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Summary of Important Safety Information for Operation (cont’d) 

 

 

 

37

• 

Electrical cords.

  Use only UL-listed, outdoor-rated, three prong extension cords of the proper size.  All 

extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise damaged.  
Use of inadequate or damaged electric cords can cause electric shock or fire. 

• 

Avoid contact

.  Avoid contact with bare wires, terminals, connections, etc. while the unit is running.   

• 

Electric shock accident.

  If an electric shock accident occurs, immediately shut down the source of electrical 

power.  If this is not possible, attempt to free the victim from the live conductor.  Avoid direct contact with 
victim.  Use a nonconducting implement, such as a dry rope or board, to free the victim from the live 
conductor.  Apply first aid and get immediate medical help. 

• 

Hot muffler

. Never touch hot muffler, hot exhaust manifold, or engine cooling fins.  Exhaust and engine parts 

can be very hot and will burn you. 

• 

Moving parts

.  Keep hands, feet, and apparel away from drive belts, fans, and other moving parts.  Never 

remove any drive belt or fan guard while the unit is operating. 

• 

Refueling

.  DO NOT refuel the engine until it has cooled at least two minutes. 

• 

Malfunction during operation.  

Immediately turn off the generator if any of the following conditions arise 

during operation: 

Excessive change in engine speed, slow or fast 

Overheating in load connecting devices 

Sparking or arcs from generator 

Loss of electrical output 

Receptacle damage 

Engine misfire 

Excessive vibration 

Flame or smoke 

Abnormal noise 

• 

Adjusting / repairing

.  Always turn off generator and remove spark plug(s) or spark plug wire(s) before 

working on the generator to prevent accidental starting.    

 

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.   

• 

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. 

Summary of Contents for M165967M

Page 1: ...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 swi...

Page 2: ...Hazard Signal Word Definitions 2...

Page 3: ...Source 13 4 Selecting a Suitable Site 16 5 Grounding the Generator 18 6 Battery Installation 19 7 Spark Arrester Installation 19 Operation 1 General Safety Rules for Operation 20 2 Preparing for Opera...

Page 4: ...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 Be sure to read about...

Page 5: ...ility 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 Regi...

Page 6: ...38 0 L Oil Capacity 1 6 US quarts Starting Method Electric start Recoil 120 V Receptacles 2 20 Amp A duplex NEMA 5 20R 30 Amp A locking receptacle NEMA L5 30R 120 240 V Receptacle 30 Amp A locking rec...

Page 7: ...cting DISCONNECT BLACK cable first then RED NEVER charge a visibly damaged or frozen battery ALWAYS read and follow charger instructions Commercial grade electric start engine Extend run 10 gallon fue...

Page 8: ...eakers 11 Engine Key Switch 3 120 240V 50A Receptacle 12 Recoil 4 120 240V 30A Locking Receptacle 13 Oil Filter 5 120V 30A Locking Receptacle 14 Muffler 6 120V 20A Duplex Receptacle 15 Battery Box 7 O...

Page 9: ...feature eliminates the tendency of the machine to walk which is common in engine powered equipment Reference 9 Optional Wheel Kit 165919 Optional heavy duty wheel kit Item 165919 Reference 10 10 0 Ga...

Page 10: ...te 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...

Page 11: ...g 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 devi...

Page 12: ...n 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 Co...

Page 13: ...ur 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 e...

Page 14: ...tor produces 40A 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 compat...

Page 15: ...0 Ga Cord 12 Ga Cord 14 Ga Cord 16 Ga Cord 10 2400 250 150 100 75 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 50 12000 15 WARNING Use of under sized extension cords can cause electric sh...

Page 16: ...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 she...

Page 17: ...use 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 i...

Page 18: ...pe 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 ra...

Page 19: ...YS 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...

Page 20: ...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 unforese...

Page 21: ...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 wat...

Page 22: ...etain 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 fu...

Page 23: ...sure that any regular maintenance has been performed as prescribed in this manual in the Maintenance Repair section 1 Refer to the engine owner s manual for engine maintenance instructions 2 Make sure...

Page 24: ...emoving gas cap Note A running or still hot engine is hot enough to ignite fuel Remove generator gasoline cap Add gasoline through the fill opening Use only a UL approved portable gasoline container t...

Page 25: ...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...

Page 26: ...the engine starts b Using recoil start i Turn the engine key switch to the ON position ii Pull the starter grip lightly until you feel resistance then pull the starter cord out briskly and rapidly iii...

Page 27: ...asured 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 fact...

Page 28: ...e 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 d...

Page 29: ...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 d...

Page 30: ...g 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 a...

Page 31: ...ging 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 performe...

Page 32: ...s Replace if damaged Keep generator clean 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 be...

Page 33: ...Generator overheating a Generator is overloaded b Insufficient ventilation a Reduce the load See Power Load Planning Mgt section of this manual b Make sure there is at least 3 feet of clearance on al...

Page 34: ...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 adjust...

Page 35: ...ITY 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...

Page 36: ...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 C...

Page 37: ...ing 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...

Page 38: ...Generator Exploded View Rev M 38...

Page 39: ...Mounts 4 12 778963 Rear Base Bracket 1 13 778506 Generator Base 1 14 82067 Clip Nut 10 32 4 15 778962 Control Panel Assembly 1 16 82007 Socket Head Cap Screw 10 32 X 75 4 17 38760 Fuel Tank Assembly 1...

Page 40: ...Wiring Diagram Rev M 40...

Page 41: ...d Wire Assembly B1 B2 W1 W2 W3 W4 W5 W6 W7 1 B15 305608 Lead Wire Assembly B15 1 B45 305609 Lead Wire Assembly B45 1 B14 306477 Lead Wire Assembly B14 1 B43 306478 Lead Wire Assembly B43 1 B12 306479...

Page 42: ...7 Fan 1 4 779920 Drive End Bracket 1 5 779558 Enclosing Band 1 6 777304 End Cover 1 7 38271 End Cover Plug 1 8 779559 Stator 1 9 779560 Rotor 1 10 307479 Diode 2 11 779561 Securing Stud Nut 1 12 38276...

Page 43: ...h as engines are guaranteed by their manufacturer and can be serviced at factory authorized locations near you Any costs incurred due to replacement or repair of items outside of a NorthStar approved...

Page 44: ...44 Manufactured by Northern Tool Equipment Co 2800 SouthCross Drive West P O Box 1499 Burnsville MN 55337 0499...

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