North Star 6500 Dpg Users Manual

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MODEL 6500 DPG, ITEM # 165930
Diesel Portable Generator
P ro v e n

P e rf o rm a nc e

M165930A

OWNER’S MANUAL

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 generator’s 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
Electric Engine Starting
Manual Engine Starting
Engine Stopping
Engine care
Generator care
Engine Fuel Line Bleeding
Troubleshooting

1

1
2
3
4-5
5
5
5
6
6-7
8
8
8-9
9
9
9
9
10

SPECIFICATIONS
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

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 lb. ( kg)
310 lb. ( kg)

2

MACHINE COMPONENT IDENTIFICATION

Figure 1 (Ref. 1-11)
Ref.
1
2
3
4
5
6
7
8

Description

Ref.

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

9
10
11
12
13
14
15
16

00309

Description
Air Cleaner Housing
Muffler
Decompression Lever
Warning Decals
Ignition Fuse
Isolation Mounts
Battery Box and Battery
Generator

Figure 2 (Ref. 12-17)
3

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.

GENERATOR FEATURES
Reference 1 - Gas Cap w ith Gauge. The gas
cap is 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. Alw ays
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 Cov er. 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. Nev er operate the
generator without the deflector installed in the
upright position.
Reference 11 - Decompression Lev er.
Reduces the force required to recoil start the
engine.
Reference 12 - Warning Labels.
Nev er
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

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 and 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
(GFCI) 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 is a 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.
4

The reset button must be pushed to reset the
receptacle.
Reference 20 - 120 Volt-30 Amp Tw istlock
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
Tw istlock 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 popular for connection to a transfer
switch for home standby power. See item #16412 in
the NORTHERN catalog.
Reference 22 - Ignition Sw itch. 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.

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
owner’s manual furnished with the generator
(Yanmar refers to the 10 HP engine as a L100AEDE).
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 serious injury. 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.

GENERATOR FEATURES NOT SHOWN
Low Oil Pressure Shutdow n. 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 position). The
engine will not start until the oil is refilled to above
the safe level.

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

Fuel Shut Off Valv e. The fuel tank is 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.

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:

Fuel Drain Valv e. 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 fuel feeding line from the
engine. Always make sure this valve is closed prior
to filling the fuel tank.

5

WARNING This generator is equipped

WARNING Check fuel system on a

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.

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.

ALWAYS use electrical cords that are in good
condition.
Worn, bare, frayed or otherwise
damaged cords can cause electric shock.

WARNING Keep fire extinguisher close
by your generator and be familiar on how to use it.
Consult your local fire department for correct
extinguisher type.

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.

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 slide 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 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.
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 install your generator inside confined
areas. Inside installation can cause health hazards
or death.

NEVER touch 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.

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.

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.

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
6

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 multiplying nameplate voltage
by nameplate amperage.
VOLTS X AMPS = WATTS
Example: 120V
X 5A
600W

1/4
1/3
1/2
1
1 1/2
2
3
5

=

STARTING ELECTRIC MOTORS
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.
Most fractional motors take about the same
amount of current to run them whether they are of
Repulsion-Induction (RI), Capacitor (Cap), or SplitPhase (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.
60

Hz

Running
Watts
525

7-11

Cap
type
9-18

12-23
14-29
20-40
32-64
40-80
48-96
68-136
112-224

22-32
26-35
NA
NA
NA
NA
NA
NA

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 is held to a minimum.
Current/Pow e
r
Amps Load
at
(watts)
240V
10
2400
20
4800
30
7200

Starting Amps
RI type

9-15
11-18
15-25
24-40
30-50
36-60
51-85
84-140

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 head winding might also be damaged.
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 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.

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.

120V,
Motors
Hp
motor
1/6

700
875
1175
1925
2400
2900
4075
6750

SP
type
16-22
7

Maximum Extension Cord Length
#10
Ga.
Cord
250’
125’
60’

#12
Ga.
Cord
150’
75’
35’

#14
Ga.
Cord
100’
50’
25’

#16
Ga.
Cord
75’
25’
10’

40
50

9600
12000

30’
15’

15’
10’
*
*
*
*
*Not recommended
CAUTION: Equipment damage can result from
the low voltage caused by using an extension cord
with a small wire size.

Submersible Pump (1/2 HP)
1500 (a)
Sump Pump
600 (a)
Table Saw (10”)
2000 (a)
Television
500
Toaster
1000
Vacuum cleaner
250
VCR
70
Water Heater
3000
Weed Trimmer
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.

Use this chart to estimate the total load on your
generator.
For Determining Generator Load Requirements
Dev ice
Running Watts
Air Conditioner (12,000 Btu)
1700 (a)
Battery Charger (20 Amp)
500
Belt Sander (3”)
1000
Chain Saw
1200
Circular Saw (6-1/2”)
900
Coffee Maker
1000
Compressor (1 HP)
2000 (a)
Compressor (3/4 HP)
1800 (a)
Compressor (1/2 HP)
1400 (a)
Curling Iron
700
Dishwasher
1200
Edge Trimmer
500
Electric Nail Gun
1200
Electric Range (one element)
1500
Electric Skillet
1250
Furnace Fan (1/3 HP)
1200 (a)
Freezer
800 (b)
Hair Dryer
1200
Hand Drill (1”)
1100
Hand Drill (1/2”)
875
Hand Drill (3/8”)
500
Hand Drill (1/4”)
250
Hedge Trimmer
450
Home Computer
150
Impact Wrench
500
Jet Pump
800 (a)
Lawn Mower
1200
Light Bulb
100
Microwave Oven
700
Milk Cooler
1100 (a)
Oil Burner on Furnace
300
Oil Fired Space Htr (140,000 Btu)
400
Oil Fired Space Htr (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
Submersible Pump (1-1/2 HP)
2800 (a)
Load Requirements, continued
Submersible Pump (1 HP)
2000 (a)

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, loose or missing nuts and
bolts. If the aforementioned problems occur, call
customer service at 1-800-270-0810.
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 10 gauge 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 system.
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.

OPERATING SPEED
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

8

so could result in damage to equipment plugged
into the unit and possible injury to the individual.
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.
Load
Percent of
Generator
Output

Speed
(RPM)

0%
50 %
100 %

3780
3600
3480

Output
Frequency
(Hz)

63.0
60.0
58.0

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
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).

Generator
Voltage at
120V
Receptacle
129V
120V
112V

ENGINE SHUTDOWN

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 spilled diesel
fuel.
4. Make sure that the exhaust fumes are
directed away from people.

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 Owner’s 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

ELECTRIC START OF ENGINE
1.
2.
3.
4.

Disconnect all loads to generator.
Turn gas line valve to ON position.
Turn the ignition key to the START position.
If the engine does not start after 10 seconds,
9

generator base. Use a deflector (piece of cardboard
or paper) to direct the oil down the hole.

6: Allow fuel to drip from the fuel line into a
small container.
7. Reattach the fuel line to the fuel injector.

GENERATOR CARE
The generator is a 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 operated 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 1-800-2700810.
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.

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.

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:
2:
3:
4:
5:

Allow engine to cool down.
Turn the fuel valve to the OFF position.
Loosen the hose clamp on the fuel line.
Pull the fuel line off of the fuel injector.
Turn the fuel valve to the ON position
10

TROUBLESHOOTING
Problem

Possible Causes

Possible Remedies

Engine will not start.

a) Low oil level.
b)
Air in the line.

Circuit breaker trips.

a)
Defective load connected to
generator.
b)
Defective receptacle.
c) Generator overloaded.

a)
Fill crankcase to proper oil
level.
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.)
a)
Disconnect load.
b)
Replace receptacle.
c) Reduce the load. (See Load
Application section of this manual.)

Voltage too high.

a)

Engine speed too high.

a)

Generator
overheating.

a)

Generator is overloaded.

b)

Insufficient ventilation.

c) Out of fuel.
d) Battery is defective.
e) Fuel Filter clogged.
f) Fuel shut off valve is in the OFF
position.
Voltage too low.

No output voltage.

a)

Engine speed too slow.

b)

Generator is overloaded.

a)
Defective load connected to
generator.
b)
Broken or loose wire.
c) Defective receptacle.
d)
Defective stator.
e)

Defective rotor.

Engine lacks power.

f) Defective capacitor.
a) Generator is overloaded.

Engine shuts down
during operation.

b)
a)
b)

Dirty air filter.
Out of fuel.
Low oil level.

11

Bring generator to a qualified
technician for adjustment.
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.
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.
a)
Reduce the load. (See Load
Application section of this manual.)
b)
Clean or replace air filter.
a)
Fill fuel tank.
b)
Fill crankcase to proper oil
level.



---

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