Proven
ITEM #165952
MODEL 10500 SBG
Stand By Generator
Installation and Operation Manual
DANGER
ONLY A QUALIFIED CONTRACTOR OR ELECTRICIAN SHOULD INSTALL THIS PRODUCT.
IT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE REGULATIONS, CODES,
AND STANDARDS.
M165952F
1
THANK YOU
Thank you for purchasing a NorthStar Standby 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 generator installation, maintenance and safety
precautions. Everyone who installs, or maintains 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 product.
IMPORTANT INSTRUCTIONS
Make certain:
- The operator and installer read and understand this manual.
- If any portion of this manual is unclear, or portions of this manual are missing please call:
NorthStar Customer Service at 1-800-270-0810
Monday - Friday, 7:00 AM to 5:00 PM, CST
Saturday 7:30 AM to 11:30 AM, CST
Throughout this manual and on safety decals located on the machinery, DANGER, WARNING,
and CAUTION headings are used to identify special instruction that must be understood prior
to installation, repair, or operation of this generator. Observe the DANGER, WARNING, and
CAUTION blocks carefully. Their definitions are as follows:
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.
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.
After the DANGER, WARNING, and CAUTION headings, appropriate instructions are relayed
about specific functions or installation procedures that may be hazardous if the safety instructions
are not followed. HOW TO OBTAIN SERVICE
When your NorthStar product requires service or repair, simply call our NorthStar Customer
Service Department. We will locate the nearest authorized service center. Please call this
number:
NorthStar Customer Service
1-800-270-0810
Monday - Friday, 7:00 AM to 5:30 PM, CST
Saturday 7:30 AM to 11:30 AM, CST
NOTICE
NTE Manufacturing 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.
2
SAFETY RULES
! SAVE THESE INSTRUCTIONS !
It is strongly encouraged that the SAFETY RULES
be copied and posted near the generator
installation site and near the transfer switch.
The safety rules must be studied carefully prior to
installing, operating, or servicing this equipment.
Become familiar with both the Installation, Owner’s
Manual, and the actual generator set prior to
installation.
For trouble free operation and safety concerns,
NorthStar recommends that installation, initial start-up,
and maintenance should issues be addressed by
professionals who are familiar with installation and
operation of stand by generator sets.
DANGER • Never operate this generator in
an enclosed area. Exhaust gases contain carbon
monoxide, an odorless and deadly poison.
DANGER • Never install the generator in
such a location that exhaust gases can seep back into
closed rooms. Gases can seep into closed rooms
through windows, doors, and floors.
DANGER • Never install this product indoors,
or modify the exhaust system for indoor installation.
DANGER • Always disconnect the battery
prior to installation or servicing the generator or
transfer switch. This product can start
automatically. Disconnect the battery cable from the
NEGATIVE, NEG, or (-) terminal first. Reconnect that
cable last.
DANGER • Never work inside the generator
unless utility power is disconnected. Remember: The
battery charger and convenience receptacle are
energized by a 120-volt electrical circuit that is
independent of the stand by generator.
DANGER • Always remove the spark plugs
or spark plug wires before working on the engine or
generator. The engine can start automatically.
SAFETY RULES
ELECTRICAL HAZARDS
The generator covered within this manual can and
will produce dangerous electrical voltages that cause
fatal electrical shocks. The utility power that is
connected to the transfer switch produces extremely
high and dangerous voltages, as does the generator
set when in operation. Avoid any contact to bare wires
while the utility is energizing the transfer switch, and
avoid any contact with bare wires until the generator
set is disabled from auto/manual start.
DANGER • Never handle any kind of electrical
device while standing in water, while barefoot, or while
hands or feet are wet. Dangerous electrical shock will
result.
DANGER • The National Electrical Code (NFPA
70) requires the frame and externally conductive parts
of the generator to be connected to an approved earth
ground.
DANGER • This home stand by electrical system
may start without warning. When the generator starts
load circuits automatically can transfer by the transfer
swi tch . Never work on the home electrical system
without first disabling the starting mechanism of the
stand by generator set. Never work on the home
electrical system without first de-energizing the
incoming utility power at the main line circuit breaker.
FIRE HAZARDS
DANGER • Gas hookup must comply with the
Federal and Local jurisdictions for Liquid (LPG) and
Natural Gas (NG) codes. ALWAYS have a qualified
technician complete the LPG/NG hookup. Improper
installation can cause injury or death.
DANGER • LPG and NG are lethal and explosive
gases. If you smell gas, exit the area immediately.
DANGER • Do not smoke around the generator.
Wipe up any fuel or oil spills immediately. Ensure that
no combustible materials are left in the generator
compartment, or near the generator. Keep area
around the generator clean and free of debris. Keep a
fire extinguisher rated “ABC” near the generator.
3
Table of Contents
Introduction Page 1
Thank you Page 1
Important Instructions Page 1
How to Obtain Service Page 1
Notice Page 1
Safety Rules Page 2
Table of Contents Page 3
Section 1 - Specifications Page 3
1.1 Engine Page 3
1.2 Generator Page 3
1.3 Control System Page 4
Section 2 - Installation Page 4
2.1 Introduction Page 4
2.2 Assistance Page 4
2.3 Unpacking the Product Page 5
2.4 Installation Preparation Page 5
2.5 Generator Location Page 5
Sizing the Generator Slab Page 5
Generator Dimensions Page 6
Mounting Pad Design Page 7
2.6 Fuel System Introduction Page 8
2.7 Fuel System Components Page 8
2.8 Generator Winding Connections Page 9-10
2.9 Wiring Connections Page 10-11
2.9.1 A.C. Wiring Connections Page 11-12
2.9.2 Battery Charger Connections Page 12
2.9.3 Automatic Start Connections Page 13
2.10 Fuel Mixture Reconfiguration Page 13
2.11 Battery Introduction Page 14
2.11.1 Battery Warnings Page 15
2.11.2 Battery Size Page 15
2.11.3 Battery Installation Page 15
Section 3 - Component Identification Page 16
3.1 Control Box Components Page 17-18
Section 4- Theory of Operation Page 18-19
Section 5- Maintenance Page 19
5.1 Spark Arrester Maintenance Page 19
5.2 Oil Drain Valve Operation Page 19
Troubleshooting Page 20
Engine Wiring Harness Page 21
Electrical Schematic Page 22
Stand-By Generator Parts Explosion Page 23-24
Fuel System Parts Explosion Page 25-26
Control Panel Wiring Diagram Page 27-28
Section 1: Specifications
1.1 Engine
Manufacturer Honda
Model
Type GX620K1
VAF
Rated Horsepower 20 H.P. @ 3600rpm
Displacement
[Bore X Stroke] 37.5 cu-in (614 cc)
[3.03X2.60 in (77X66mm)]
Number of Cylinders 2
Cylinder Block Cast Aluminum
Valve Arrangement 4--Stroke, Overhead Valve
Ignition System Transistorized Magneto
Compression Ratio 8.3:1
Max Torque 32.5 lb-ft @ 2500 rpm
Cooling System Forced Air
PTO Shaft Rotation Counterclockwise
(viewed from PTO side)
Spark Plug Gap 0.028 - 0.031 in.
Recommended Spark Plug ZGR5A (NGK)
J16CR-U (DENSO)
Valve Clearance (cold) IN: 0.15 ± 0.02 mm
EX: 0.20 ± 0.02 mm
Oil Specifications Engine Owner’s Manual
Oil Capacity
Oil Capacity with Filter 1.59 US Quarts
1.90 US Quarts
Recommended Oil Filter
Honda # 15400-POH-305PE
Recommended Air Filter
Honda # 17010-ZJ1-000
Starter 12 Vdc, Solenoid Shift
Battery 12 Vdc, Negative Ground
Battery Size Group U1-7
Battery Amp-Hour Rating 45 Minimum
Battery Dimensions (l,w,h) 7.25”, 5.00”, 8.75”
Engine Charging System 12 Vdc, 20 Amp
1.2 Generator
Continuous Power (Watts) 9600 (LPG) / 8000 (NG)
Voltage (Volts) 120/240
Continuous Current (Amps) 40.0 (LPG) / 33.3 (NG)
Frequency Range (Hz.) 56.6 - 63.3
Power Factor (p.f.) 1.0
Main Line Circuit Breaker 120/240 Volt, 40 Amps
Phase Single
Rotor Poles 2
Insulation Class H
Windings 100% Copper
Nominal Operation Speed 3600 rpm
4
1.3 Control System
Battery Charger
Input Specification
Output Specification
Charging
Maintaining
115 Vac, 1.0 Amp
12.0 Vdc, 2.0 Amp
13.3 Vdc, 0.1 Amp
Battery Charger Fuse Bussman AGX 6
32Vdc, 6 Amp
1/4” X 1” Non-Time Delay
Convenience Receptacle 125Volt, 20 Amp, GFCI
Convenience Receptacle
Circuit Breaker 125 Volt, 20 Amp, Push
to Reset Style
Engine Controller
Voltage
Overspeed Shutdown
High Temp. Shutdown
Oil Pressure Shutdown
Over Crank Shutdown
12 Vdc
4080 rpm (68 Hz.)
300° F
14.22 psi (98 kPa)
3 Attempts at Starting
Engine Controller Fuse 12 Vdc, 20 Amp
ATO Series
(Automotive Style)
Fuel Lockoff Solenoid 12 Vdc.
Cooling Fan 12 Vdc.
Section 2: Installation
2.1 Introduction
DANGER • Only qualified electricians or
contractors should attempt installation of
either the stand by generator or transfer
switch. The installation must comply with all
applicable codes, regulations, or standards.
Note: Please read the entire manual before
attempting to install the stand by generator or
transfer switch.
NorthStar designs products that are safe to
operate and easily installed. We cannot predict all
installation procedures or methods required to
install our products. It is the installer’s
responsibility to follow safe work procedures, and
to correctly identify potential hazards while
installing this product.
2.2 Assistance
1: For Home or Business installation, a certified
electrician or contractor is required. To arrange
for proper installation, contact one of the
following sources:
• Electrical Contractors: Consult the local phone
book under the classification “ Electrical
Contractors”.
• Heating and A/C Contractors: Look in your local
phone book under the classification “ Heating
Contractors” or “Air Conditioning Contractors.”
• Call Customer Service at 1-800-270-0810
between the hours of 7:30 a.m. and 5:00 p.m.
CST. Our Customer Service Department will
assist in finding the nearest qualified installer.
2: For installation by a Certified Electrician or
Contractor: all required information is contained
within this manual for proper installation and
startup. If further information is required please
call Customer Service directly at 1-800-270-
0810 between the hours of 7:30 a.m. and 5:00
p.m. Our Customer Service Department will
assist in finding the nearest qualified installer.
2.3 Unpacking the Product
WARNING • NEVER stand underneath
this product while attempting to move or lift
this product. NEVER attempt to lift without
proper help and equipment.
Please handle your NorthStar Stand By generator
with care. The shipping carton cannot protect your
generator from damage due to bumping, dropping,
or collision. Always store the generator with the
proper side up. Do not stack other items on top of
the carton.
If possible, loss of contents or damage should be
documented at time of delivery. The person(s)
delivering the Stand By generator should note all
damage on the freight bill.
After unpacking the stand by generator, inspect all
contents for damage during shipment. If damage
is detected, contact the carrier for their damaged
claim procedures.
“Concealed Damage” is damage to the contents
that was not evident when the product was
delivered. This damage is discovered at a later
time. It is always prudent to take a photograph of
shipping damage.
5
Shipping Restraint
The stand by generator is delivered with a
shipping restraint to prevent damage. Remove the
bolt, spacer, and yellow tag located just below the
engine starter. Failure to remove shipping restraint
may cause damage to machine.
2.4 Installation Preparation
Prior to installation of this equipment check the
ratings of both the generator set and transfer
switch. The generator and transfer switch voltage,
amperage, and wattage must be adequate to
handle all electrical loads that the generator and
transfer switch will power. In some instances
critical or essential electrical loads will require
“grouping” together into a separate load panel as
the generator will not be of sufficient size to carry
all electrical loads.
CAUTION • Electrical and/or building
permits may be required in your area for
installation of a Standby generator. Check
your local codes for routing of gas lines and
noise ordinance allowances.
Fig. 01164 – Pallet Disassembly
The stand by generator is fastened to the shipping
pallet by four 1/4” X 1.5” lag bolts. A 1/2” wrench is
required to remove the lag bolts from the pallet
(Figure 01164).
2.5 Generator Location
DANGER • Never operate this generator in
an enclosed area. Exhaust gases contain carbon
monoxide, an odorless and deadly poison.
DANGER • Never install the generator in
a location that exhaust gases can seep back
into closed rooms. Gases can seep into closed
rooms through windows, doors, and floors.
Install the stand by generator set outdoors where
there is an adequate supply of fresh cooling air. To
help ensure trouble free operation, the following
suggestions should be considered:
1: Never install the generator in areas prone to the
collection of rainwater.
2: Never install the generator in an area that is
prone to flooding.
3: Never locate the generator on a roof.
4: Always locate the generator as close to the
transfer switch as possible. This will shorten the
length of electrical lead wire and conduit that is
required for the installation.
5: Always install the generator as close as
possible to the fuel source. This will help reduce
the length of pipe required for the installation.
ALWAYS consult your gas supplier, as they are
aware of laws and local codes governing the
placement of the gas pipe.
6: Always install the generator such that the air
inlets and outlets will not become blocked or
clogged with grass, leaves, litter, snow, or other
items. Clogged inlets or outlets will cause the
engine and generator to perform poorly, and
possibly result in equipment failure.
7: Always install the generator such that there is
adequate space on all sides for servicing and
performing maintenance. A minimum of 7 feet on
all sides should be adequate. REMEMBER:
LAWS OR CODES MAY DICTATE REQUIRED
DISTANCES FROM STRUCTURES OR FUEL
SOURCES.
2.6 Sizing the Generator Mounting Slab
The stand by generator must be mounted on a
mounting pad that adequately supports the
generator housing. External isolation mounts are
not required as the generator set has vibration
isolation mounts located between the engine -
generator and the base.
It is advisable to fasten the generator
compartment to a concrete mounting slab with a
quantity (4) of 1/4 - inch masonry type anchor
bolts. Check that the bolts are of sufficient length
to adequately secure the enclosure.
The concrete slab should extend past the
enclosure by a minimum of 3 inches on all sides.
The concrete slab must be level. For further
details concerning concrete slab dimensions and
details, see FIG 01168.
LAG BOLT
PALLET
FIG01164
Bolt
Space
r
Yello
w
Tag
6
FIG. 01165 - GENERATOR DIMENSIONS
7
FIG. 01168 - Mounting Pad Design
8
2.6 Fuel System Introduction
The following information is only to assist the
gaseous fuel technician with installation and set-
up. ALWAYS follow LOCAL and FEDERAL gas
codes when installing this product. Consult your
local fuel supplier or Fire Marshall if questions or
installation problems occur.
When installing the fuel system, place a flexible
length of fuel line between the generator fuel
connection point and the rigid piping. The section
of flexible fuel line must be approved for gaseous
fuel use, and meet the requirements as dictated by
LOCAL and FEDERAL gas codes.
It is advised that a manual fuel shutoff valve be
placed in-line with the rigid piping.
This product is designed to operate on either
Natural Gas (NG) or Liquid Petroleum Gas (LPG).
Only use a vapor withdrawal system to deliver fuel
to the engine. A vapor withdrawal system uses
the vapors that are formed on top of the liquid fuel.
Note: This engine only burns vapor fuel.
The fuel system is factory preset for NG. If the fuel
source is LPG, follow the fuel reconfiguration
directions in Section 2.10.
To achieve maximum horsepower from the
engine, the recommended fuels should have a
minimum BTU content of 1,000 BTU per cubic foot
for Natural Gas (NG) and 2516 BTU per cubic foot
for Liquid Petroleum Gas (LPG). See Table 1.5 for
fuel
LPG Conversion Factors:
1 lb. = 8.58 cubic feet
1 gallon = 36.39 cubic feet
Table 1.5 - Inlet Fuel Requirements
NG LPG
Pressure 4-6 oz. 7-11” Water Column
Flow 3.25 CFM 9.33 lb/hr, 2.2 gal / hr
BTU/HR 161374 201718
2.7 Fuel System Components
The fuel system is composed of four main
components: fuel lock off, demand regulator, load
block, and carburetor adapter. See Figure 01174.
The fuel lock-off is a safety device that
electrically operates with 12 Vdc. The valve is
open while 12 Vdc is present at its two electrical
terminals. If the engine should fail while
unattended, this device positively shuts off the flow
of fuel. The fuel lock-off has 3/4” NPT inlet pipe
thread, labeled “inlet”. This is the fuel inlet
connection point.
The demand regulator allows low-pressure fuels
to pass through if 4 ounces of vacuum is applied
to the outlet side of the regulator.
This device is sometimes called a “zero governing”
or “secondary”. The regulator is a vacuum
demand device, which is normally shut when the
engine is not running. Venturi vacuum causes the
secondary regulator to open and allow the flow of
fuel at a zero or negative pressure. This device is
not to be considered as a satisfactory fuel
lock-off valve, or a pressure regulator.
The load block is a device that adjusts the fuel
mixture. If this device is set incorrectly, the engine
will experience difficulty in starting, and cause
poor engine performance.
The adapter mounts between the engine
carburetor and the air cleaner. Inside the adapter
is a venturi. The venturi is a symmetrical restriction
that produces a pressure drop (vacuum) and
draws fuel into the air stream. The amount of fuel
drawn in is proportional to the volume and speed
of the air passing through the venturi.
FIG 01174 - Fuel System Components
VENTURI
ADAPTER
FUEL LOCKOFF
(fuel inlet)
DEMAND
REGULATOR
LOAD BLOCK
9
2.8 Generator Winding Connections
Figure 01175 represents a simplified pictorial of
the generator stator AC connection system. This
system is described as a 60-Hertz, single phase,
four-wire design. The generator stator produces
120/240 volts by means of two independent
stationary coil groups (windings), with two leads
brought out of each winding. Each winding can
nominally produce 120 Volts at 60 Hertz.
Combining both windings in series produces 240
Volts at 60 Hertz. Generator output leads 1 and 4
are ”HOT”. Generator output leads 2 and 3 are
“Neutral”.
Fig. 01175 - Generator AC Connection System
2.9 Wiring Connections
DANGER • Qualified electricians or
contractors should complete the wiring
connections. Follow all applicable electrical
codes, regulations, and standards.
CAUTION • Customer installed wires
designated as “power” lead should not be
mixed with “signal” leads in the same
electrical conduit.
CAUTION • The generator is configured
with a ‘bonded neutral” wire. The neutral wire
exiting the generator is bonded to the ground
circuit.
DANGER • Always disconnect the battery
prior to installation or servicing the generator or
transfer switch. This product can start
automatically. Disconnect the battery cable from the
NEGATIVE, NEG, or (-) terminal first. Reconnect that
cable last.
DANGER • Never work inside the generator
unless utility power is disconnected. Remember: The
battery charger and convenience receptacle may be
energized by a 120-volt electrical circuit that is
independent of the stand-by generator.
This generator is designed with a 3.25” diameter
hole in the base. This access hole allows for
routing of electrical conduit up through the
concrete mounting pad and into the generator
housing. See Figure 01168 (page 8). If the
installation does not allow the conduit to route
through the concrete pad, see the Right Side View
of Figure 01165 (page 7) for the area to locate
conduit elbows.
To complete the electrical connections, first
remove the (4) #10 socket head cap screws from
the lower cover plate. The #10 socket head cap
screws can be removed with a 5/32” hex key. See
Figure 01186.
Fig. 01186 - Generator Control Box
#10 SOCKET HEAD
CAP SCREWS
LOWER
COVER
PLATE
10
Route the electrical lead wires from the transfer
switch, through the grommets and into the
generator control box as pictured in Figure 01189.
Fig. 01189 - Routing of Lead Wires
2.9.1 A.C. Wiring Connections
All lead wires used for electrical connections
should be properly sized per the National Electric
Code (NEC). Always use stranded lead wire, and
NEC approved electrical conduit. When routing
lead wires into the generator housing and control
panel, check that sharp edges do not come into
contact with the lead wires.
To complete the electrical connections, route two
lead wires from the transfer switch connection
points marked E1 and E2 to the main line circuit
breaker (MCB) inside the generator set control
box. See Figure 01192 for the MCB location. Strip
1/2” of insulation from the ends of the lead wires.
Insert one wire into each circuit breaker
connection lug, and torque to 35 in-lbs.
Helpful Hint: Check that the lead wire has
adequate insulation removed prior to insertion into
the connection lug. A lead wire that is inserted
into a compression connection without adequate
insulation removed may create an open circuit .
Inside most transfer switches, the generator
contacts are designated as EMERGENCY
POWER, and labeled as connection points E1 and
E2.
Route the neutral wire from the transfer switch to
the generator control panel (Figure 01192). The
neutral lead wire shall only be connected to DIN
rail terminal block location #1. This terminal block
is rated for lead wire ranging from 22 AWG to 6
AWG. To install the neutral lead wire into the
terminal block, rotate the set screw
counterclockwise to open the funnel.
Fig. 01195 - Neutral Terminal Block
The set screw that opens the funnel is a size M4.
Strip adequate insulation from the NEUTRAL lead
wire and insert the lead wire completely into the
funnel (Figure 01196). Turn the set screw
clockwise to close the funnel. The set screw has a
torque specification of 16 inch-pounds minimum.
FROM TRANSFER SWITCH
(CUSTOMER INSTALLED)
LOWER COVER
PLATE
SET SCREW
CUSTOMER INSTALLED
(NEUTRAL WIRE)
SET SCREW
FUNNEL
Fig. 01196 - Neutral Terminal Block
11
FACTORY CONNECTIONS
CUSTOMER CONNECTIONS
LEAD WIRES TO THE GFCI RECEPTACLE
DO NOT DISTURB
LEAD WIRES TO THE GENERATOR HEAD
DO NOT DISTURB
MAIN LINE CIRCUIT BREAKE
R
LEAD WIRES TO ENGINE CONTROLLE
R
FOR REMOTE AUTOMATIC ENGINE START
DO NOT DISTURB
LOCATION #
DIN RAIL
CONNECTION LUGS- 35 IN-LBS TORQUE
EXTERNAL ELECTRICAL CIRCUI
T
TO POWER THE GFCI
RECEPTACLE AND BATTERY
CHARGER
“HOT” LEAD WIRE- 120V CIRCUIT
NEUTRAL LEAD WIRE
GROUND LEAD WIRE
LEAD WIRES TO TRANSFER SWITCH
“HOT” - TO TRANSFER SWITCH TERMINAL E1
“HOT” - TO TRANSFER SWITCH TERMINAL E2
NEUTRAL - TO TRANSFER SWITCH NEUTRAL
CONNECTION POINT
GROUND - TO TRANSFER SWITCH GROUND
LUG
Figure 01192 -Customer Field Wire Connections
REMOTE - AUTO STAR
T
12
Route the ground wire from the transfer switch to
the generator control panel (Figure 01192). The
ground lead wire shall only be connected to DIN
rail terminal block location #2 (Figure 01197). This
terminal block is colored GREEN and is rated for
lead wires ranging from 22 AWG to 6 AWG. To
install the ground lead wire into the terminal block,
rotate the set screw counterclockwise to open the
funnel (Figure 01198).
Fig. 01197 - Ground Terminal Block
The set screw that opens the funnel is a size M4.
Strip adequate insulation from the GROUND lead
wire and insert the lead wire completely into the
funnel (Figure 01198). Turn the set screw
clockwise to close the funnel. The set screw has a
torque specification of 16 inch-pounds minimum.
Fig. 01198 - Terminal Block
2.9.2 A.C. Battery Charger Connection
The battery charger is configured to plug into the
Ground Fault Circuit Interrupt (GFCI) receptacle.
This receptacle is located on the left side of the
control box (Figure 01199). The GFCI receptacle
is rated for 125 volts A.C. with a current rating of
20 Amps. The GFCI receptacle accepts either
NEMA 5-15P or NEMA 5-20P electrical plugs. A
125 volt, 20-amp circuit breaker, protects the GFCI
receptacle. If the circuit breaker trips, the black
post in the center of the circuit breaker will be
extended. Allow the circuit breaker to cool and
then press the black post back into the circuit
breaker. The circuit breaker is resettable, and is
located adjacent to the GFCI receptacle.
The battery charger electrical requirements are
115 Volts A.C. with a current rating of 0.8 Amps.
For the battery charger to operate, separate power
must be routed from the home to the generator set
by a separate circuit. Protect the wires with
electrical conduit. This separate circuit connects
into the control box at terminal blocks #2, #3, and
#4 (See figure 01192). Terminal block location #2
is designated for the Ground wire. Terminal block
location #3 is designated for the Neutral lead wire.
Terminal #4 is designated for the “hot” lead wire.
Insert the respective lead wires into the funnels
per Figure 01196.
FACTORY INSTALLED
(DO NOT DISTURB)
LOCATION #2
SET SCREW CUSTOMER INSTALLED
(GROUND WIRE)
SET SCREW
FUNNEL
CUSTOMER INSTALLED
A
UTO/OFF/MANUAL
SELECTOR SWITCH
13
2.9.3 Automatic Start Connections
This generator is equipped with a automatic
engine start feature. If it is desired to enable this
feature, the Auto/Off/Manual selector switch
(Figure 01199) is located on the control panel and
must be in the Auto position. The generator will
then start when terminals #5 and #6 (Figure
01192) are connected to a remote set of contacts.
The remote contacts must be configured as such:
close to start the engine, and open to stop the
engine. Generally, all transfer switches have a set
of remote engine start contacts. These contacts
close upon loss of utility power, and open once
utility power is restored. If your transfer switch is a
General Electric ZTX100 (Northern Tool &
Equipment item #165969) or General Electric
ZTX200 (Northern Tool & Equipment item #
165970) the engine start contacts are labeled as
X1 and X2 inside the transfer switch enclosure.
Refer to your Transfer Switch owners’ manual for
further information.
2.10 Fuel Mixture Reconfiguration
This generator set is designed to operate on either
Liquid Propane Gas (LPG) or Natural Gas (NG).
The fuel system was factory set for NG. If the
engine will not start, starts poorly, or requires
conversion to LPG, it may be necessary to adjust
the fuel mixture. To adjust the fuel mixture, locate
the fuel regulator assembly (Figure 01201). The
following tools are required to reconfigure the fuel
mixture: (1) 11/16” open-end wrench and (1)
straight blade screw driver.
Fig. 01201 - Regulator Assembly
The load block adjusts the fuel mixture that is fed into
the carburetor. To adjust the load block, loosen the
lock nut. The adjustment screw now can be turned
either clockwise or counter clockwise. While LPG or
NG is supplied to the fuel connection point (Figure
01174) put the Auto/Off/Manual selector switch in the
Manual position (Figure 01199) and slowly turn the
adjustment screw clockwise until the engine starts
(Figure 01202). Once the engine is running turn the
adjustment screw very slowly to smooth out engine
performance. Once the proper setting is achieved turn
the brass lock nut to secure the adjustment screw.
Fig. 01202 - Load Block Adjustment
FUEL REGULATOR ASSEMBLY
A
DJUSTMENT
SCREW
SCRE
W
DRIVER
11/16” WRENCH
DEMAND
REGULATOR
14
2.11 Battery Introduction
Installation or servicing the battery should only be
performed or supervised by personnel know-
legible about batteries and required precautions.
ALWAYS unplug the battery charger power cord
from the GFCI receptacle prior to installation or
removal of the battery. If the battery charger is left
plugged in, sparks will occur at the battery posts
as the battery cables are either attached or
removed. ALWAYS make sure the
AUTO/OFF/MANUAL selector switch is in the
OFF position prior to installation of the battery.
If the selector switch is in the AUTO or
MANUAL position during battery installation,
the engine may start. Always read the
following warnings prior to working on or
around the battery.
2.11.1 Battery Warnings
DANGER
• ALWAYS be sure that the utility power is
turned off to the battery charger, or sparks will
occur at the battery posts as the battery cables
are connected or disconnected.
• Always wear safety glasses.
•Shield eyes-explosive gases can cause
blindness.
•Sulfuric acid can cause blindness or severe
burns.
•Flush eyes immediately with water. Seek
medical help immediately.
•Never install or charge a visibly damaged or
frozen battery.
• Never dispose of a battery in a fire. The
battery is capable of exploding.
WARNING
• Spilled electrolyte or sulfuric acid is to be
washed down with an acid-neutralizing agent. A
common neutralizing agent is a mixture of 1 pound
of bicarbonate of soda to 1 gallon of water. The
resulting solution is to be applied to the acid spill
until evidence of reaction (foaming) has ceased.
Rinse the entire area with tap water and allow to
dry.
• Do not smoke when near the battery.
• Lead-Acid batteries present a risk of fire.
Batteries generate explosive hydrogen gas.
• Discharge static electricity from your body
prior to touching the battery. First, touch a
grounded metal surface.
ELECTRICAL HAZARDS
The battery can present a risk of electrical
shock from high electrical currents generated
from a short circuit. The following precautions
should ALWAYS be followed when working on
or near the battery.
• Disconnect power source from the battery
charger prior to connecting/disconnecting
electrical cables from the battery terminals.
• Remove watches, jewelry, rings, or other
metal objects.
• Never lay tool or other metal objects on top
of the battery.
• Wear rubber boots and rubber gloves.
2.11.2 Battery Size
The generator set is designed to operate on a 12
VDC negative ground system. The battery
compartment is sized for a Group U1 battery. A
Group U1 battery is sometimes referred to as a
“lawn and garden” style battery. See Figure 01203
for general dimensions and style of a Group U1
battery. Battery specifications are listed in Section
1.1.
Figure 01203 - Battery Dimensions
2.11.3 Battery Installation
The battery compartment is located behind an
access panel located on the front of the generator.
The access panel is removed by loosening the (4)
5/16 hex bolts with a 1/2” socket wrench (Figure
01204 and Figure 01205).
15
Figure 01204 - Battery Location
2.11.3 Battery Installation-Continued
When installing the battery, first review all of the
battery warnings in Section 2.11.1. ALWAYS
connect the positive battery cable first and the
negative battery cable last. The positive battery
cable should be connected to the RED,
POSITIVE, or “+” battery terminal. The negative
battery cable should be connected to the BLACK,
NEGATIVE, or “-” battery terminal.
Figur
e 01205 - Battery Installation
The battery charger has two leads, one red and
the other black. These two leads should be
connected to their respective locations on the
battery. The positive battery charger cable is
colored RED and is labeled “+”. There is also an
inline fuse and fuse holder associated with the
RED battery charger lead. The negative battery
charger cable is colored BLACK and should be
connected to the BLACK, NEGATIVE, or “-”
battery terminal. See Figure 01206.
WARNING • Disconnect power source
from the battery charger prior to connecting or
disconnecting electrical cables from the
battery terminals.
Failure to disconnect the incoming power from the
battery charger may cause a spark during
connection of either the battery cables or battery
charger cables. Sparks can ignite hydrogen or
other gases. Hydrogen is a gas vented from
batteries during charging.
Figure 0120 - Battery Installation
END OF SECTION
(4) 5/16” HEX BOLTS
FUSE
RED CABLES BLACK CABLE
16
Section 3:
Component Identification
Reference 1: Battery Compartment Cover
Plate. The battery compartment is located behind
the cover plate. The cover plate is secured with
four bolts.
Reference 2: Fuel Inlet. The fuel inlet is the fuel
connection point between the generator set and
the fuel delivery pipe. The fuel inlet is tapped for
3/4” NPT pipe. Always use a section of approved
flexible gas pipe between the fuel inlet and rigid
gas pipe.
Reference 3: Door and Door Lock. There are
two locking doors. The doors are designed to lift
completely out of the housing. To open the door,
press the key lock portion of the door latch. Each
door can be locked with the provided keys. Two
sets of keys are included with the generator.
Reference 4: Spark Arrester. The exhaust
system incorporates a removable spark arrester.
The spark arrester is a safety feature that insures
that sparks will not exit the muffler and cause a
fire. The spark arrester is USDA approved. The
spark arrester should be cleaned after every 50
hours of engine use. See Section 5.1of this
manual for further details.
Reference 5: Generator Head. The electricity
producing portion of the generator.
Reference 6: Dipstick. Use the oil dipstick to
monitor the engine oil level. Consult the Honda
engine owners’ manual for further information.
Reference 7: Remote Oil Drain and Plug. The
remote oil drain provides a clean and convenient
method to change engine oil.
Reference 7: (Continues) The oil drain plug
prevents accidental loss of engine oil. A 5/16” hex
key (Allan Wrench) is required to remove the oil
drain plug.
Reference 8: Engine Oil Drain Valve. The
engine oil drain valve provides a convenient
method to change oil. By opening the valve engine
oil flows to the remote oil drain (Reference 7).
Reference 9: Demand Regulator Assembly.
Supplies LP or NG fuel at a negative pressure
when the engine is running. The regulator is
sometimes referred to as a Secondary. The
Secondary regulator gauges the fuel flow or
amount of fuel delivered to the engine.
Reference 10: Engine. The engine is a 20 H.P.
Honda GX620 K1VXA. Refer to the Honda engine
owner’s manual for maintenance intervals. Refer
too Section 1.1 of this manual for general engine
information.
Reference 11: Battery Charger. The battery
charger is of a “3-stage” electronic design. The 3
charging stages are bulk, absorption, and float.
This charger is not of the “trickle” design that can
boil off the electrolyte and destroy a battery. The
battery charger plugs into the GFCI convenience
receptacle, which is located on the control panel.
When the battery charger is operating, a green
LED light on the front of the charger will be lit.
Reference 12: Spark Plug. The Honda engine
has two spark plugs. One is located on each side
of the engine. Refer to the Honda engine owners’
manual for maintenance.
Reference 13: Engine Oil Fill Cap. Remove cap
to add oil to the engine. Refer to the Honda engine
owners’ manual for oil recommendations.
Reference 14: Engine Air Cleaner. Refer to the
Honda engine owners’ manual for air cleaner
maintenance.
Reference 15: Control Box. Refer to Section 3.1
(page 18) for detailed information.
17
3.1 Control Box Components
START SWITCH
OFF
RESET
HOUR METER
AUTO
10500 SBG
S
TANDBY
G
ENERAT
O
R
70
Reference 16: Main Line Circuit Breaker. The
main circuit breaker is a 2-pole design that
protects the generator from electrical overloads. If
the circuit breaker trips, reset the breaker by
moving the lever to the OFF position and then
back to the ON position.
Reference 17: ON/OFF/AUTO. This switch will
start the engine if placed in the ON position. When
the switch is in the AUTO position, the generator
will start when the transfer switch senses loss of
utility power. The OFF position shuts down the
engine.
WARNING • With the switch set in the
AUTO position, the engine can crank and start
without warning. Automatic starting can occur
with loss of normal utility power or during a
normal exercise initiated by the transfer
switch. To prevent accidental engine starting,
place the switch in the OFF position and
disconnect the battery prior to working on or
around the generator.
Reference 18: Maintenance Interval Reset
Switch. The maintenance interval meter can be
instantly reset to zero by depressing the switch.
Reference 19: Total Hour Meter. The total hour
meter measures hours the engine has
accumulated while running. This portion of the
meter cannot reset.
Reference 20: Maintenance Interval Meter.
The lower meter is a maintenance interval meter.
It is used to measure hours between scheduled
maintenance. To reset this meter, depress the
maintenance interval reset switch (Reference 18).
This meter provides a convenient way to monitor
oil change intervals.
Reference 21: System Controller. T he system
controller starts, stops, and monitors the generator
set. There are five alarm lamps associated with
the engine controller. Their functions are as
follows:
Low Oil Pressure- In the event of low engine oil
pressure, the “low oil pressure” lamp will glow red,
and the engine will shut down. To reset the system
controller, place the ON/OFF/AUTO switch in the
OFF position. Check the engine oil level.
High Temperature- In the event of high
temperature, the “high temperature” lamp will glow
red, and the engine will shut down. To reset the
system controller, place the ON/OFF/AUTO switch
in the OFF position. Check for leaves or debris
blocking air inlets and outlets.
High Engine Speed- The system controller will
shut down the engine in the event that the engine
operating speed exceeds 4080 rpm for 5 seconds.
The “engine over crank” lamp will glow red. To
reset the system controller, place the
ON/OFF/AUTO switch in the OFF position.
Engine Over crank- The system controller will
engage the starter for 15 seconds. If the engine
does not start, the system controller will allow the
starter to cool down for 15 seconds, then attempt
to start the engine again. This process will repeat
three times. If the engine does not start after the
third attempt, the red “engine over crank” lamp will
glow. To reset the system controller, place the
ON/OFF/AUTO switch in the OFF position.
System Normal- This lamp indicates everything is
normal. The lamp will glow while the unit is
running, or in automatic mode.
3.1 Control Box Components
Reference 22: GFCI Receptacle. The GFCI
(ground fault circuit interrupter) duplex receptacle
18
is different from a conventional receptacle. In the
event of a ground fault, the GFCI will trip and
quickly stop the flow the flow of electricity, to
prevent serious injury. A ground fault is defined as
a condition where electricity does not follow its
normal path, but passes through a person’s body
to reach ground. A defective power tool can cause
a ground fault.
The GFCI receptacle designation is a NEMA 5-
20R, and will accept either a NEMA 5-15P or a
NEMA 5-20P electrical plug. This receptacle is
powered from a separate circuit-not the generator,
and will not work during a utility power outage.
This receptacle is rated for 125 volts at 20 amps
and will power most portable hand tools.
Reference 23: GFCI Test Button. This button
tests the operation of the GFCI receptacle. When
pressing the TEST button, the receptacle will trip.
Then press the reset button to reactivate the
GFCI. Test the GFCI receptacle every month.
Reference 24: Circuit Breaker. A 125-volt, 20-
amp push to reset circuit breaker protects the
GFCI receptacle. If this circuit breaker trips, the
black center post will be extended. Allow the
circuit breaker to cool for 1 minute and press the
black post beak into the housing.
Reference 25: GFCI Reset Button. If the GFCI
trips, press the reset button to reactivate the
receptacle.
Section 4
Theory of Operation
When starting the 165952A generator in manual
mode (Section 3, Reference 17), the following
sequence of events occur:
1: 12 volts (dc) is delivered from the battery “+”
terminal on the engine starter to the on/off/auto
three position switch located on the control panel
via lead wire “012” which is located inside the
engine wiring harness.
2: If the three position switch is in the manual
mode, 12 volts (dc) is then delivered to the system
control board which is located inside the control
box via lead wire “01A”.
3: Simultaneous to delivering 12 volts via lead wire
“01A” the three position switch closes a circuit
between lead wires “06A and 07”. The closure of
lead wires “O6A and O7” tells the system
controller to send 12 volts (dc) to the engine start
solenoid via lead wire “O3”. Lead wire “O3” is
located inside the engine wiring harness.
Trouble Shooting Hint: When the system control
board inputs (leads “O7 and O6A”) are connected
together, the engine will attempt to start if 12 volts
is present between lead wires “01A” and “G2B”.
System Control Board
4: At the same time the engine is cranking, both
the LP/NG fuel lock off valve and compartment fan
are energized by 12 volts via lead wire “O4”. Lead
wire “O4” exits the control box inside the engine
wi ring harness.
5: As the engine cranks, the pistons create
vacuum. The vacuum will influence the secondary
gas regulator to open and allow fuel to flow. The
secondary regulator reacts to a minimum of 4
ounces per square inch of vacuum.
Trouble Shooting Hint: It is crucial to have both
correct gas inlet pressure and fuel mixture for
quick starting. There is a 1/8” NPT port on the side
of the regulator that provides a convenient point to
measure inlet pressure.
6: As the engine comes up to operating speed
(3600 rpm), the engine continually sends an
electrical signal through a black with red stripe
lead wire that exits the engine. The black with red
stripe lead wire is connected into lead wire “O5A”.
Lead wire “O5A” is located inside of the engine
wiring harness and terminates at the system
control board. The importance of this signal is that
once a stable frequency is measured from the
magneto, the system control board takes the
engine starter off line. Secondly, if the frequency
exceeds 4080rpm for a time interval of 5 seconds
or greater, the system control board will alarm and
shutdown the engine down as a result of an over
speed condition.
7: During start up, the control board disregards low
oil pressure for 15 seconds. If after that period of
time, oil pressure has not developed, the system
control board will alarm and shut down the engine
as a result of low oil pressure.
1/8” NPT PORT
19
The oil pressure sender is located on the muffler
side of the engine, and is connected to the system
controller via lead wire “O9”. The oil pressure
sender is normally closed when the engine is not
running. A normally closed sender will complete
an internal circuit to the engine block, which is the
system ground. An ohmmeter is useful for
checking if the sender is functioning correctly.
Trouble Shooting Hint: If lead wires “G8 and O9”
are connected together, the system control board
will always shut down the engine as a result of low
oil pressure. Lead wire “G8” is a system ground
wire, and if the oil pressure sender is closed, lead
wire “O9” will be connected to ground.
8: The system control board can shut down the
generator at any time due to high engine
temperature. A high temperature condition is
monitored by a thermo-disk mounted to the
engine. The thermo-disk is normally open and
closes if the compartment air temperature
becomes excessive. The thermo-disk is connected
to the system control board via the two lead wires
“O10 and O11”.
Trouble Shooting Hint: The system control board
will shut down the engine if lead wires “O10 and
O11” are connected together. If the thermo-disk is
closed, lead wires “O10 and O11” are connected
together.
Section 5
Maintenance
To insure reliable and trouble free operation of
your stand by generator, it is important to follow
recommended maintenance schedules. Consult
your Honda engine owner’s manual for
maintenance schedules.
5.1 Spark Arrester Maintenance
The spark arrester should be removed and
cleaned with a wire brush every 50 hours of
engine operation.
1: Remove the setscrew and clean it with a
brush.
2: Pull the spark arrester out of the outlet
tube.
3: Clean the screen assembly with a wire brush.
If breaks in the screen are discovered, the
screen assembly must be replaced.
4: Return the screen assembly to the muffler
outlet tube and refasten with the set screw.
Muffler Assembly
Spark Arrester
5.2 Oil Drain Valve Operation
The engine oil drain valve can be opened with
either a 10mm metric socket, or a pair of pliers.
Simply turn the valve counterclockwise to open the
valve. Turn the valve clockwise to close.
SET SCRE
W
SPAR
K
ARRESTER
MUFFLE
R
OUTLET TUBE
SCREEN
VALVE
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