operating hours,  
b) Change oil after the first 20 operating hours, and at least every 100  
operating hours thereafter, as directed in the engine owner’s manual.  
WARNING:  
Never open oil port while engine is running. Hot oil can  
spray over face and body.  
Using Gasoline  
To start engine using gasoline:  
1) Disconnect all loads to the generator.  
2) Flip the fuel selector switch to the GASOLINE position.  
3) Turn the gasoline line valve to the ON position.  
4) For cold engine, move choke lever to full choke position. To restart a  
warm engine, move choke lever to half choke or to RUN position.  
5) Start the engine:  
a) Using electric start –  
i) Turn the engine key switch to the START position and hold it there  
until the engine starts.  
NOTE: If the engine fails to start after 5 seconds, release key and  
wait 10 seconds before attempting to start again.  
Cranking the electric starter for more than 5 seconds  
continuously can overheat and damage the starter motor.  
ii) Release the key when the engine starts.  
b) Using recoil start –  
i) Turn the engine key switch to the ON position.  
ii) Pull the starter grip lightly until you feel resistance, then pull the starter  
cord out briskly and rapidly.  
iii) Allow starter cord to return slowly.  
6) When engine starts, move choke lever to RUN position.  
7) Under long, continuous-run operating conditions, be prepared to:  
a) Check and refuel the engine on a regular basis. A tank of gas should  
last about 4 hours under 100% load, and about 8 hours under 50%  
load. See engine owner’s manual for more detail.  
WARNING:  
A running engine is hot enough to ignite fuel. Never add fuel  
or remove gas cap if engine is running or still hot. Let cool at  
least 2 minutes.  
b) Check engine oil level each time you refuel.  
c) Change oil after the first 20 operating hours, and at least every 100  
operating hours thereafter, as directed in the engine owner’s manual.  
WARNING:  
Never open oil port while engine is running. Hot oil can  
spray over face and body.  
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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. Failure to do so could result in  
damage to equipment powered by the generator and possible injury to the  
individual.  
Output voltage should be checked with a portable voltage meter:  
1. Start engine and allow to warm up for five minutes. Do not connect any loads.  
2. Use voltage meter to check output voltage  
at the generator’s outlets/receptacles.  
3. Measured voltage should be within the  
following ranges:  
a. 120V +/- 10% at 120V receptacles.  
b. 240V +/- 10% at 240V receptacles.  
4. If measured voltage is not within the specified range, have generator adjusted by factory  
authorized personnel. Do not attempt to adjust the engine speed yourself.  
NOTE:  
All engines have a tendency to slow down when a load is applied. When  
electrical loads are connected to the generator, the engine is more heavily  
loaded and as a result the speed drops slightly.  
Slight variation in  
voltage/speed with  
changing electrical  
loads  
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.  
Additionally, there may be small brief surges and drops in voltage as motors  
connected to the generator cycle on or off.  
The slight variation has no appreciable effect in the operation of motors,  
lights, and most appliances.  
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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:  
Do not overload generator. Make sure that combined starting and running  
loads do not exceed rated capacity of generator. Overloading the generator  
can cause damage to the generator and attached electrical devices, and may  
result in fire.  
Using as a  
Portable Power  
Source  
Connect electrical loads one at a time according to the following  
instructions:  
1. Allow engine to reach operating speed by allowing it to warm up for  
approximately 5 minutes before connecting electrical devices.  
2. After engine is warmed up, begin by connecting the items that require  
the highest wattage first. The recommended sequence is as follows:  
a. Connect items with motors such as refrigerators, freezers, air  
conditioners, or small hand tools, one at a time. Let each motor  
stabilize before connecting the next device.  
b. Connect any lights you are planning on powering.  
c. Connect voltage sensitive equipment such as electronics via surge  
protectors. Plug devices such as TV’s, computers, and microwaves  
into a UL listed voltage surge protector, then plug the surge  
protector into the generator.  
Using as a  
Each transfer switch installation will be unique.  
Back-up Power  
Source for a  
Building  
Proper instructions for how to safely bring the generator online with the  
building’s electrical system should be provided by the installing electrician,  
who should also provide personal instruction to the owner/operator.  
Failure to follow the proper procedure as provided by the electrician could  
expose persons to the hazards noted above.  
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Operation (cont’d)  
6. Switching Fuels (during operation)  
You can switch fuel sources (from gasoline to LP/NG, or from LP/NG to gasoline) while the  
generator is running. Follow the instructions below:  
Switching from  
1. Disconnect all loads to the generator. Leave the engine running.  
LP/NG to Gasoline  
2. Turn the gasoline line shut-off valve to ON position.  
3. Flip the fuel selector switch to the GASOLINE position.  
1. Disconnect all loads to the generator. Leave the engine running.  
Switching from  
Gasoline to LP/NG  
2. Make sure LP or NG fuel is properly connected to ¾” NPT supply inlet  
and is being supplied.  
WARNING:  
If you smell gas, turn off engine and shut off gas supply  
immediately. Exit area and call gas supplier or fire  
department.  
3. Flip the fuel selector switch to the NONE position. The fuel conversion  
should take 1-2 seconds.  
4. Wait for the engine to begin sputtering. This indicates the engine is  
being starved of gasoline.  
5. Flip the fuel selector switch to the LP/NG position.  
6. Turn the gasoline line shut shut-off valve to OFF position.  
7. Stopping  
Stop the engine using the following steps:  
1. Disconnect all loads to the generator.  
2. Turn engine key switch to OFF position.  
3. Turn gasoline line shut-off valve to OFF position.  
4. The fuel lock-off solenoid automatically stops the flow of LP or NG to the engine.  
5. Remove key from starter to prevent accidental starting of engine.  
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Operation (cont’d)  
8. 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.  
Detailed instructions are provided below.  
Disconnect loads & When you are finished using the generator, disconnect all loads and  
turn off fuel supply turn off all sources of fuel supply:  
1. Make sure all devices that were connected to the generator’s outlets  
are disconnected.  
2. Check to be sure gasoline line shut-off valve is in OFF position.  
3. If using propane, shut off propane tank valve.  
4. If applicable, shut off natural gas line valve.  
Cool engine before Let engine cool for at least five minutes before storing. A hot engine can  
storing  
be a fire hazard.  
Choose a storage  
location  
Store the generator in a location that is:  
o Clean and dry  
o Away from sources of heat, open flames, sparks, or pilot lights, even  
if the generator’s fuel tank is empty. Residual fuel in the tank could  
ignite.  
o Away from extreme high or low temperatures.  
Note: Do not store with battery charger always connected. Batteries that  
are over-charged can boil themselves dry and produce excessive amounts of  
hydrogen, an explosive gas.  
Prevent accidental  
starting  
Remove key from starter (for electric start engines) and secure key in a  
safe location, or remove spark plug(s) in order to ensure the generator  
cannot be started accidentally in a storage location or by untrained persons.  
Exercise generator The generator should be exercised regularly.  
every 4 weeks  
At least every four weeks, start the engine and let it run for 10 to 15 minutes  
with a small load plugged in, such as a lamp or fan.  
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.  
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Operation (cont’d)  
Perform regular  
maintenance  
Perform periodic maintenance as directed in this manual to keep the  
generator in safe working condition.  
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 gasoline from the tank and carburetor  
OR  
o Adding fuel stabilizer to the gasoline (following manufacturer’s  
instructions)  
Fuel stabilizer steps:  
1. Ensure gasoline tank is full.  
2. Add fuel stabilizer to fuel tank.  
3. Run engine at least 10 minutes after adding stabilizer to  
allow it to enter the fuel system.  
4. Shut off engine  
5. Disconnect spark plug wire and remove spark plug  
6. Add one teaspoon oil through spark plug hole  
7. Place rag over spark plug hole and turn starter (or pull the  
recoil) a few times to lubricate the combustion chamber.  
8. Replace spark plug, but do not reconnect the spark plug wire.  
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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. Make sure all guards and shields are  
replaced before using.  
Note: The generator head is brushless and maintenance free. The bearing is a heavy-duty  
sealed ball bearing which requires no maintenance or lubrication.  
Maintenance & Repair  
Read and follow these safety rules whenever you will be servicing the  
generator:  
Follow safety rules  
Turn off generator. Always turn off generator and remove spark plug(s)  
or spark plug wire(s) before working on the engine or generator to prevent  
accidental starting.  
Discharge capacitor. When the generator is shut down, the capacitor may  
maintain a charge. Always discharge the capacitor before working on the  
generator head to prevent electrical shock. Discharge using a screwdriver  
with an insulated handle. While wearing safety glasses, touch opposite  
terminals of the capacitor together with the tip of the screwdriver. If there  
is stored charge in the capacitor, a spark will be generated thereby  
discharging the capacitor.  
Replace guards. Make sure all guards and shields are replaced after  
servicing the generator.  
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. Replacement parts that do not meet specifications  
may result in a safety hazard or poor operation of the generator and will  
void the warranty.  
Perform engine  
maintenance  
Perform engine maintenance as specified in the engine owner’s manual.  
Engine maintenance items include:  
1. Changing oil and oil filter  
2. Air filter check/replacement  
3. Spark plug cleaning and replacement  
4. Fuel filter check/replacement  
5. Fuel tank cleaning.  
Check receptacles  
Check receptacles before each use to make sure they are not cracked or  
broken.  
If a receptacle is cracked or otherwise damaged, do not use until replaced  
with an authorized factory part. Using cracked or damaged receptacles can be  
both dangerous to the operator and destructive to the equipment.  
37  
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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, damaged gasoline tank, or defective gasoline shut-off valve.  
2) If you are using LPG or NG, test for leaks. After opening LPG/NG  
supply valve, apply a soap and water solution over pipes, hoses, and  
connections. Soap bubbles will form if there is a leak. Use this method  
to test after each reconnection to NG/LPG supply (such as after  
transporting generator), and on a regular basis thereafter.  
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 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.  
Clean & inspect  
spark arrestor  
(if equipped)  
Clean and inspect the spark arrestor muffler. (Only for those models  
equipped with a spark arrestor – See the “Specifications” section.)  
If the engine is equipped with a spark arrester muffler, clean and inspect it  
regularly (follow manufacturer’s service instructions). Replace if damaged.  
Keep generator clean.  
If dust or debris accumulates on the generator, clean the generator with a  
damp cloth or soft bristle brush. Do not allow air intakes to become blocked.  
Keep generator  
clean  
Note: Do not spray generator with a garden hose or pressure washer.  
Water may enter the generator and cause damage to the rotor, stator, or  
internal windings.  
Recharge and  
maintain battery  
(if electric start)  
Inspect, recharge, and maintain your battery according to your battery  
manufacturer’s instructions. (Only for those models equipped with electric  
start.)  
Do not store with battery charger always connected. Batteries that are over-  
charged can boil themselves dry and produce excessive amounts of hydrogen,  
an explosive gas.  
IMPORTANT:  
If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replace-  
ment parts that do not meet specifications may result in a safety hazard or poor operation of the  
generator.  
Contact NorthStar Product Support at 1-800-270-0810  
for any questions, problems, or parts orders  
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Troubleshooting  
TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Engine will not start.  
a) Low oil level.  
b) Fouled spark plug.  
c) Out of fuel.  
a) Fill crankcase to proper oil level.  
b) Clean or replace spark plug.  
c) Fill fuel tank.  
d) Stop switch in OFF position.  
e) Battery disconnected or dead.  
f) Fuel selector switch is OFF position.  
d) Place switch in ON position.  
e) Charge or replace battery.  
f) Place switch in desired location (Gasoline or  
LP/NG).  
Voltage too low.  
a) Engine speed too slow.  
b) Generator is overloaded.  
a) Bring generator to a qualified technician for  
adjustment.  
b) Reduce the load. (See Power Load Planning  
& Mgt. 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 Power Load Planning  
& Mgt. section of this manual.)  
a) Bring generator to a qualified technician for  
adjustment.  
a) Reduce the load. (See Power Load Planning  
& Mgt. section of this manual.)  
b) Make sure there is at least 3 feet of clearance  
on all sides of generator.  
Voltage too high.  
a) Engine speed too high.  
a) Generator is overloaded.  
b) Insufficient ventilation.  
Generator overheating.  
No output voltage.  
a) Defective load connected to generator.  
b) Broken or loose wire.  
a) Disconnect load.  
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) Defective rotor.  
e) Bring generator to a qualified technician for  
repair.  
f) Defective capacitor.  
a) Generator is overloaded.  
f) Bring generator to a qualified technician for  
repair.  
Engine lacks power or  
sputters.  
a) Reduce the load. (See Power Load Planning  
& Mgt. section of this manual.)  
b) Clean or replace air filter.  
c) For LP, the hose should be on the left inlet.  
For NG, the hose should be on the right inlet.  
d) Clean or replace spark plug.  
b) Dirty air filter.  
c) LP/NG hose is connected to the wrong  
carburetor inlet.  
d) Fouled spark plug.  
a) Out of fuel.  
b) Low oil level.  
a) Engine out of fuel.  
b) Engine cold.  
Engine shuts down  
during operation.  
Engine will not start on  
gasoline.  
a) Fill fuel tank.  
b) Fill crankcase to proper oil level.  
a) Refuel engine.  
b) Choke engine.  
c) Vacuum hose is loose.  
c) Reattach vacuum hose. Item 29 on  
Exploded View.  
Engine will not start on  
LP or Natural Gas.  
a)Load Block needs adjustment  
b) Battery is low on charge causing engine to  
crank at a lower rpm.  
a) See page 8 of this manual.  
b) Recharge battery.  
c) Inlet fuel pressure is incorrect.  
c) Inlet fuel pressure should be within 7”-11” water  
column, or 4-6 oz.  
d) Engine choke lever is in the choke position. d) Move the choke lever to the open position.  
Never choke the engine when operating on LP or  
e) Fuel lockoff valve upstream of the  
generator set is turned off.  
NG fuel.  
e) Open valve.  
Engine sputters when  
switching from gasoline  
to LP or Natural Gas.  
a) This is normal operation.  
a) Run the unit with the fuel switch in the NONE  
position for several seconds until the engine  
begins to hunt. Then move the switch to the  
LP/NG position.  
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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. Improper use or maintenance of the generator can result in serious injury or  
death from carbon monoxide poisoning, electric shock, fire/explosion, or burns.  
General  
Read manual. Read this Owner’s Manual and the engine Owner’s Manual completely before attempting to  
set-up and use the generator. Serious injury or death can result if safety instructions are not followed.  
Instruct operators. The generator owner must instruct all operators in safe generator set-up and operation.  
Do not allow anyone to operate the generator who has not read the Owner’s Manual and been instructed on its  
safe use.  
Adults only. Only trained adults should set up and operate the generator. Do not let children operate.  
Under the influence. Never operate, or let anyone else operate, the generator while under the influence of  
alcohol, drugs, or medication.  
Intended use. Carefully read about and understand the intended use of this generator. Do not use for other  
purposes, as unforeseen hazards or equipment damage may result.  
Prohibition Against Modifications  
Never modify or alter the generator in any way. Modifications can create serious safety hazards and will also  
void the warranty.  
Engine speed. Never attempt to modify the engine speed setting. The engine speed is preset at 3600 RPM for  
safe and optimal performance of the generator. If speed needs adjusting, it must be done by factory-  
authorized personnel.  
Fuel/exhaust system. Never modify the exhaust system, fuel tanks, or fuel lines. Carbon monoxide  
poisoning, fire, or explosion could result.  
Guards. Do not operate generator unless all guards and cover shields, which prevent access to moving parts  
and pinch points, are in place. Failure to guard the power transmission mechanisms may result in serious  
injury or death.  
Safety – Installation & Set-up  
Battery Safety  
Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause electric shock.  
Caution must be exercised when making connections to a battery to avoid shock and contact with the acid, and to  
prevent any sparking that could lead to an explosion. Follow safety rules carefully when connecting battery to  
generator:  
Eye/skin protection. Always wear eye protection and protective clothing when connecting or disconnecting  
battery.  
Sparks/Smoking. Never smoke or work near sparks or other sources of ignition.  
Electric shock. Never touch both battery terminals at the same time with your hand or any non-insulated  
tools.  
Connection/disconnection sequence. ALWAYS connect and disconnect cables to the correct battery  
terminals in the proper sequence:  
o When CONNECTING the battery, connect the RED cable to the POSITIVE terminal FIRST.  
o When DISCONNECTING the battery, disconnect the BLACK cable from the NEGATIVE terminal FIRST  
Acid/skin contact. If battery acid contacts skin or clothing, flush immediately with water and neutralize with  
baking soda.  
40  
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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.  
Operate OUTSIDE only – dangerous carbon monoxide exhaust! Generators give off carbon monoxide  
exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator  
OUTDOORS and away from building air intakes. NEVER run generator inside homes, garages, sheds, or  
other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.  
Carbon monoxide is given off whether you are using gasoline, natural gas, or propane to power the generator.  
No vehicle/marine use. This generator is NOT designed or approved for use in vehicles or marine  
applications. Never run the generator inside RVs or other vehicles, on boats, or on pick-up truck beds.  
Cooling ventilation. The generator needs adequate, unobstructed flow of air to allow for proper cooling of  
engine and generator head. Situate so there is adequate clearance around generator to allow for cooling  
airflow. Do not allow debris to accumulate and block airflow.  
Grounding. Always ensure generator is properly grounded to prevent electrical shock. This generator is  
equipped with a grounding post. Always complete the grounding path from the generator to a copper pipe/rod  
driven into moist earth to a sufficient depth. Check with an electrician for local grounding requirements. If a  
licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a  
standby power system, grounding will be complete through the building’s grounding system.  
Isolate connection to building’s electrical circuit. 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 an UL-approved transfer switch installed by a licensed electrician in compliance with all  
applicable local building and electrical codes. If the generator is not isolated from the utility power system by  
such means, generator output will back feed into the utility power grid. This may result in injury or death to  
utility power workers or others who contact the lines during a power outage. It may also cause the generator  
to explode or cause fires when utility power is restored.  
Natural gas hook-up. Always consult with your gas utility company to determine installation requirements  
for a natural gas hook-up. In order to safely operate your generator, you may need either a higher or lower  
pressure than the standard delivery pressure provided to your building. You may need a pressure reducing  
regulator, or you may need elevated delivery pressure which would require changes to your natural gas  
service. All natural gas generator hook-ups should be completed by trained personnel from your natural gas  
utility company and inspected as required by you local building code.  
LPG hook-up. A qualified propane gas technician must set up the valve and hose connection between the  
propane tank and generator in accordance with all local regulations and electric code. Check with your local  
propane gas supplier.  
Wet conditions. Water conducts electricity. Do not operate generator where it is wet. Operate on a dry  
surface under an open, canopy-like structure.  
CO alarms. Ensure that working, battery-operated or battery back-up carbon monoxide alarms are used in  
any dwelling/structure that is in close proximity to the running generator.  
Hot exhaust - fires. Exhaust from engine can be extremely hot and cause fire. Position muffler at least 7’  
from combustible objects during operation.  
Spark arrestor. Equip engine with a spark arrestor if 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.  
Fire extinguisher. Keep a fire extinguisher rated “ABC” by the National Fire Protection Association nearby.  
Keep it properly charged and be familiar with its use.  
Safety – Before Use  
Know how to operate  
Review safety rules. Before each use of this generator, review the “Rules for Safe Operation.” Failure to  
follow these rules may result in serious injury or death.  
Know how to operate. Be thoroughly familiar with all controls and with the proper use of the equipment.  
Know how to stop the generator quickly if needed.  
41  
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Summary of Important Safety Information for Operation (cont’d)  
Personal protective equipment  
Hearing protection. The use of ear plugs 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. Never wear jewelry or loose-fitting clothing when operating the generator.  
Gasoline Safety  
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use  
extreme care when handling:  
Fuel outdoors. Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an  
enclosure. Explosion can result.  
Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and  
ignite fuel. Use an UL approved fuel container to transfer gas to the engine.  
Running / hot engine. A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if  
engine is running or still hot. Stop the engine and allow to cool at least two minutes before adding fuel.  
Heat / flames / sparks. Stay away from sources of heat, flame, or sparks while adding fuel.  
Don’t overfill. DO NOT overfill the gas tank. Allow at least 1/2” of empty space below the fill neck to  
allow for fuel expansion.  
Replace cap. Replace gas cap securely before starting engine.  
Spills. Clean up fuel spills immediately. Move generator away from spilled fuel on the ground. Wipe fuel  
off engine and wait 5 minutes for excess fuel to evaporate before starting engine. Gas soaked rags should be  
disposed of properly.  
On skin / clothes. If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately.  
Inspect fuel system. Check fuel system on a regular basis. Look for signs of leaks, deterioration, chafed or  
spongy fuel hose, loose or missing fuel hose clamps, damaged fuel tank, or a defective fuel shut-off valve.  
Do not start generator until needed repairs have been completed.  
Gasoline storage. Store gasoline in a cool, dry place in an UL-approved, tightly sealed container.  
Propane & Natural Gas Safety  
LP gas (propane) and natural gas are highly flammable and explosive. Even the slightest spark can ignite these  
fuels. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak  
when you start the engine.  
Initial hook-up by qualified personnel. Initial hook-up must be completed by qualified personnel from your  
natural gas company or propane supplier and inspected per local code.  
Inspect regularly. Inspect fuel system regularly for leaks. Do not start generator until leaks are repaired.  
Smell for gas before starting the generator:  
Natural gas. Natural gas is lighter than air and tends to collect in high areas. After opening NG line  
supply, smell for gas BEFORE starting engine.  
LP gas (propane). LP gas is heavier than air and tends to settle in low areas. After opening propane  
tank valve, smell next to floor for gas BEFORE starting engine.  
If you do smell gas, DO NOT start engine. DO NOT light a match. DO NOT flip on an electrical switch. Exit  
area immediately and call gas supplier or fire department. If possible shut off gas supply.  
Safety – During Use  
Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in  
place and in good working order, and all controls properly adjusted for safe operation.  
Know how to stop. Be thoroughly familiar with proper use of the equipment and all generator controls,  
output receptacles, and connections. Know how to stop the generator quickly if needed.  
Damaged. Do not operate the generator with damaged, missing, or broken parts.  
Check for gas leak before starting. After opening gasoline valve or LP/NG line supply, smell for gas before  
starting engine. If you do smell gas, DO NOT start engine. DO NOT light a match. DO NOT flip on an  
electrical switch. Exit area immediately and call gas supplier or fire department. If possible shut off the  
LP/NG supply.  
42  
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Summary of Important Safety Information for Operation (cont’d)  
Carbon monoxide exhaust. The running engine gives off carbon monoxide, a poisonous gas that can kill  
you. You CANNOT smell it, see it, or taste it. If you start to feel sick, dizzy, or weak while using the  
generator, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon  
monoxide poisoning.  
Other exhaust dangers. This product contains or emits chemicals known to the State of California to cause  
cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust.  
Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or  
flames.  
Check output voltage. Check output voltage to ensure the generator is working properly before connecting  
loads to the generator. Failure to do so could result in damage to equipment powered by the generator and  
possible injury to the individual. Do not adjust output speed of engine to change voltage. If voltage is not  
within specified range, have generator repaired by factory authorized personnel.  
Stabilize before connecting loads. Start generator and let engine stabilize before connecting electrical loads.  
Do not overload. Do not overload the generator. Make sure that combined starting and running loads do not  
exceed rated capacity of generator or damage will result.  
Protect sensitive electronics. Some electronic equipment, such as computers and audio/video equipment,  
can be damaged by small fluctuations in the flow of power. Use a surge suppressor for any voltage-sensitive  
electronic equipment you will be powering with the generator.  
Wet conditions. Do not 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.  
Ground fault circuit interrupter. Always use a ground fault circuit interrupter (GFCI) protected extension  
cord (or outlet, if generator is equipped) in damp or highly electrical conductive areas and on construction  
jobsites to prevent electrical shock.  
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.  
Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running.  
Electric shock accident. If an electric shock accident occurs, immediately shut down the source of electrical  
power. If this is not possible, attempt to free the victim from the live conductor. Avoid direct contact with  
victim. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live  
conductor. Apply first aid and get immediate medical help.  
Hot muffler. Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine parts  
can be very hot and will burn you.  
Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never  
remove any drive belt or fan guard while the unit is operating.  
Refueling. DO NOT refuel the engine until it has cooled at least two minutes.  
Malfunction during operation. Immediately turn off the generator if any of the following conditions arise  
during operation:  
o
o
o
o
o
o
o
o
o
Excessive change in engine speed, slow or fast  
Overheating in load connecting devices  
Sparking or arcs from generator  
Loss of electrical output  
Receptacle damage  
Engine misfire  
Excessive vibration  
Flame or smoke  
Abnormal noise  
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.  
43  
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Summary of Important Safety Information for Operation (cont’d)  
Safety – After use  
Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine can be a  
fire hazard.  
Shut off fuel supply. Make sure gasoline shut-off valve is in the OFF position. Turn off propane tank valve  
or shut NG line valve, as applicable.  
Prevent accidental starting. When generator is not in use, remove key from starter (key start engines) and  
secure in a safe location, or remove spark plug(s) in order to ensure that generator cannot be started in a  
storage location or by untrained persons.  
Storage location. Store the generator in a dry location away from sources of heat, open flames, sparks or  
pilot lights – such as water heaters, space heaters, furnaces, clothes dryers, or other gas appliances – EVEN IF  
the generator’s gas tank is empty. Residual gasoline could ignite.  
Exercise regularly. Exercise generator every four weeks to dry out moisture that accumulates in the  
windings. If generator cannot be exercised on a regular basis, prepare generator for long term storage.  
Periodic maintenance. Perform periodic maintenance as directed in this manual to keep the generator in safe  
working condition.  
Safety - Inspection/Maintenance  
Inspect and maintain your generator on a regular basis and repair as needed to keep it in safe working condition:  
Turn off generator. Always turn off generator and remove spark plug(s) or spark plug wire(s) before  
working on the engine or generator to prevent accidental starting.  
Discharge capacitor. When the generator is shut down, the capacitor may maintain a charge. Always  
discharge the capacitor before working on the generator head to prevent electrical shock.  
Replace guards / shields. Make sure all guards and shields are replaced after servicing the generator.  
Replacement parts. If a part needs replacement, only use parts that meet the manufacturer’s specifications.  
Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the  
generator and will void the warranty.  
44  
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Generator Exploded View Rev- N  
45  
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Generator Exploded View Rev- N  
Diag #  
Part #  
Description  
Qty  
1
2
3
4
5
6
7
8
171410  
777164  
38759  
30754  
779422  
32833  
33482  
36298  
36297  
31770  
32811  
31335  
778530  
777304  
36300  
33319  
777338  
777119  
32798  
35946  
36825  
33435  
31708  
31772  
32815  
32809  
32810  
306459  
777621  
33321  
34172  
32844  
778483  
82018  
777305  
33277  
32797  
777108  
38435  
779396  
777352  
31868  
32848  
31850  
779424  
33484  
30755  
777345  
38184  
39260  
32813  
777163  
777147  
Hose Clamp  
5
1
1
4
1
1
1
1
1
1
22”  
1
1
1
1
1
1
2
1
1
1
1
7”  
1
1
1
22”  
1
1
1
4
4
1
4
1
4
4
1
1
1
1
1
4
1
1
1
1
15”  
1
1
2
1
1
Positive Battery Cable  
Fuel Tank Assembly  
Leather Washer  
Decal  
Roll Cage  
6mm Stud and Coupler Nut  
Straight Hose Nipple  
Load Block  
Engine Adapter  
LP/NG Hose  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
Engine, GX390 Honda  
Generator  
Generator Cover  
Regulator Assembly  
LP/NG Fuel Lockoff  
3/8 X 1/4 Reducer  
1/2” Hose Clamp  
3/4” Pipe  
O-Ring  
Regulator  
Regulator Bracket  
3/8” Split Conduit  
Vacuum Switch  
Wire Harness  
Elbow  
Vacuum Hose  
Ground Wire  
Generator Base Bracket  
Fuel Cap  
Isolation Mount  
Lower Bracket  
Generator Base  
5/16-18 X 2 Hex Head Bolt  
Control Box  
Clip Nut, 10-32  
10-32 X .75 Screw  
Negative Battery Cable  
Control Panel Assembly  
Battery Decal  
Battery Box  
Battery (Not Included)  
Upper Bracket  
Wire Harness  
Warning Decal  
Nameplate  
Fuel Filter  
1/4” Fuel Line  
Engine Cover  
Burn Warning  
1/4” NPT, 1/4” Hose Barb  
Gas Lockoff Bracket  
Gasoline Lockoff  
46  
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Wiring Diagram Rev- N  
Diag #  
Part #  
Description  
Qty  
1
2
3
4
5
6
7
8
9
31086  
30643  
306433  
30975  
306429  
306438  
31736  
31824  
306422  
Thermal Circuit Breaker, 30 Amp  
Thermal Circuit Breaker, 20 Amp  
Thermal Circuit Breaker, 15 Amp  
Control Panel Face  
2
2
1
1
1
1
1
1
1
Binding Post  
15 Amp, 120 Volt Receptacle (NEMA 5-15R)  
20 Amp, 120 Volt Receptacle (NEMA 5-20R)  
Switch  
30 Amp, 120/240 Volt Locking Device Receptacle  
(NEMA L14-30R)  
10  
11  
12  
38191  
31107  
306604  
38334  
31106  
31108  
31109  
306599  
30660  
306601  
31823  
30977  
Wire Harness  
Wire Assembly  
Wire Assembly  
Wire Harness  
Black Terminated Wire  
Black Terminated Wire  
Black Terminated Wire  
Black Terminated Wire  
Black Terminated Wire  
Black Terminated Wire  
Green Terminated Wire  
White Terminated Wire  
1
1
1
1
1
1
1
1
1
1
1
1
13  
B23  
B24  
B26  
B28  
B29  
B31  
G22  
W25  
47  
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Generator Head Exploded View Rev- N  
Item #  
Part #  
Description  
Qty  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
779919  
779556  
779557  
779920  
779786  
777304  
38271  
779787  
779788  
307481  
779789  
779790  
38276  
Mount Plate (J609B)  
Fan Bolts  
Fan  
Drive End Bracket  
Enclosing Band  
End Cover  
End Cover Plug  
Stator  
Rotor  
Varistor  
Diode  
Securing Stud + Nut  
Bearing  
1
2
1
1
1
1
1
1
1
2
2
1
1
1
1
4
38278  
779791  
779792  
Non Drive End Bracket  
Capacitor  
Bracket Securing Stud  
48  
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