North Star Portable Generator 5000 PG User Manual

MODEL 5000 PG, ITEM #165965  
Portable Generator  
P r o v e n P e r f o r m a n c e  
M165965A  
OWNER’S MANUAL  
Any Questions, Comments, or Problems?  
Call Customer Service at 1-800-270-0810  
 
SPECIFICATIONS  
Item Number  
Maximum Output  
Continuous Output  
Voltage  
#165965  
5000 Watts (W)  
4000 Watts (W)  
120 / 240 Volt (V)  
Phase  
Single phase (4-wire)  
56.5 - 63.3 Hertz (Hz)  
112-129V  
1.0 p.f.  
8 HP Tecumseh (HM80)  
3390 - 3798 RPM  
Frequency Regulation  
Voltage Regulation  
Power Factor  
Engine  
Engine Speed  
Fuel Type  
Unleaded gasoline  
Fuel Capacity  
Oil Capacity  
Starting Method  
120 VReceptacle  
240 VReceptacle  
Circuit Breaker  
Grounding Post  
Dimensions  
Length  
Width  
Height  
Dry Weight  
1 gallon (3.8 L)  
1.63 US quarts (1.5 L)  
Recoil  
20 Amp (A) duplex (NEMA 5-20R)  
20 Amp (A) duplex (NEMA 6-20R)  
17 Amp (A) thermal, push to reset  
Receives 12 Ga. wire or fork terminal  
26.00” (66 cm)  
19.00” (48 cm)  
17.50” (45 cm)  
106 lb. (45 kg)  
117 lb. (53 kg)  
Gross Weight  
2
 
MACHINE COMPONENT IDENTIFICATION  
Figure 1 (Ref. 1-9)  
fig.01858  
Ref. Description  
Ref. Description  
1
2
3
4
5
6
7
8
Muffler  
Gas Cap  
Engine Stop Switch  
Recoil  
Air Cleaner  
Vibration Isolation Mount  
Oil Drain Plug  
Choke Lever  
Dipstick  
10  
11  
12  
13  
14  
15  
16  
17  
Protective Frame  
Grounding Screw  
120V 20A Duplex Rec  
Circuit Breakers  
240V 20A Duplex Rec.  
Generator Head  
Warning Instructions  
Gas Tank  
9
Figure 2 (10-17)  
Fig01857  
3
 
GENERATOR FEATURES  
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 Tecumseh engine owner’s manual  
furnished with the generator (Tecumseh refers to the  
8 HP engine as a HM80).  
Reference 1 - Muffler. Allow 3clearance  
around the hot exhaust gas.  
Reference 2 - Gas Cap.  
Reference 3 - Engine Stop Switch. The rocker  
engine stop switch is located on the engine. I means  
ON. O means OFF.  
Reference 4 - Recoil. Grasp firmly when starting  
engine.  
Reference 5 - Air Cleaner.  
Refer to your  
Tecumseh engine manual for air cleaner care.  
Reference 6 - Vibration Isolation Mounts. The  
engine and generator are mounted on rubber cylinders  
that absorb most of the engine vibration. This feature  
eliminates the tendency of the machine to “walk” which  
is common in engine powered equipment.  
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 of any  
modification and/or alterations on this equipment from  
original design and manufacture.  
Reference 7 - Oil Drain Plug. Refer to your  
Tecumseh engine  
recommendations.  
Reference 8 - Choke Lever. Used during cold  
starts. Refer to the starting/stopping instructions and  
the Tecumseh engine manual for usage.  
manual  
for  
oil  
change  
Before using, the user shall determine the  
suitability of this product for its intended use and  
assumes liability therein.  
ANSI SAFETY DEFINITIONS  
Reference 9 - Dipstick  
Reference 10. Protective Frame. The frame  
protects to engine and generator from damage.  
Reference 11 - Grounding Screw. Ground the  
generator via the grounding screw, to a copper pipe or  
rod that is driven into moist soil.  
DANGER indicates an imminently hazardous  
situation which, if not avoided, will result in death or  
serious injury. This signal word is to be limited to the  
most extreme situations.  
Reference 12 - 120V Receptacle. The generator  
has a control panel with one duplex (two receptacles in  
a common housing) receptacle. The 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 numbers  
5-15P and 5-20P. Each receptacle on the duplex is  
capable of drawing 17A simultaneously.  
Reference 13 - Circuit Breakers. This portable  
single phase generator has two, 17 amp (A) push to  
reset circuit breakers to protect against electrical  
overloads.  
Reference 14 - 240V Receptacle. This device is  
a 240V 20A NEMA 6-20R receptacle. This receptacle  
accepts a NEMA plug number 6-20P.  
ALWAYS use grounded male plugs. The neutral  
line of the generator is mechanically grounded to the  
frame. Matching NEMA male plugs must always be  
used.  
WARNING indicates a potentially hazardous  
situation which, if not avoided, could result in a  
death or seri ous i nj ury.  
CAUTION indicates a potentially hazardous  
situation, which if not avoided, may result in minor or  
moderate injury. It may also 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:  
Reference 15 - Generator Head. The electricity  
producing part of the generator.  
Reference 16 – Warning Instructions.  
Reference 17 - Gas Tank. Always allow room  
for gasoline expansion by not filling the gas tank  
completely full.  
WARNING This generator is equipped  
with a grounding post, located on the control panel 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. Worn, bare, frayed or otherwise damaged  
cords can cause electric shock.  
4
 
generator so that the exhaust fumes will not be  
directed towards people.  
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.  
The installation site must be free from water,  
moisture, or dust. All electrical components should be  
protected from excessive moisture or the insulation  
system will 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.  
ALWAYS use a ground fault circuit interrupter  
(GFCI) 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.  
NEVER install your generator inside confined  
areas. Inside installation can cause health hazards or  
death.  
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.  
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 allowed to flow in and  
exhausted out to ensure proper cooling of the engine  
and generator head.  
NEVER touch hot muffler, hot exhaust manifold or  
engine cooling fins.  
LOAD APPLICATION  
ALWAYS remove all oil or gasoline deposits and  
accumulated dirt from generator and immediate area.  
Keep generator head and engine clean.  
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 can 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 more wattage than its rating on the nameplate,  
as the 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  
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.  
I. Flame or smoke.  
J. Rain, snow or wet conditions.  
K. Operator non-attendance.  
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 tank or a defective fuel shut-off  
valve. Correct any defects before operation.  
multiplying  
amperage.  
nameplate voltage by nameplate  
WARNING Keep fire extinguisher close  
VOLTS X AMPS = WATTS  
by your generator and be familiar on how to use it.  
Consult your local fire department for correct  
extinguisher type.  
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.  
INSTALLATION  
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.  
OUTDOORS:  
Choose locations 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 slide down a hill. Place the  
5
 
STARTING ELECTRIC MOTORS  
EXTENSION CORDS  
Electric motors require much more current (amps)  
to start than to run. Some motors, particularly low cost  
split-phase 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.  
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 is held  
to a minimum.  
Current/Power Maximum Extension Cord Length  
Most fractional motors take about the same  
amount of current to run them whether they are of  
Repulsion-Induction (RI), Capacitor (Cap), or Split-  
Phase (SP) type. The following chart shows the  
approximate current required to start and run various  
types and sizes of 120 volt 60 cycle electric motors  
under various conditions.  
Amps  
at  
240V  
10  
20  
30  
40  
50  
Load  
(watts)  
#10  
Ga.  
Cord  
250’  
125’  
60’  
30’  
15’  
#12  
Ga.  
Cord  
150’  
75’  
35’  
15’  
*
#14  
Ga.  
Cord  
100’  
50’  
25’  
10’  
*
#16  
Ga.  
Cord  
75’  
25’  
10’  
*
2400  
4800  
7200  
9600  
12000  
*
Starting Amps  
RI type Cap type SP type  
120V, 60 Hz Motors  
Hp motor Running  
Watts  
*Not recommended  
CAUTION: Equipment damage can result from the  
low voltage caused by using an extension cord with a  
sm all wi re si ze.  
1/6  
1/4  
1/3  
1/2  
1
1 1/2  
2
525  
700  
875  
1175  
1925  
2400  
2900  
4075  
6750  
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-224  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
Use this chart to estimate the total load on your  
generator.  
For Determining Generator Load Requirements  
Device  
Running Watts  
1700 (a)  
500  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
Chain Saw  
Circular Saw (6-1/2”)  
Coffee Maker  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling Iron  
Dishwasher  
Edge Trimmer  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
Furnace Fan (1/3 HP)  
Freezer  
Hair Dryer  
Hand Drill (1”)  
Hand Drill (1/2”)  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
3
5
1000  
1200  
900  
1000  
The figures given above are for an average load  
such as a 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 speed. 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 winding might also be  
damaged.  
2000 (a)  
1800 (a)  
1400 (a)  
700  
1200  
500  
1200  
1500  
1250  
1200 (a)  
800 (b)  
1200  
1100  
875  
500  
250  
450  
150  
500  
Running the generator under these conditions may  
result in damage to the generator stator as well as the  
motor windings. Because the heavy surge of current  
is required for only an instant, the generator will not be  
damaged if it can bring the motor up to speed in a few  
Jet Pump  
Lawn Mower  
Light Bulb  
Microwave Oven  
Milk Cooler  
800 (a)  
1200  
100  
700  
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.  
1100 (a)  
Oil Burner on Furnace  
Oil Fired Space Htr (140,000 Btu)  
Oil Fired Space Htr (85,000 Btu)  
300  
400  
225  
6
 
Oil Fired Space Htr (30,000 Btu)  
Oven  
150  
4500  
damage to equipment plugged into the unit and  
possible injury to the individual.  
Paint Sprayer, Airless (1/3 HP)  
Paint Sprayer, Airless (handheld)  
Radio  
Refrigerator  
Slow Cooker  
Submersible Pump (1-1/2 HP)  
Submersible Pump (1 HP)  
Submersible Pump (1/2 HP)  
Sump Pump  
Table Saw (10”)  
Television  
600 (a)  
150  
200  
600 (b)  
200  
2800 (a)  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
All engines have a tendency to slow 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 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.  
Toaster  
1000  
Vacuum Cleaner  
VCR  
250  
70  
Water Heater  
Weed Trimmer  
3000  
500  
(a) Hard-starting motors require 3 to 5 times the  
rated running watts.  
(b) These loads may require up to 15 minutes to  
restart due to its normal build up of compressor head  
pressure.  
NOTE: For extremely hard to start loads such as  
air conditioners and air compressors, consult the  
equipment dealer to determine the maximum wattage.  
Load  
Output  
Frequency  
Percent of  
Generator  
Output  
0 %  
50 %  
100 %  
Speed  
(RPM)  
Generator  
Voltage at 120V  
Receptacle  
(Hz)  
3780  
3600  
3510  
63.0  
60.0  
58.5  
129V  
120V  
112V  
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.  
PRE-START PREPARATIONS  
Your generator has been thoroughly tested prior to  
shipment from the factory. A factory test report has  
been included with this manual. However, damage  
can occur during shipping, so be sure to check for  
damaged parts or loose or missing nuts and bolts. If  
the aforementioned problems occur, call Customer  
Service at 1-800-270-0810.  
BEFORE STARTING  
GROUNDING - All units must be grounded. Drive  
a 3/4” or 1” copper pipe or rod into the ground close to  
the generator. The pipe/rod must penetrate moist  
earth. Connect an approved ground clamp to the pipe.  
Run a no. 12 Ga. wire from the clamp to the generator  
grounding post located on the control panel. Do not  
connect to a water pipe or a ground used by a radio  
sy stem .  
1. Make sure the generator is positioned on firm  
l evel surface.  
2. Check the crankcase for oil and maintain at a  
proper level.  
3. Check fuel level and fill tank with fresh unleaded  
gasoline if necessary. Allow for gasoline expansion by  
never filling fuel tank completely to the top. Always  
wipe up and remove any spilled gasoline.  
4. Make sure that the exhaust fumes are directed  
away from people.  
CAUTION: The engine has been shipped without  
oil. Fill the crankcase with oil before trying to start.  
Low oil shut down prevents your generator from  
starting without sufficient oil.  
STARTING  
OPERATING SPEED  
1. Disconnect all loads to generator.  
2. Move engine on-off lever located on engine to  
the I position.  
3. For cold engine, move choke lever to full choke  
position. For a warm engine, move choke lever to to  
half choke or run position.  
4. Grasp recoil handle and pull.  
5. When engine starts, move choke lever to run  
position.  
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.  
The output voltage should be checked to ensure  
the generator is working properly before connecting a  
load to the generator. Failure to do so could result in  
6. Loads may now be connected to generator.  
7
 
STOPPING  
1. Disconnect all loads to generator.  
2. Move engine on-off switch to the O position.  
ENGINE CARE  
Refer to your Tecumseh Owner’s Manual for  
proper care and maintenance.  
CAUTION NEVER change oil on a hot  
engine, the hot oil could cause severe burns.  
GENERATOR CARE  
The generator head is a two pole, 3600 RPM, 60  
Hz, brushless, revolving field and synchronous type  
with one sealed radial roller bearing. The rotor of the  
generator head is directly connected to the engine  
crank shaft and the stator is rigidly coupled to the  
engine casting via the generator head casting.  
Exercising The Generator - The generator  
should be operated every 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 all factory parts  
from Customer Service at 1-800-270-0810.  
A. Bearing - The bearing used in these generators  
is a heavy duty sealed ball bearing. They require 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.  
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.  
8
 
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.  
a) Engine speed too slow.  
d) Place switch in ON position.  
a) Bring generator to a qualified  
technician for adjustment.  
Voltage too low.  
b) Generator is overloaded.  
b) Reduce the load. (See Load  
Application section of this manual.)  
a) Disconnect load.  
Circuit breaker trips.  
Voltage too high.  
a) Defective load connected to generator.  
b) Defective receptacle.  
b) Replace receptacle.  
c) Generator overloaded.  
c) Reduce the load. (See Load  
Application section of this manual.)  
a) Bring generator to a qualified  
technician for adjustment.  
a) Engine speed too high.  
Generator overheating. a) Generator is overloaded.  
b) Insufficient ventilation.  
a) 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.  
a) Disconnect load.  
No output voltage.  
a) Defective load connected to generator.  
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) Bring generator to a qualified  
technician for repair.  
e) Defective rotor.  
f) Defective capacitor.  
a) Generator is overloaded.  
f) Bring generator to a qualified  
technician for repair.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Clean or replace air filter.  
a) Fill fuel tank.  
Engine lacks power.  
b) Dirty air filter.  
a) Out of fuel.  
b) Low oil level.  
Engine shuts down  
during operation.  
b) Fill crankcase to proper oil level.  
9
 

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