North Star Portable Generator M165939J User Manual

M165939J

ITEM NUMBER: 165939

SERIAL NUMBER: _____________

Owner’s Manual

Instructions for Installation/Set-up, Operation, Servicing, &

Storage

Portable, Outdoor Use-Only, Triple Fuel Generator

10,500 Watt Continuous (13,000 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

Fuel Delivery System.....................................................................................................................49

Generator Head Exploded View ..................................................................................................50

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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 8000 Watts of

electrical power (10,500 watts continuous, 13,000 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 #165939J

SPECIFICATIONS

Item Number

#165939

Maximum Output

Continuous Output:

Gasoline

13500 Watts (W)

10500 Watts (W)

Liquid Petroleum Gas (LPG)

Natural Gas (NG)

Voltage

9600 Watts (W)

8400 Watts (W)

120 / 240 Volt (V)

Phase

Single phase (4-wire)

Frequency Regulation

Voltage Regulation

Power Factor

56.5 - 63.3 Hertz (Hz)

218 - 258 V

1.0 p.f.

Engine

20 HP Honda

Engine Speed

3390 - 3798 RPM

Fuel Type

Unleaded gasoline/LPG/NG

7-11” Water Column, 4-6 oz.

2.2 Gal/Hr (LPG), 3.25 CFM (NG)

10.0 Gallons (38.0 L)

Pressure Range (LPG, NG)

Min. Flow Range (LPG, NG)

Fuel Capacity

Oil Capacity

See Honda Manual

Starting Method

120V Receptacle

Electric

20 Amp (A) duplex (NEMA 5-20R)

30 Amp (A) locking device

(NEMA L5-30R)

120/240V Receptacle

Circuit Breaker

30 Amp (A) locking device

(NEMA L14-30R)

50 Amp (A) straight blade (NEMA 14-50R)

(1) 50 Amp (A) thermal magnetic

(1) 30 Amp (A) thermal magnetic

(1) 30 Amp (A) thermal, push to reset

(2) 30 Amp (A) thermal, push to reset

12 Volt, 400 CCA minimum,

Group size U1

Battery (not included)

Dimensions

Length

35.75” (90.8 cm)

24.25” (61.6 cm)

26.25” (66.7 cm)

340 lb. (155 kg)

410 lb. (186 kg)

Width

Height

Dry Weight

Gross Weight

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Safety Label Locations – Item #165939J

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

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.

PN 779396

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

Battery Warning

Warning 1

779396

779427

779464

Warning 2

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Machine Component Identification - Item #165939J

Figure 1 (Ref. 1-19)

Ref. Description

Air Cleaner

Gas Cap with Gauge

10.0 Gallon Gas Tank

Battery Box

Hour Meter

Oil Drain Area

Demand Regulator Assembly

Engine Oil Drain Plug

Oil Level Dip Stick

Engine Oil Fill Port

Engine Key Switch

Engine Choke Lever

Vibration Isolation Mount

Engine Exhaust Muffler

Engine Oil Filter

LPG/NG-3/4” NPT Gas Inlet

120/240V, 50A, Circuit Breaker

120/240V, 50A Receptacle

120/240V, 30A Receptacle

120/240V, 30A, Circuit Breaker

120V, 30A Receptacle

120V, 30A Circuit Breaker

120V, 20A Circuit Breaker

120V, 20A, Duplex Receptacle

Fuel Selector Switch

Generator Head

Gas Line Shutoff Valve

Figure 2 (Ref. 20-27)

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Machine Component Identification - Item #165939J

REFERENCE GUIDE

Reference 1 – Air Cleaner

Refer to your Honda engine manual for air cleaner care.

The gas cap is extra large, creating a large hole for refueling

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.

Reference 2 – Gas Cap with Gauge

Reference 3 – 10.0 Gallon Gas Tank

Reference 4 – Battery Box

Large tank allows for extended run capabilities. Always allow

room for gasoline expansion by not filling the gas tank

completely full.

The battery box provides protection for the battery and will accept

the standard lawn tractor size battery (Group U1-7). The engine

requires a 12 volts battery. See battery section for sizing.

WARNING Hookup must comply with the Federal and Local

jurisdiction of Liquid Petroleum (LP) and Natural Gas (NG).

ALWAYS have a qualified technician complete the LP/NG

hookup. Improper installation can cause injury or death. LP/NG

are lethal and explosive gases. If you smell gas, exit area

immediately, if possible shut off the LP/NG supply. Before you

start engine, smell next to floor for gas, if you do smell gas:

Reference 5 - LPG/NG-3/4” NPT Gas

Inlet

•

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 - 3.25 CFM;

LPG - 9.33 LB/hr., or 2.2 GAL/hr.

Pressure Range: 4-6 ounces, OR 7-11 inches of water column.

NEVER over pressurize.

Reference 6 - 120/240V, 50A, Circuit

Breaker

This portable generator has one 120/240 volt, 50 Amp thermal

magnetic 2 pole circuit breaker. This circuit breaker is the main

line circuit breaker and will sever power to the control panel

receptacles when in the off or tripped position. To reset this circuit

breaker, move the circuit breaker handle to the OFF position.

Then move the breaker handle to the ON position. If the circuit

breaker continues to trip, reduce load to the generator. If

nuisance tripping continues one or more electrical loads may be

defective and must be repaired by a qualified electrician.

The generator control panel has one 120/240 volt, 50 amp NEMA

14-50R receptacle. This receptacle is protected by Reference 6.

The mating plug for this receptacle is a NEMA 14-50P. This

receptacle is useful when installing a transfer switch.

The generator control panel has one 120/240 volt, 30 amp

NEMA L14-30R locking device receptacle. This receptacle is

protected by Reference 9. The mating plug for this receptacle is

a NEMA L14-30P.

Reference 7 - 120/240V, 50A

Receptacle

Reference 8 - 120/240V, 30A

Receptacle

Reference 9 - 120/240V, 30A, Circuit

Breaker

This generator has one 120/240 volt, 30 Amp thermal magnetic

2 pole circuit breaker. To reset this circuit breaker, move the

circuit breaker handle to the OFF position. Then move the

breaker handle to the ON position.

Reference 10 - 120V, 30A Receptacle

The control panel has one 120 volt, 30 amp NEMA L5-30R

receptacle. This receptacle is protected by Reference 11. The

mating plug for this receptacle is a NEMA L5-30P.

Reference 11 - 120V, 30A Circuit

Breaker

The generator control panel has a 120-volt, 30 amp thermal

circuit breaker. To reset the circuit breaker, wait 15 seconds

and press the extended button back into the circuit breaker

housing.

Reference 12 - 120V, 20A Circuit

Breaker

The generator control panel has two 120 volt, 20 amp thermal

circuit breakers. To reset the circuit breaker, wait 15 seconds

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Machine Component Identification - Item #165939J

and press the extended button back into the circuit breaker

housing.

Reference 13 - 120V, 20A, Duplex

Receptacle

The generator has a control panel with two duplex (two

receptacles in a common housing) receptacles. This duplex is a

120-volt (V) 20 amp (A) straight blade receptacle, National

Electrical Manufacturer’s Association (NEMA) number 5-20R.

This receptacle accepts NEMA plug number 5-20P. The

duplex is capable of drawing 20A out of either receptacle or a

combination of both.

Reference 14 - 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 LP/NG position.

4. Momentary sputtering is common.

5. Turn gasoline line valve to OFF position.

Reference 15 – Hour Meter

The control panel includes an hour meter to monitor engine run

time. The hour meter will not work if the 120 volt, 20 amp circuit

breaker is OFF (Reference 12).

Reference 16 – Oil Drain Area

This product was designed with a large window in the base

directly below the engine oil drain plug (Reference 18). The

large window facilitates a quick and clean process to change

engine oil.

Reference 17 – Demand Regulator

Assembly

Controls the flow of LP or NG gas into the engine carburetor.

Reference 18 – Oil Drain Plug

Refer to your Honda engine manual for oil change

recommendations.

Reference 19 – Oil Level Dip Stick

Refer to your Honda engine manual for proper oil level

recommendations.

Reference 20 – Engine Oil Fill Port

Reference 21 – Engine Key Switch

Remove the oil fill cap to add engine oil.

The engine key switch is located on the front of the engine.

Always locate this switch and be familiar with its location before

operating the generator.

Reference 22 – Engine Choke Lever

Used during cold starts. Refer to the Honda engine manual for

usage.

Reference 23 – Vibration Isolation

Mount

The engine and generator head is mounted on rubber cylinders

that absorb most of the engine vibration.

This feature

eliminates the tendency of the machine to “walk” which is

common with engine powered equipment.

Reference 24 – Engine Exhaust Filter The muffler is designed to reduce engine noise. Keep debris

and combustible materials away from the muffler. The muffler

contains a spark arrester. Refer to the Honda engine owner’s

manual for spark arrester maintenance.

Reference 25 – Engine Oil Filter

Replace the oil filter at each oil change. Replace with Honda

genuine replacement parts.

Reference 26 – Generator Head

Reference 27 – Gas Line Shutoff

Valve

The electricity producing part of the generator.

The fuel tank has an ON-OFF valve mounted underneath.

Always keep this valve closed (OFF) when the generator is not

in use.

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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

Air conditioner (12.000 BTU)

Battery charger (20 Amp)

Belt sander (3”)

Chain saw

500

1000

1200

Lawn mower

Light bulb (100 Watt)

Microwave oven

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

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Power Load Planning & Management (cont’d)

Running

Watts

Running

Watts

2800 (a)

2000 (a)

1500 (a)

600 (a)

2000 (a)

500

Device

Furnace fan (1/3 HP)

Freezer

Device

1200 (a) Submersible pump (1-1/2 HP)

800 (b)

1200

1100

875

Submersible pump (1 HP)

Submersible pump (1/2 HP)

Sump pump

Table saw

Television

Hair dryer

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

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

Device to be Powered

Light Bulb

Starting/Running 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.

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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 13,000W 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 an 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.

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.

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Installation / Initial Set-Up

The generator cannot power your entire home -- you must work with the

installing electrician to determine which devices/appliances you wish to

power during an outage. The electrician can help you determine which

circuits and devices can be powered simultaneously without overloading the

generator.

(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 four different kinds of electrical outlets on the generator:

1. One 120/240 Volt, 50 Amp straight-blade receptacle (NEMA 14-50R

receptacle compatible with NEMA 14-50P mating plug)

2. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R

locking receptacle compatible with L14-30P mating plug)

3. One 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle

compatible with NEMA L5-30P mating plug)

4. Two 120 Volt, 20 Amp duplex straight-blade receptacles (NEMA 5-

20R duplex receptacles compatible with NEMA 5-20P or 5-15P

mating plugs).

NEMA

LP /N

(2)

14-50R

NEMA

5-20R

Duplex

NEMA

L14-30R

NEMA

L5-30R

(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 Load #10 Ga. #12 Ga. #14 Ga. #16 Ga.

240V

(watts) Cord

Cord

150'

75'

35'

15'

Cord

100'

50'

25'

10'

Cord

75'

25'

10'

2400

4800

7200

9600

12000

250'

125'

60'

30'

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

Ground

Grounding

Post

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) Using LP/NG

b) Using Gasoline

4. Checking Generator Output

5. Connecting Electrical Loads (Portable Power Generation)

6. Switching Fuels:

a) From LP/NG to Gasoline

b) 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

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Operation (cont’d)

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.

• Malfunction during operation. Immediately turn off the generator if any of the following

conditions arise during operation:

o Excessive change in engine speed, slow or fast

o Overheating in load connecting devices

o Sparking or arcs from generator

o Loss of electrical output

o Receptacle damage

o Engine misfire

o Excessive vibration

o Flame or smoke

o Abnormal noise

• Adjusting / repairing. Always 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

Make sure that any regular maintenance has been performed as prescribed

in this manual in the “Maintenance & Repair” section.

scheduled

maintenance as

needed

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:

• 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 –

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Operation (cont’d)

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.

Start LPG/NG Propane (LPG):

supply

(if using)

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.

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.

Check ¾” NPT gas inlet connection for leaks each time you connect. Use the

leak test method described below.

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Operation (cont’d)

Inspect Fuel

Inspect fuel system & check for leaks BEFORE starting generator.

System / Check Do not start generator until all needed repairs have been completed.

for 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.

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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) Turn the engine key switch to the START position and hold it there

until the engine starts.

b) When the engine starts, release the key, allowing it to return to the

ON position.

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.

Lock Nut

Adjustment

Screw

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.

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.

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Operation (cont’d)

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) 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.

b) Release the key when the engine starts.

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.

Perform regular

maintenance

Perform periodic maintenance as directed in this manual to keep the

generator in safe working condition.

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Operation (cont’d)

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

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.

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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 set to the

incorrect fuel.

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.

a) Bring generator to a qualified

technician for adjustment.

b) Reduce the load. (See Power

Load Planning & Mgt. section of this

manual.)

b) Generator is overloaded.

Circuit breaker trips.

a) Defective load connected to generator. a) Disconnect load.

b) Defective receptacle.

c) Generator overloaded.

b) Replace receptacle.

c) Reduce the load. (See Power

Load Planning & Mgt. section of this

manual.)

Voltage too high.

a) Engine speed too high.

a) Generator is overloaded.

a) Bring generator to a qualified

technician for adjustment.

a) Reduce the load. (See Power

Load Planning & Mgt. section of this

manual.)

Generator

overheating.

b) Insufficient ventilation.

b) Make sure there is at least 3 feet

of clearance on all sides of generator.

No output voltage.

a) Defective load connected to generator. a) Disconnect load.

b) Broken or loose wire.

b) Bring generator to a qualified

technician for repair.

c) Defective receptacle.

d) Defective stator.

c) Replace receptacle.

d) Bring generator to a qualified

technician for repair.

e) 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.

a) Reduce the load. (See Power

Load Planning & Mgt. section of this

manual.)

Engine lacks power

or sputters.

b) Dirty air filter.

b) Clean or replace air filter.

c) LP/NG hose is connected to the wrong c) For LP, the hose should be on the

Carburetor inlet.

left inlet, For NG, the hose should be

on the right inlet.

d) Fouled spark plug.

a) Out of fuel.

b) Low oil level.

d) Clean or replace spark plug.

a) Fill fuel tank.

b) Fill crankcase to proper oil level.

Engine shuts down

during operation.

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Summary of Importation 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

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Summary of Importation Information for Operation cont’d

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.

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.

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Summary of Importation Information for Operation cont’d

• 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.

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.

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Summary of Importation Information for Operation cont’d

• 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.

• 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

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Summary of Importation Information for Operation cont’d

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:

oExcessive change in engine speed, slow or fast

oOverheating in load connecting devices

oSparking or arcs from generator

oLoss of electrical output

oReceptacle damage

oEngine misfire

oExcessive vibration

oFlame or smoke

oAbnormal 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.

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.

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Generator Exploded View Rev - J

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Generator Exploded View Rev - J

Fig #

Part #

Description

Qty

777149

38760

171410

30754

779429

779464

35298

35844

31007

778553

34857

31210

34172

32844

32848

778500

82018

35490

33277

32797

35310

35304

306579

35296

32840

777345

779396

777352

32839

777108

Fuel Cap, With Gauge

Fuel Tank Assembly

Fuel Clamp

18”

Leather Washer

Decal, Control Panel Side

Decal, Gas Valve Side

Cradle Weldment

Nameplate

Spark Arrester

Generator Head

Generator Bracket

Lead Wire

Isolation Mounts

Lower Bracket

Upper Bracket

Generator Base

5/16-18 X 2” Flange Bolt

Fuel System Components

10-32 Clip Nut

10-32 X .75” Socket Head Cap Screw

Electrical Diagram

Receptacle Box Weldment

Grommet

Engine Mount Plate

Engine, 20 HP Honda

Gasoline Fuel Line

Battery Decal

Battery Box

Battery Cable, Positive

Battery Cable, Negative

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Wiring Diagram Rev - J

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Wiring Diagram Rev - J

Diag #

Part # Description

Qty

306422

306426

30643

306434

306423

31953

31211

35309

32805

31824

Twist Lock Receptacle, NEMA L14-30R

Receptacle, 120 Volt, 20 Amp, NEMA 5-20R

Circuit Breaker, 20 Amp

Circuit Breaker, 30 Amp

Receptacle, 120 Volt, 30 Amp, NEMA L5-30R

Receptacle, 120/240 Volt, 50 Amp, NEMA 14-50R

Circuit Breaker Mounting Clip

Panel Face Graphics

Hour Meter

Fuel Selector Switch

Circuit Breaker, 30 Amp

Circuit Breaker, 50 Amp

Fuel Selector Switch Wiring Harness

Lead Wire, B15

Lead Wire, B45

Lead Wire Assembly, G5, G6

Lead Wire, B14

Lead Wire, B43

Lead Wire, B12

Lead Wire, B42

Lead Wire, B11

Lead Wire, B41

Lead Wire, B18

31005

31223

32816

B15

B45

G5,G6

B14

B43

B12

B42

B11

B41

B18

B13

B16

B46

W3-W7

305608

305609

305588

306477

306478

306479

306488

31214

31215

306608

306609

307500

307501

31217

Lead Wire, B13

Lead Wire, B16

Lead Wire, B46

Lead wire, W2

Lead Wire Assembly, W3, W4, W5, W6, W7

Lead Wire, G4

Lead Wire, G3

Lead Wire, G1

Lead Wire, B1

31216

307503

307504

307505

307506

307507

35324

W44

B44

Lead Wire, B4

Lead Wire, W44

Lead Wire, B44

306498

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Fuel Delivery System Rev - J

Diag #

Part #

Description

Qty

82187

35846

35847

32808

777119

37748

35488

777239

32811

36297

38183

36825

32822

32798

777148

35330

777237

777238

32821

32817

35325

35008

35037

M6-1.0 X 65mm Socket Head Cap Screw, w/ thread locking patch

Venturi

Adapter

Elbow

Hose Clamp

Regulator Wire Harness

Oil Pressure Switch Wire Harness

Protective Sleeve

Gas Hose

Load Block

Street Elbow, 3/8” MPT x 1/4” FPT

Gas Regulator

13.2”

16.6”

1/8” NPT Plug

Pipe Nipple, 1-5/16”

LP/NG Fuel Lock Solenoid

Pipe Nipple, 12”

Pipe Hanger

Hex Nut Coupler

Lanyard

Triple Fuel Hang Tag

Oil Pressure Switch

O-Ring

Air Cleaner Riser

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Generator Head Exploded View Rev - J

Ref #

Part #

Description

Qty

30991

30994

31013

Drive End Bracket

Protection Screen

Phillips Screw

Fan

Grommet

Terminal Box Cover

M5 X .8, 16mm Long

M5 X .8, 10mm Long, Green

M5 X .8, 10mm Long

Rubber Cup

Rear Bearing

Nylock Nut and Star Washer

Grill

30995

307489

305605

31014

31018

31015

307484

306403

306416

30997

31065

30999

Securing Stud Cap

Fixing Ring

Rotor Assembly

Diode

30992

307479

307481

9910303129

39256

Varistor

Capacitor, 35uF

Frame and Stator Assembly

M5 X .8, Nut

Brass Jumper

Terminal Board

Securing Stud (333mm)

31017

31011

307478

31022

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