North Star 6500 DPG User's Manual
Contents
1. 1 Disconnect all loads to generator 2 Turn fuel line valve to ON position 3 Turn the ignition key to the RUN position 4 Grasp the recoil handle and pull until a strong resistance is felt 5 Let the recoil handle return to the initial position 6 Push down the decompression lever The lever is located on top of the engine and is colored RED 7 Pull out the recoil handle briskly with both hands 8 If the engine will not start consult the trouble shooting table page 10 ENGINE SHUTDOWN 1 Disconnect all loads from generator 2 Turn the ignition key to the OFF position 3 Turn the fuel valve to the OFF position ENGINE CARE Refer to your Yanmar Owners Manual for proper care and maintenance Refer to your Yanmar Owners manual for fuel and oil information IMPORTANT It is possible that the fuel line will need to be bled the first time the fuel tank is filled NOTE When changing the oil on a hot engine the oil might overshoot the oil drain hole on the generator base Use a deflector piece of cardboard or paper to direct the oil down the hole GENERATOR CARE The generator isa two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with one sealed radial roller bearing The generator rotor is directly connected to the engine crank shaft and the stator is rigidly coupled to the engine casting via the generator adapter casting Exercising The Generator The generator should be operated2. 5 Turn the fuel valve to the ON position 10 6 Allow fuel to drip from the fuel line into a small container 7 Reattach the fuel line to the fuel injector A WARNING Stand by Operation If your generator is to be used as a standby electric power source in case of utility failure it must be installed by a registered and licensed electrician and in compliance with all applicable state and local electrical codes Also local Fire Departments must be consulted concerning proper and safe handling procedures for gasoline NEVER connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician TROUBLESHOOTING Problem Engine will not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Engine shuts down during operation Possible Causes Possible Remedies a Low oil level b Airin the line c Out of fuel d Battery is defective e Fuel Filter clogged f Fuel shut off valve isin the OFF position Engine speed too slow Generator is overloaded Defective load connected to generator b Defective receptacle c Generator overloaded Engine speed too high Generator is overloaded Insufficient ventilation a Defective load connected to generator b Broken or loose wire c Defective receptacle Defective stator Defective rotor
3. will not be damaged if it can bring the motor up to speed in a few seconds If difficulties in starting a motor are experienced turn off all other electrical loads and if possible reduce the load on the electric motor EXTENSION CORDS When electric power is to be provided to various loads at some distance from the generator extension cords can be used These cords should be sized to allow for distance in length and amperage so that the voltage drop between the set and point of use isheld to a minimum Maximum Extension Cord Length r Amps Load 10 12 14 16 at watts Ga Ga Ga Ga 240V Cord Cord Cord Cord 10 2400 250 150 100 75 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 i Submersible Pump 1 2 HP 1500 a 50 12000 15 a Sump Pump 600 a Not recommended Table Saw 10 2000 a CAUTION Equipment damage can result from Television 500 the low voltage caused by using an extension cord Toaster 1000 with a small wire size Vacuum cleaner 250 VCR 70 Use this chart to estimate the total load on your Water Heater 3000 generator Weed Trimmer 500 For Determining Generator Load Requirements a Hard starting motors require 3 to 5 times the PaO UME als l Air Conditioner 12 000 Btu 1700 a b These loads may require up to 15 minutes to Battery Charger 20 Amp 500 restart due to its normal build up of compressor Belt Sander 3 1000 head pr
4. be used to alert against unsafe practices RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operation will considerably lessen the possibilities of a personal injury This manual will warn of specific personal injury potential and these will be designated by the symbol A WARNING This generator is equipped with a grounding screw located on the rear of the generator for your protection Always complete the grounding path from the generator to a copper pipe rod that is driven into moist earth to prevent electrical shock ALWAYS use electrical cords that are in good condition Wor bare frayed or otherwise damaged cords can cause electric shock NEVER operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in the rain or snow Electric shock may result ALWAYS use a ground fault circuit interrupter GFCl in damp or highly electrical conductive areas and on construction job sites to prevent electric shock ALWAYS remove the spark plug or spark plug wire before working on the engine or generator to prevent accidental starting ALWAYS provide adequate ventilation Do not operate generator in any enclosed or narrow space Engines consume oxygen and give off deadly carbon monoxide poisonous gas Improper ventilation will cause damage to generator and possible injury to people NEVER to
5. every three to four weeks Warm the unit up by starting the engine and letting it run for 10 to 15 minutes This will dry out any moisture that has accumulated in the windings If left this moisture can cause corrosion in the winding Frequent operation of the engine generator will also ensure that the set is operating properly should it be needed in an emergency Generator Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technician USE ONLY FACTORY APPROVED REPAIR PARTS Obtain factory parts from Customer Service at 1 800 270 0810 A Bearing The bearing used in the generators is a heavy duty sealed roller bearing requires no maintenance or lubrication B Receptacles Quality receptacles have been utilized If a receptacle should become cracked or otherwise damaged replace it Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment ENGINE FUEL LINE BLEEDING If the engine is having difficulty in starting and the fuel and oil levels are acceptable the problem can usually be traced to air bubbles trapped in the fuel line To bleed air from the fuel line 1 Allow engine to cool down 2 Turn the fuel valve to the OFF position 3 Loosen the hose clamp on the fuel line 4 Pull the fuel line off of the fuel injector
6. extra large creating a large hole for refilling and a comfortable grip You can always monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap Reference 2 6 5 Gallon Fuel Tank Large tank allows for extended run capabilities Always allow room for fuel expansion by not filling the tank completely full Reference 3 Operating Instructions Reference 4 Control Panel See Figure 3 for details WARNING Contact a licensed electrician to wire electrical plugs and or cordsets Improper wiring could result in a fire or electrical shock Reference 5 Oil Filter Access Cover Your Yanmar engine is equipped with a reusable oil filter Access to the oil filter is achieved by loosening the fixing bolt and then rotating the cover plate The filter should be inspected during each oil change Consult your Yanmar engine manual for further details Reference 6 Oil Drain Plug Removal of plug allows drainage of oil from the engine Consult your Yanmar engine manual for further details Reference 7 Oil Fill and Dip Stick Consult your Yanmar engine owners manual for details concerning oil changing intervals Reference 8 Recoil Handle Consult your owners manual for engine starting or refer to page 8 of this manual Reference 9 Air Cleaner Housing Refer to your Yanmar engine manual for air cleaner care Reference 10 Muffler Never operate the generator without the deflector installed
7. f Defective capacitor a Generator is overloaded Dirty air filter Out of fuel Low oil level 11 Fill crankcase to proper oil ae b Bleed the air from the fuel line see page 9 c Fill fuel tank d Charge or replace battery e Replace fuel filter f Turn the valve to the ON position a Bring generator to a qualified technician for adjustment b Reduce the load See Load Application section of this manual Disconnect load Replace receptacle c Reduce the load See Load Application section of this manual Bring generator to a qualified technician for adjustment Reduce the load See Load Application section of this manual b Make sure there is at least 3 feet of clearance on all sides of generator Disconnect load Bring generator to a qualified technician for repair Replace receptacle Bring generator to a qualified technician for repair Bring generator to a qualified technician for repair Bring generator to a qualified technician for repair Reduce the load See Load Application section of this manual Clean or replace air filter Fill fuel tank Fill crankcase to proper oil
8. start and run various types and sizesof 120 volt 60 cycle electric motors under various conditions 120V 60 Motors Starting Amps Hp Running RI type Cap motor type 1 6 11 9 18 16 22 1 4 700 9 15 12 23 22 32 1 3 875 11 18 14 29 26 35 1 2 1175 15 25 20 40 NA 1 1925 24 40 32 64 NA 1 1 2 2400 30 50 40 80 NA 2 2900 36 60 48 96 NA 3 4075 51 85 68 136 NA 5 6750 84 140 112 224 NA The figures given above are for an average load such asa blower or fan If the electric motor is connected to a hard starting load such as an air compressor it will require more starting current If it is connected to a light load or no load such as a power saw it will require less starting current The exact requirement will also vary with the brand or design of the motor Generators respond to severe overloading differently than the power line When overloaded the engine is not able to supply enough power to bring the electric motor up to operating seed The generator responds to the high initial starting current but the engine speed drops sharply The overload may stall the engine If allowed to operate at very low speeds the electric motor starting winding will burn out in a short time The generator head winding might also be damaged Running the generator under these conditions may result in damage to the generator stator as well asthe motor windings Because the heavy surge of current is required for only an instant the generator
9. MODEL 6500 DPG ITEM 165930 Diesel Portable Generator M165930A 00308 6500 DPG Shown with Optional Wheel Kit Item 165916 Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 Hours Monday Friday 7 00 AM to 5 30 PM CST Saturday 7 30 AM to 11 30 AM CST THANK YOU Thank you for purchasing a NorthStar Diesel Series Generator Your machine is designed for long life dependability and the top performance you demand Please take time now to read through this manual so you can better understand the machine s operation maintenance and safety precautions Everyone who operates this generator must read and understand this manual The time you take now will prolong your generators life and prepare you for its safe operation Enjoy the exceptional performance of your NorthStar Diesel Series Generator IMPORTANT Make certain the operator Reads and understands the manuals pertaining to this machine Is instructed in safe and proper operation of this machine NOTICE K BAR Industries Incorporated reserves the right to make improvements in design and or changes in specifications at any time without incurring any obligation to install them on units previously sold TABLE OF CONTENTS Thank you Specifications Machine component identification Generator features Introduction ANSI safety definitions Rules for safe operation Installation Load application Pre start up preparation El
10. ar for connection to a transfer switch for home standby power See item 16412 in the NORTHERN catalog Reference 22 Ignition Switch To start the engine turn the key to the START position To stop the engine turn the key to the OFF position See the section on starting for further details Reference 23 Charging Lamp The charging lamp will glow when the engine charging system is not functioning correctly The lamp will glow when the ignition key is in the run position and the engine is not running Reference 24 Hour Meter The hour meter allows for monitoring of engine maintenance schedules Reference 25 Voltmeter The voltmeter allows for monitoring of the generator The needle should be in the green area for all load conditions GENERATOR FEATURES NOT SHOWN Low Oil Pressure Shutdown The Yanmar engine is protected against damage resulting from a low oil level As the oil falls below the safe level the engine automatically shuts off the engine ignition switch remains in the on postion The engine will not start until the oil is refilled to above the safe level Fuel Shut Off Valve The fuel tankis equipped with a fuel shut off valve Always turn the fuel valve to the off position when the generator is not in use The valve is located underneath the fuel tank Fuel Drain Valve The fuel tank is equipped with a unique feature A fuel drain valve is installed to drain diesel fuel from the tank without disconnecting the fue
11. e wattage than its rating on the nameplate asthe wattage is influenced by the equipment efficiency power factor and starting system NOTE If wattage is not given on equipment nameplate approximate wattage may be determined by multiplying nameplate voltage by nameplate amperage VOLTS X AMPS WATTS Example 120V X 5A 600W When connecting a resistive load such as incandescent lights heaters or common electric power tools a capacity of up to the generator full rated wattage output can be used When connecting a resistive inductive load such as a fluorescent or mercury light transformers or inductive coils a capacity of up to 0 6 times the generator s full rated output can be used Always allow the generator to reach operating speed before a load is applied STARTING ELECTRIC MOTORS Electric motors require much more current amps to start than to run Some motors particularly low cost split ohase motors are very hard to start and require 5 to 7 times more current to start than to run Capacitor motors are easier to start and usually require 2 to 4 times as much current to start than to run Repulsion Induction motors are the easiest to start and require 1 5 to 2 5 times as much to start than to run Most fractional motors take about the same amount of current to run them whether they are of Repulsion Induction Rl Capacitor Cap or Split Phase SP type The following chart shows the approximate current required to
12. ectric Engine Starting Manual Engine Starting Engine Stopping Engine care Generator care Engine Fuel Line Bleeding Troubleshooting Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method 120V Receptacle 120 240V Receptacle Circuit Breakers Grounding Screw Dimensions Length Width Height Dry Weight Gross Weight SPECIFICATIONS 165930 6500 Watts W 6120 Watts W 120 240 Volt V Single phase 4 wire 58 0 63 0 Hertz Hz 1 0 p f 10 HP Yanmar L100AE DEG 3480 3720 RPM Diesel 6 5 gallons 24 6 L 1 76 US quarts 1 65 L Electric Recoil 20 Amp A Duplex GFCI NEMA 5 20R 30 Amp A Twistlock NEMA L5 30R 30 Amp A Twistlock NEMA L14 30R 30 Amp A Magnetic Qty 1 20 Amp A Thermal type Qty 2 Receives 10 Ga Fork Terminal 34 00 86 4 cm 23 25 59 1 cm 22 25 56 5 cm 295 Ib kg 310 Ib kg MACHINE COMPONENT IDENTIFICATION OND Of WP Gas Cap with Gauge 6 5 Gallon Fuel Tank Operation Instructions Control Panel Oil Filter Access Cover Oil Drain Plug Oil Fill and Dip Stick Recoil Handle Figure 1 Ref 1 11 00309 Air Cleaner Housing Muffler Decompression Lever Warning Decals Ignition Fuse Isolation Mounts Battery Box and Battery Generator Figure 2 Ref 12 17 GENERATOR FEATURES Reference 1 Gas Cap with Gauge The gas cap is
13. essure Chain Saw 1200 NOTE For extremely hard to start loads such as Circular Saw 6 1 2 900 air conditioners and air compressors consult the Coffee Maker 1000 equipment dealer to determine the maximum Compressor 1 HP 2000 a wattage Compressor 3 4 HP 1800 a Compressor 1 2 HP 1400 a PRE START PREPARATIONS Curling Iron 700 Dishwasher 1200 Your generator has been thoroughly tested prior Edge Trimmer 500 to shipment from the factory A factory test report Electric Nail Gun 1200 has been included with this manual However Electric Range one element 1500 damage can occur during shipping so be sure to Electric Skillet 1250 check for damaged parts loose or missing nuts and Furnace Fan 1 3 HP 1200 a bolts If the aforementioned problems occur call Freezer 800 b customer service at 1 800 270 0810 Hair Dryer 1200 Hand Drill 1 1100 GROUNDING All units must be grounded Hand Drill 1 2 875 Drive a 3 4 or 1 copper pipe or rod into the ground Hand Drill 3 8 500 close to the generator The pipe rod must Hand Drill 1 4 250 penetrate moist earth Connect an approved Hedge Trimmer 450 ground clamp to the pipe Run a 10 gauge wire Home Computer 150 from the clamp to the generator grounding post Impact Wrench 500 located on the control panel Do not connect to a Jet Pump 800 a water pipe or a ground used by a radio system Lawn Mower 1200 CAUTION The engine has been shipped Light Bulb 100 without oil F
14. ill the crankcase with oil before trying Microwave Oven 700 to start Low oil shut down prevents your generator Milk Cooler 1100 a from starting without sufficient oil Oil Burner on Furnace 300 Oil Fired Space Htr 140 000 Btu 400 OPERATING SPEED Oil Fired Space Hir 85 000 Btu 225 Oil Fired Space Htr 30 000 Btu 150 Oven 4500 Paint Sprayer Airless 1 3 HP 600 a Paint Sprayer Airless handheld 150 Radio 200 Refrigerator 600 b Slow Cooker 200 The output voltage should be checked to Submersible Pump 1 1 2 HP 2800 a ensure the generator is working properly before Load Requirements continued connecting a load to the generator Failure to do Submersible Pump 1 HP 2000 a The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency The speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency so could result in damage to equipment plugged into the unit and possible injury to the individual All engines have a tendency to sow down when a load is applied When the electrical load is connected to the generator the engine is more heavily loaded and as a result the speed drops slightly This slight decrease in speed together with the voltage drop within the generator itself results in a slightly lower voltage when the generator is loaded to its full capacity than when it is running with no load The
15. in the upright position Reference 11 Decompression Lever Reduces the force required to recoil start the engine Reference 12 Warning Labels Never operate the generator or engine until all warning labels are fully understood If warning labels are missing contact our customer service department at 1 800 270 0810 Reference 13 Ignition Fuse Your engine is equipped with a 15 Amp automotive style fuse located inside the white protective case Reference 14 Vibration Isolation Mounts The engine and generator are mounted on rubber mounts that absorb most of the engine vibration This feature eliminates the tendency of the machine to walk which is common in most engine powered equipment If the mounts appear damaged replace with factory approved parts Reference 15 Battery Box and Battery The battery is located inside the battery box and is intended for starting the engine Reference 16 Generator Your NorthStar product is equipped with a high quality brushless generator The generator is maintenance free and will provide years of dependable service OIBSFEL PORTABLE BS n DPG CPNEFATOR Saas 7 EM uk FUN y i Figure 3 Ref 17 25 00323 Reference 17 Main line Breaker The main line breaker is a two pole thermomagnetic resettable circuit breaker The circuit breaker will protect the generator from overload and short circuit conditions To reset the circuit breaker move the toggle to the OFF position a
16. l deteriorate and result in grounding or shorting out the generating system Foreign matters such as dust dirt sand lint or abrasive materials can cause damage to the generator head and engine if allowed into its cooling system NEVER install your generator inside confined areas Inside installation can cause health hazards or death A DANGER Remember exhaust fumes are deadly carbon monoxide gas and must be vented to the outside where there are no people Cooling air of sufficient amounts must be brought in and exhausted out to ensure proper cooling of the engine and generator head LOAD APPLICATION It is important to determine the total electrical load before it is connected to the generator The two major factors in determining the life of a generator head are heat build up caused by overloading the generator and corrosive contaminants that attack the wiring insulation If the generator is overloaded the wires become excessively hot and cause the insulation to break down reducing its ability to resist corrosive contaminants Over time the effectiveness of the insulation is eliminated and a dead short can result Always compare the generator nameplate data with that of the equipment to be used to ensure that watts volts amperage and frequency requirements are suitable for operating equipment The wattage listed on the equipment nameplate is its rated output However some equipment may require three to ten times mor
17. l feeding line from the engine Always make sure this valve is closed prior to filling the fuel tank INTRODUCTION Before starting your generator thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator Proper preparation operation and maintenance will result in operator safety best performance and long life of the generator For detailed engine operation and maintenance always refer to the Yanmar engine owners manual furnished with the generator Yanmar refers to the 10 HP engine as a L100AE DE NorthStar is constantly improving its products The specifications outlined herein are subject to change without prior notice or obligation The purchaser and or user assumes liability of any modification and or alterations on this equipment from original design and manufacture Before using the user shall determine the suitability of this product for its intended use and assumes liability therein ANSI SAFETY DEFINITIONS DANGER indicates an imminently hazardous situation which if not avoided will result in death or seriousinjury This signal word is to be limited to the most extreme situations WARNING indicates a potentially hazardous situation which if not avoided could result in a death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also
18. nd then back to the ON position When this circuit breaker is in the OFF position all receptacles will be off Reference 18 Thermal Circuit Breakers The control panel has two thermal circuit breakers If the circuit breaker trips a black post will extend from the circuit breaker push the black post to reset the circuit breaker If the circuit breaker will not reset wait two minutes and try again Reference 19 120 Volt 20 Amp GFCI Duplex Receptacle The control panel is equipped with four 120 Volt 20 Amp ground fault circuit interrupt GFCl receptacles NEMA 5 20R The receptacles will accept either NEMA 5 15P or NEMA 5 20P plugs In the center of each duplex receptacle there are both a test reset button and a indicator lamp If there isa fault condition with a load connected to a duplex receptacle the indicator lamp will glow and the reset button will extend To test the GFCI press the test button and the reset button should extend The reset button must be pushed to reset the receptacle Reference 20 120 Volt 30 Amp Twistlock Receptacle The control panel is equipped with one NEMA L5 30R receptacle This receptacle accepts only NEMA L5 30P plugs one of which is shipped with the generator Reference 21 120 240 Volt 30 Amp Twistlock Receptacle The control panel is equipped with one NEMA L14 30R receptacle This receptacle accepts only NEMA L14 30P plugs one of which is shipped with the generator This receptacle is popul
19. slight variation has no appreciable effect in the operation of motors lights and most appliances Electronic equipment and clocks will be affected if correct RPM is not maintained See Load vs Output chart Generator Voltage at Percent of Frequency Generator Hz Output 120V Receptacle Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances it can be checked with a portable meter Frequency can be checked by using an electric clock with a sweep second hand Timed against a wrist watch or a stop watch the clock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician BEFORE STARTING 1 Make sure the generator is positioned on a firm level surface 2 Check the crankcase for oil and maintained at a proper level 3 Check fuel level and fill tank 7 8 full with diesel fuel Never fill fuel tank completely to the top Always wipe up and remove any gpilled diesel fuel 4 Make sure that the exhaust fumes are directed away from people ELECTRIC START OF ENGINE 1 Disconnect all loads to generator 2 Turn gas line valve to ON position 3 Turn the ignition key to the START position 4 If the engine does not start after 10 seconds wait 15 seconds before attempting to start again 5 If the engine will not start consult the trouble shooting table page 10 MANUAL START OF ENGINE
20. uch hot muffler hot exhaust manifold or engine cooling fins ALWAYS remove all oil or fuel deposits and accumulated dirt from generator and immediate area Keep generator and engine clean NEVER operate the generator under the following conditions A Excessive change in engine speed slow or fast B Overheating in load connecting devices C Sparking or arcs from generator D Loss of electrical output E Damaged receptacles F Engine misfire G Excessive vibration H Enclosed compartments or confined areas Flame or smoke J Rain snow or wet conditions K Operator non attendance A WARNING 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 tankor a defective fuel shut off valve Correct any defects before operation A warwnc Keep fire extinguisher close by your generator and be familiar on how to use it Consult your local fire department for correct extinguisher type INSTALLATION OUTDOORS Choose a location where the generator will not be exposed to rain snow or direct sunlight Position the generator on secure level ground so it will not tip or side down a hill Place the generator so that the exhaust fumes will not be directed towards people The installation site must be free from water moisture or dust All electrical components should be protected from excessive moisture or the insulation system wil
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