NorthStar 165165 Product Manual Download

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Specifications – Item #165165A

SPECIFICATIONS

Item Number

165165

Maximum Output

6500 Watts (W)

Continuous Output

6120 Watts (W)

Voltage

120 / 240 Volt (V)

Phase

Single phase (4-wire)

Frequency

56.5 - 63.3 Hertz (Hz)

Power Factor

1.0 p.f.

Engine

9.4 HP Kubota OC95

Engine Speed

3600 RPM

Fuel Type

Diesel

Fuel Capacity

6.5 gallons (24.6 L)

Oil Capacity

1.76 US quarts (1.65 L)

Starting Method

Electric

120V Receptacle

20 Amp (A) Duplex GFCI (NEMA 5-20R)

30 Amp (A) Locking device

(NEMA L5-30R)

120/240V Receptacle

30 Amp (A) Locking device

(NEMA L14-30R)

Circuit Breakers

30 Amp (A) Magnetic, Qty. 1

20 Amp (A), Thermal type, Qty. 2

Grounding Screw

Receives 10 Ga. Fork Terminal

Battery (not included)

12 Volt, 36 Amp-Hour minimum,

Group size U1

Dimensions

Length

34.00" (86.4 cm)

Width

23.25" (59.1 cm)

Height

22.25" (56.5 cm)

Dry Weight

315 lb. (143 kg)

Gross Weight

330 lb. (150 kg)

Summary of Contents for 165165

Page 1: ...n 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 listed 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 ONL...

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

Page 3: ...UP or PORTABLE Power Source 13 4 Selecting a Suitable Site 16 5 Grounding the Generator 18 6 Battery Installation 19 Operation 1 General Safety Rules for Operation 20 2 Preparing for Operation 23 3 Starting the Engine 26 4 Checking Generator Output 27 5 Connecting Loads 28 6 Stopping the Engine 29 7 Storage and Exercise 29 Maintenance and Repair 31 Troubleshooting 33 Summary of Important Safety In...

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 site selection and grounding requirements for running this generator More detailed information can be found in the Installation and Initial Set up Steps 5 and 6 of this manual This generator is too he...

Page 5: ...bility 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 Co...

Page 6: ...ns 24 6 L Oil Capacity 1 76 US quarts 1 65 L Starting Method Electric 120V Receptacle 20 Amp A Duplex GFCI NEMA 5 20R 30 Amp A Locking device NEMA L5 30R 120 240V Receptacle 30 Amp A Locking device NEMA L14 30R Circuit Breakers 30 Amp A Magnetic Qty 1 20 Amp A Thermal type Qty 2 Grounding Screw Receives 10 Ga Fork Terminal Battery not included 12 Volt 36 Amp Hour minimum Group size U1 Dimensions L...

Page 7: ...issing 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 779396 Battery Warning 791697 NorthStar 791724 Warning 793520 Fuel Warning 786635 Burn Hazard 793562 Fire Hazard fig05699 ...

Page 8: ...er Housing 3 Voltmeter 13 Decompression Lever 4 120 Volt 20 Amp GFCI Duplex Receptacles 14 Muffler 5 Hour Meter 15 Ignition Fuse 6 Engine Stop Lever 16 Isolation Mounts 7 120 Volt 30 Amp Locking Receptacle 17 Battery Box 8 Engine Starting Key 18 Generator Head 9 120 240 Volt 30 Amp Locking Receptacle 19 6 5 Gallon Fuel Tank 10 Oil Drain Plug 20 Fuel Cap with Gauge Figure 2 Ref 14 20 ...

Page 9: ...gs Reference 8 Engine Starting Key To start the engine turn the key to the START position Reference 9 120 240 Volt 30 Amp Locking Receptacle The control panel is equipped with one NEMA L14 30R receptacle This receptacle accepts only NEMA L14 30P plugs This receptacle is popular for connection to a transfer switch for home standby power Reference 10 Oil Drain Plug Removal of plug allows drainage of...

Page 10: ...plate 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 Es...

Page 11: ...ring 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...

Page 12: ...generator 5 Grounding 6 Battery installation electric start models only Each of these steps is discussed in detail below 1 Unpacking and 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 or damaged components contact Product...

Page 13: ...r 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 listed transfer switch installed by a lice...

Page 14: ...al outlets There are three different kinds of electrical outlets on the generator 1 One 120 240 Volt 30 Amp locking receptacle NEMA L14 30R locking receptacle compatible with L14 30P mating plug 2 One 120 Volt 30 Amp locking receptacle NEMA L5 30R receptacle compatible with NEMA L5 30P mating plug 3 Two 120 Volt 20 Amp duplex GFCI straight blade receptacles NEMA 5 20R duplex receptacles compatible...

Page 15: ...10 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 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 elect...

Page 16: ...d 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 ca...

Page 17: ...e 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...

Page 18: ...ipe 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 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 ...

Page 19: ...ent 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 clothin...

Page 20: ...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 guar...

Page 21: ...rate 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 el...

Page 22: ...aterial 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 fuel vapors that are present during fuel...

Page 23: ... 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 Ow...

Page 24: ...e fuel container to transfer the diesel fuel to the generator s tank Follow the safety warning and instructions below for avoiding static electric sparking Do NOT overfill the fuel 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 ignite fuel vapor resulting in a flash fire that could cause seriou...

Page 25: ...enerator until all needed repairs have been completed WARNING Fuel leak hazard Standard diesel fuel is combustible with ethanol diesel blends being nearly as flammable as gasoline Fuel leaks can result in fire 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 Inspect the entire fuel system Look for signs of leaks ...

Page 26: ...Release the key when the engine starts or after 10 seconds vi If engine does not start after 10 seconds wait 30 seconds before attempting to start again vii If the engine will not start consult the Troubleshooting section of this manual 4 Under long continuous run operating conditions be prepared to a Check and refuel the engine on a regular basis A tank of fuel should last about 14 hours under 50...

Page 27: ... The voltmeter s needle should be within the green area initially and during all load conditions 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 Slight variation in voltage speed with changing electrical loads All engines have a tendency to slow down when a load is applied When e...

Page 28: ...e 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 vol...

Page 29: ...rn fuel line shut off valve to OFF position as shown 5 Remove key from starter or remove spark plug to prevent accidental starting of engine 7 Storage and 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 in...

Page 30: ...storage location or by untrained persons Exercise generator every 4 weeks The generator should be exercised regularly 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 wi...

Page 31: ...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 replace...

Page 32: ...ctions 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 become blocked 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 batter...

Page 33: ...eed too high a Bring generator to a qualified technician for adjustment Generator overheating a Generator is overloaded b Insufficient ventilation a Reduce the load See Power Load Planning and Mgt section of this manual 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 b Broken or loose wire c Defective receptacle ...

Page 34: ...ill 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 o...

Page 35: ... UTILITY POWER via an UL listed 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 ou...

Page 36: ...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 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...

Page 37: ...arting 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 fuel 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 the gene...

Page 38: ...Generator Exploded View Rev A 2 38 ...

Page 39: ...nerator Mount 1 12 777362 Screw w locking patch 3 8 16 x 1 4 13 32844 Lower Bracket 6 14 791517 Base 1 15 791646 Control Panel Weldment 1 16 82067 Clip Nut 10 32 4 17 791642 Control Panel Assembly 1 18 793292 Exhaust Deflector 1 19 32567 Isomount 6 20 306459 Engine Ground Wire 1 21 32848 Upper Bracket 6 22 791436 Diesel Engine 1 23 791724 Decal 1 24 777345 Fuel Line 29 25 793603 Fuel Filter 1 26 7...

Page 40: ... Receptacle 30 Amp 120 Volt 1 8 306422 Locking device Receptacle 30 Amp 120 240 Volt 1 9 791645 Engine Ignition Stop Run Start Switch 1 10 30646 Hour Meter 1 11 38763 Lead Wire Assembly 2 3 G1 G3 G4 G5 G6 W3 W4 W5 W6 W18 NG B1 B4 1 B11 31956 Lead Wire Assembly B11 1 B14 B41 38772 Lead Wire Assembly B14 B41 1 B12 31958 Lead Wire Assembly B12 1 B42 31959 Lead Wire Assembly B42 1 B13 31962 Lead Wire ...

Page 41: ...n 1 4 781479 Drive End Bracket 1 5 MA38270 Enclosing Band 1 6 788185 End Cover 1 7 MA38271 End Cover Plug 1 8 780142 Stator 1 9 780229 Rotor 1 10 MA307479 Diode 2 11 780143 Securing Stud Nut 1 12 MA38276 Bearing 1 14 MA38278 Non Drive End Bracket 1 15 MA38279 Capacitor 1 16 MA38280 Bracket Securing Stud 4 17 MA307481 Varistor 2 ...

Page 42: ...42 This page has intentionally been left blank ...

Page 43: ...aced or repaired is the sole decision of NorthStar NorthStar will not provide for replacement of complete products due to defective parts Any costs incurred due to replacement or repair of items outside of a NorthStar approved facility is the responsibility of the buyer and not covered under warranty Transportation costs to and from service center is the responsibility of the customer In addition ...

Page 44: ...44 Assembled by Northern Tool Equipment Co Inc Burnsville MN 55306 NorthernTool com ...

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