Troubleshooting. NORTHSTAR Belt Driven Generator Head, Belt Driven Generator Head, 10,000 Surge Watts, 9,600 Rated Watts, 18 HP Required

Troubleshooting

Problem

Voltage too low.

Circuit breaker trips.

Voltage too high.

TROUBLESHOOTING

Possible Causes a) Engine speed too slow. b) Generator is overloaded. c) Belt slippage. (Or coupler slippage) a) Defective load connected to generator. b) Defective receptacle. c) Generator overloaded. a) Engine speed too high.

Generator overheating. a) Generator is overloaded.

No output voltage. b) Insufficient ventilation. a) Defective load connected to generator. b) Broken or loose wire. c) Defective receptacle. d) Defective stator. e) Defective rotor. f) Defective capacitor. g) Defective circuit breaker. h) Belt(s) is slipping or broken. (Or coupler slipping or broken) i) Circuit breaker tripped.

Possible Remedies a) Bring generator to a qualified technician for adjustment. b) Reduce the load. (See Power Load

Planning & Mgt. section of this manual.) c) Tighten belt(s). (Or tighten coupler) a) Disconnect load. b) Replace receptacle. c) Reduce the load. (See Power Load

Planning & Mgt. section of this manual.) a) Bring generator to a qualified technician for adjustment. a) Reduce the load. (See Power Load

Planning & Mgt. section of this manual.) b) Make sure there is at least 7 feet of clearance on all sides of generator. a) Disconnect load. b) Bring generator to a qualified technician for repair. c) Replace receptacle. d) Bring generator to a qualified technician for repair. e) Bring generator to a qualified technician for repair. f) Bring generator to a qualified technician for repair. g) Bring generator to a qualified technician for repair. h) Tighten or replace belt(s). (Tighten or replace coupler) i) Reset circuit breaker and reduce loads connected to the generator.

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Summary of Important Safety Information

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, entanglement, fire, or burns. In addition, the generator can lift or flip and cause severe injury if improperly secured.

General

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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.

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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.

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Adults only.

Only trained adults should set up and operate the generator. Do not let children operate.

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Under the influence . Never operate, or let anyone else operate, the generator while under the influence of alcohol, drugs, or medication.

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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

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Modifications prohibited.

Never modify or alter the generator in any way. Modifications can create serious safety hazards and will also void the warranty.

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Fuel/exhaust system . Never modify the engine’s exhaust system, fuel tank, or fuel lines. Carbon monoxide poisoning, fire, or explosion could result.

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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

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Mount generator and engine.

Failure to properly mount the generator may cause the unit to lift or flip during use, which could result in severe injury to the operator or bystanders, or cause damage to surrounding objects.

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The generator and engine must be securely mounted to a common base such as a heavy-duty metal plate.

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The mounting base must be of adequate size and strength to withstand operating torque and vibration without either flipping or experiencing stress failure.

• See the “Installation / Initial Set-Up” section of this Owner’s Manual for mounting requirements and instructions.

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Power transmission guarding.

The power transmission assembly must be equipped with a guard that prevents contact with all rotating shafts, pulleys, belts, and couplings. Clothing or hair can become rapidly entangled in unguarded rotating parts, resulting in serious injury or death. This guard is not supplied with the unit because the generator manufacturer does not know the size and dimensions of the engine to be used. The customer is responsible for installing an appropriate guard.

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Dry, level surface . Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation.

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DANGEROUS carbon monoxide exhaust - Operate OUTSIDE only ! The engine gives 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,

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Summary of Important Safety Information (cont’d)

barns, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.

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Cooling ventilation . The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head so it does not overheat and possibly cause fire. Situate so there is adequate clearance around generator to allow for cooling airflow. Do not allow debris to accumulate and block airflow.

Keep all objects at least 7 feet away from vent slots.

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Grounding . Always ensure generator is properly grounded to prevent electrical shock. This generator is equipped with a grounding screw. 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 fire when utility power is restored.

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Wet conditions . Water conducts electricity. Do not operate generator where it is wet. Operate on a dry surface under an open, canopy-like structure.

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Hot engine exhaust . Engine exhaust can be extremely hot and cause fire. Refer to your engine manual to determine safe clearance distance required between hot exhaust and nearby combustible objects.

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Belt tension.

Belt slippage can cause static electricity build-up, which may result in sparking. Fire ignition can result. Follow instructions in this manual for adjusting belt tension.

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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.

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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

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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.

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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.

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Inspect . Before each use, inspect the generator, engine, and power transmission assembly (belts, pulleys, couplings). Ensure generator/engine mounting is secure. Check for fuel leaks and loose or damaged parts. Do not operate the generator with damaged, missing, or broken parts.

Personal protective equipment

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Hearing protection . The use of earplugs or other hearing protection device is recommended for those in close proximity to the generator while it is operating.

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No loose / dangling apparel . Loose or dangling apparel and long hair can become entangled in moving/rotating parts. Metal jewelry can conduct electricity. Never wear jewelry or loose-fitting clothing such as neckties, scarves, or long-sleeved or untucked shirts when operating the generator. Tie back hair and secure close to head.

Battery Safety

(If engine is equipped with battery start)

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 engine:

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Eye/skin protection.

Always wear eye protection and protective clothing when connecting or disconnecting battery.

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Summary of Important Safety Information (cont’d)

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Sparks/Smoking.

Never smoke or work near sparks or other sources of ignition.

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Electric shock.

Never touch both battery terminals at the same time with your hand or any non-insulated tools.

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Connection/disconnection sequence.

ALWAYS connect and disconnect cables to the correct battery terminals in the proper sequence: 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

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Acid/skin contact.

If battery acid contacts skin or clothing, flush immediately with water and neutralize with baking soda.

Gasoline safety - fueling your engine

Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use extreme care when handling:

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Fuel outdoors . Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result.

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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.

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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.

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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.

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Replace cap . Replace gas cap securely before starting engine.

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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.

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On skin / clothes . If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately.

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Inspect fuel system . Check fuel system on a regular basis. Look for signs of leaks, deterioration, or damaged fuel tank. Do not start engine until needed repairs have been completed.

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Gasoline storage . Store gasoline in a cool, dry place in an UL-approved, tightly sealed container.

Safety – During Use

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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.

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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.

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Power transmission guarding . Never operate the generator without proper guarding of the power transmission assembly, including all rotating shafts, pulleys, belts, and couplings. Clothing or hair can become rapidly entangled in unguarded rotating parts, resulting in serious injury or death.

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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.

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Stabilize before connecting loads. Start generator and let engine stabilize before connecting electrical loads.

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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.

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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.

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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.

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GFCI extension cords.

Always use ground fault circuit interrupter (GFCI)-equipped extension cords to prevent electrical shock in damp or highly electrical conductive areas and on construction jobsites.

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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.

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

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Summary of Important Safety Information (cont’d)

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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.

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Hot parts. Parts of the engine and generator are extremely hot during and after operation and can burn you.

Never touch hot muffler, hot exhaust manifold or any other part of the engine or generator unless you have first determined if it is hot. Wait a sufficient time for parts to cool before touching any part of the generator or engine.

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Moving parts . Keep hands, feet, and apparel away from drive belts, sheaves, couplings, fans, and other moving parts. Never attempt to remove any guard or shield while the unit is operating.

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Smoking/sparks . Never smoke near the running generator, and never operate near sources of sparks or flames.

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Carbon monoxide poisoning . The 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.

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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

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Adjusting / repairing . Before working on the generator or engine, always turn off engine and remove spark plug(s) or spark plug wire(s) to prevent accidental starting.

Safety – After use

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Cool before storing. Let engine and generator cool for at least five minutes before storing. Hot equipment can be a fire hazard near combustible materials.

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Prevent accidental starting.

When generator is not in use, remove key from engine starter (key start engines) and secure in a safe location, or remove spark plug(s) or spark plug wires(s) in order to ensure that generator cannot be started in a storage location or by untrained persons.

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Storage location.

Store the generator/engine assembly 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 engine’s gas tank is empty. Residual gasoline could ignite.

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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.

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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:

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Turn off engine . Always turn off engine and remove spark plug(s) or spark plug wire(s) before working on the engine or generator to prevent accidental starting.

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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.

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Clear debris/deposits.

Keep generator head and moving parts clean. This will ensure the generator is in safe working condition.

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Replace guards / shields.

Make sure all guards and shields are replaced after servicing the generator.

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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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