North Star 5500 BDG User manual

Proven Performance
MODEL 5500 BDG,ITEM #165913
Belt Driven Generator
M165913B
OWNER’S MANUAL
AnyQuestions, Comments,or Problems?
Call Customer Service at 1-800-270-0810

1
THANK YOU
Thank you forpurchasing a North Star Belt Driven 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 operatesthisgenerator must readand understand this manual.
The time you take now will prolong your generator’s life and prepare you for its safe operation.
Enjoy the exceptional performanceof your North Star Belt Driven Generator.
IMPORTANT
If thismachineisused by anyone who isnotthe owner orisloanedor rented, make certain the
operator:
- Isinstructedinthe safeand properoperation ofthismachine.
- Readsand understandsthemanualspertaining to thismachine.
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 1
Specifications 2
Machine componentidentification 3
Generator features 3-4
Introduction 4
ANSI safety definitions 4
Rules forsafe operation 4-5
Installation 5-6
Load application 6-7
Pre-startup preparation 7-8
Generator care 8
Troubleshooting 9

2
SPECIFICATIONS
Item Number #165913
Maximum Output 5500 Watts (W)
Continuous Output 5000 Watts (W)
Voltage 120 /240 Volt(V)
Phase Single phase (4-wire)
Frequency 59.0-62.0 Hertz(Hz)
Power Factor 100 %
Engine 11 hpmax.,9 hp recommended
Engine Speed 3540-3720 RPM
120 VReceptacle 20 Amp (A) duplex
(NEMA 5-20R)
240 VReceptacle 20 Amp (A) Locking Device
(NEMAL6-20R)
CircuitBreaker 20 Amp (A) thermal, push to resetstyle
Dimensions
Length 16.25” (413 cm)
Width 7.25” (184 cm)
Height 7.75” (197 cm)
Gross Weight 53 lb.(24.1 kg)
.

3
MACHINE COMPONENT IDENTIFICATION
Figure 1 (Ref.1-4) 00041
Ref. Description Ref. Description
1Circuit Breakers 5 7/8” shaft
2 120V 20A Duplex Receptacle 6Mounting feet
3240V 20ALocking Receptacle 7 Fan vents
4 Grounding screw
Figure 2 (Ref. 5-7)
00042

4
GENERATOR FEATURES
Reference 1 - Circuit Breakers. This belt driven
single phase generator has 2, 20 amp (A) push to
reset circuit breakers to protect against electrical
overloads.
Receptacles
Reference 2 - 120V Receptacle. The generator
hasanend cover with one duplex (two receptacles in
a commonhousing) receptacleand onelocking device
receptacle. The duplex is a 120 volt (V) 20 amp (A)
straight blade receptacle, National Electrical
Manufacturer’s Association (NEMA) number 5-20R.
This receptacle accepts NEMA plug numbers 5-15P
and5-20P. Each receptacle on the duplex is capable
of drawing20A.
Reference 3 - 240V Receptacle. The locking
deviceisa 240V 20A NEMA L6-20R receptacle. This
receptacle acceptsa NEMA plug number L6-20P.
ALWAYS use grounded male plugs. The neutral
line of the generator is mechanically grounded to the
frame. Matching NEMA male plugs must always be
used.
Reference 4 - Ground Screw. Ground the
generator via the ground screw, to a copper pipe or
rod thatisdrivenintomoist soil.
Reference 5 - 7/8” diameter Shaft. The shaft is
1.50” long andhasa 3/16” keyway.
Reference 6 - Mounting feet. Use these three
locationsto bolt the generator headin place.
Reference 7 - Fan Vents. Never block the vent
slots or insert objects through the slots.
INTRODUCTION
Before attempting to mount 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.
North Star 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 andmanufacture.
Before using, the user shall determine the
suitability of this product for its intended use and
assumesliabilitytherein.
ANSI SAFETY DEFINITIONS
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
seriousinjury. Thissignal wordisto belimited to the
most extremesituations.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a
deathor serious injury.
CAUTION indicates a potentially hazardous
situation, which ifnotavoided, may resultinminor or
moderateinjury. Itmay also beused to alert against
unsafepractices.
RULES FOR SAFE OPERATIONS
Safety precautions are essential when operating
this generator. Respectful and cautious operation will
considerably lessen the possibilities of a personal
injury. This manual will warn of specific personal injury
potential, and these will be designated by the symbol:
WARNING This generator is equipped
with a grounding screw, located on the generator
frame for your protection. Always complete the
grounding path from the generator to a copper
pipe/rod that is driven into moist earth, to prevent
electrical shock.
ALWAYS use electrical cords that are in good
condition. Worn, bare, frayed or otherwise damaged
cordscan cause electric shock.
NEVER operate the generator, or handle any
electrical equipment while standing in water, while
barefoot, while hands are wet or while in the rain or
snow. Electric shockmay result.
ALWAYS use a ground fault circuit interrupter
(GFCI) in damp or highly electrical conductive areas
andonconstruction job-sitesto preventelectric shock.
ALWAYS remove the spark plug or spark plug
wire before working on the engine or generator, this
preventsaccidental starting.
ALWAYS provide adequate ventilation. Do not
operate generator in any enclosed or narrow space.
Engines consume oxygen and give off deadly carbon
monoxide, a poisonous gas. Improper ventilation will
cause damage to generator and possible injury to
people.

5
ALWAYS remove all oil or gasoline deposits
andaccumulated dirtfrom generator and immediate
area. Keep generator head and engine clean.
NEVER operate the generator under the
following conditions:
A. Excessive change in engine speed, slow or
fast.B. Overheatinginload connectingdevices.
C. Sparking orarcsfrom generator.
D. Lossof electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
H. Enclosed compartments, or confined
areas.
I. Flameor smoke.
J. Rain, snow or wet conditions.
K. Operator non-attendance.
WARNING Keep fire extinguisher
close by yourgenerator and be familiar with how to
use it. Consult your local fire department for correct
extinguisher type.
INSTALLATION
OUTDOORS: Choose a location where the
generator will not be exposed to rain, snow or direct
sunlight. Position the generator on secure, level
ground soit will nottip or slide down a hill. Place the
generator so that the exhaust fumes will not be
directedtowardspeople.
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 thegenerating system.
Foreign matters, such as dust, dirt, sand, lint, or
abrasivematerialscan cause damage tothe generator
head andengineif allowedintoitscooling system.
POWER TRANSMISSION: The recommended
method to transfer the power from the engine to the
generator is by using sheaves (pulleys) and a V-belt.
The generator shaftis 7/8” diameter X 1.50” long with
a 3/16” keyway. Use the table below to select the
correct diameter sheave. Note that a notched V-belt
requires only one sheave while the standard V-belt
requires 2 side by side sheaves and 2 V-belts. All V-
beltshaveaB size crosssection.
Figure 3 00038
Note: Guardsare removed to show details.
The shaftspeedofthegeneratormust be between
3540-3720 RPM. Atno load the correct speedis 3720
RPM. If the engine is a 3600 RPM engine, then a
sheave diameter ratio of 1:1 should be used. This
meansthat the diameterof the sheave on the engine
is the same as the diameter of the sheave on the
generator. Ifsmaller than recommended sheaves are
used, the life of the belt will be shortened. The
possibility of belt slippage also increases with a
smaller sheave.
The engine and generator should be mounted to a
plate or surface that can withstand the constant
vibration and stressesthat will be produced. See figure
3 fora possiblemounting configuration.
The user shall determine the proper belt
tensioning method for their specificuse.
To determine belt tension:
Measure L - the center
to centerdistanceof the
two sheaves
Measure d - the
deflection ofthebelt.
Tighten orloosen belt
until:
d = 0.016 X L
00039
If you desire to direct couple the generator to the
engine,great care must be taken to align the shaft of
the generator and engine to within the specified
tolerancesof the chosen coupler.
NEVER install your generator inside confined
areas. Inside installation can cause health hazards or
death.
DANGER Always have proper guarding
on the V-belt and sheaves to prevent access to any
pinchpoints. Failure to guard the power transmission
mechanisms may result in serious injury or death.
Engine hp SingleSheave Dia.
BeltType - Qty. DoubleSheave Dia. BeltType - Qty.
9 hp 5.00”
Notched V-Belt - 1 4.60” V-Belt - 2
11hp 5.80”
Notched V-Belt - 1 5.00” V-Belt - 2

6
Cooling air of sufficient amounts must be brought in
and exhausted out to ensure proper cooling of the
engineand generator.
DANGER Remember,exhaust fumesare
deadly carbon monoxide gas, and must be vented to
theoutside where there arenopeople.
LOAD APPLICATION
Itisimportanttodetermine the total electrical load
beforeitisconnected to thegenerator. Thetwo major
factorsin determining the lifeof a generator head are:
heat build up, caused by overloading the generator,
and corrosive contaminants that attack the wiring
insulation. If the generator is overloaded, the wires
become excessively hot and cause the insulation to
break down, reducing its ability to resist corrosive
contaminants. Over time the effectiveness of the
insulation iseliminatedand 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
When connecting a resistive load such as
incandescentlights, heatersor common electric power
tools, a capacity of up to the generator full rated
wattage outputcanbe 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’sfull rated output can beused.
Always allow the generator to reach operating
speed before a loadisapplied.
STARTING ELECTRICMOTORS
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 currentto start than to run. Capacitor motorsare
easier to start andusually require2 to 4timesasmuch
current to start than to run. Repulsion Induction
motors are the easiest to start and require 1.5 to 2.5
timesasmuch 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 Split-
Phase (SP) type.
The following chart shows the approximate
current required to start and run various types and
sizes of 120 volt 60 cycle electricmotorsunder various
conditions.
120V,60 HzMotors Starting Amps
Hp motor Running
Watts RI type Cap type SP type
1/6 525 7-11 9-18 16-22
1/4 700 9-15 12-23 22-32
1/3 875 11-18 14-29 26-35
1/2 1175 15-25 20-40 NA
11925 24-40 32-64 NA
1 1/2 2400 30-50 40-80 NA
22900 36-60 48-96 NA
3 4075 51-85 68-136 NA
56750 84-140 112-224 NA
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
themotor.
Generators respond to severe overloading
differently thanthe power line. When overloaded, the
engineisnotable tosupply 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
theengine. If allowed to operate at very low speeds,
the electric motor starting winding will burn out in a
short time. The generator head windingmightalso be
damaged.
Running thegenerator underthese conditionsmay
resultin damage to the generator stator as well as the
electric 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.
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
allowfor distance in length and amperage so that the
voltage dropbetween the set and point of use is held
to a minimum.

7
Current/Power Maximum Extension Cord Length
Amps
at
240V
Load
(watts) #10 Ga.
Cord
#12
Ga.
Cord
#14
Ga.
Cord
#16
Ga.
Cord
10 2400 250’ 150’ 100’ 75’
20 4800 125’ 75’ 50’ 25’
30 7200 60’ 35’ 25’ 10’
40 9600 30’ 15’ 10’ *
50 12000 15’ ***
*Not recommended
CAUTION: Equipment damage can resultfrom the
low voltage caused by using an extension cord with a
small wire size.
Use this chart to estimate the total load on your
generator.
For Determining Generator Load Requirements
Device 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 (oneelement) 1500
ElectricSkillet 1250
FurnaceFan(1/3HP) 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
HedgeTrimmer 450
HomeComputer 150
Impact Wrench 500
Jet Pump 800 (a)
LawnMower 1200
LightBulb 100
MicrowaveOven 700
MilkCooler 1100 (a)
Oil Burneron 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)
PaintSprayer, Airless(hand held) 150
Load Requirements Continued
Radio 200
Refrigerator 600 (b)
Slow Cooker 200
Submersible Pump (1-1/2 HP) 2800 (a)
SubmersiblePump (1 HP) 2000 (a)
Submersible Pump (1/2 HP) 1500 (a)
Sump Pump 600 (a)
TableSaw (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 themaximum wattage.
PRE-START PREPARATIONS
Yourgenerator hasbeen thoroughly tested priorto
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
damagedparts,loose ormissing nutsandbolts. 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 intothe ground close to
the generator. The pipe/rod must penetrate moist
earth. Connect an approvedgroundclamp to thepipe.
Run a 12 gauge wire from the clamp to the generator
ground screw. Do not connect to a water pipe or a
groundused bya radio system.
OPERATING SPEED
The generator must be run at the correct speed in
order to produce the proper electrical voltage and
frequency.
The output voltage should be checked to ensure
the generator is working properly subsequent to
connecting a load to the generator. Failure to do so
could result in damage to equipment plugged into the
unit and possible injury to the individual.
All engineshave a tendency to slow down when a
load isapplied. 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 whenthegeneratorisloaded to itsfull 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
equipmentand clockswill be affected if correct RPM is
notmaintained. See Load vs. Output chart.

8
Load Output
Percent of
Generator
Output
Speed
(RPM) Frequency (Hz) Generator voltage at 120V
Receptacle
0 % 3720 62.0 129V
50 % 3600 60.0 120V
100% 3540 59.0 115V
Output voltage should be checked periodically to
ensure continued proper operation of the generating
plantand appliances, it can be checked withaportable
meter. Frequency can be checkedby usingan electric
clockwith asweep 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 aqualifiedtechnician.
GENERATOR CARE
The generator headisa two pole, 3600 RPM, 60
Hz, brushless, revolving field and synchronous type
withtwo sealed radial roller bearings.
Proper care and maintenance are necessary to
ensure along trouble freelife.
Exercising The Generator - The generator
should be operated every four weeks. Warm the
unitup by starting theengine and lettingit run for 10 to
15 minutes. This will dry out any moisture that has
accumulatedin the windings. If left, this moisture can
cause corrosionin 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
brushlessand maintenance free. Anymajor generator
service including the installation or replacement of
partsshould be performedonlyby aqualified electrical
service technician. USE ONLY FACTORY
APPROVED REPAIR PARTS.
A. Bearing - The bearings used in this generators
are a heavy duty, sealed roller bearing. They require
nomaintenance orlubrication.
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 destructiveto 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 Departmentsmust be
consulted concerning proper and safe handling
procedures for gasoline. NEVER connect any
generator toanyexisting electrical system without an
isolating, UL approved transfer switch, installed by a
licensedelectrician.

9
TROUBLESHOOTING
Problem Possible Causes Possible Remedies
Voltage toolow. a) Engine speed too slow.
b) Generatorisoverloaded.
a) Bring generator to a qualified
technician for adjustment.
b) Reduce the load.(SeeLoad
Application section ofthismanual.)
Circuit breaker trips. a) Defective load connected to generator.
b) Defectivereceptacle.
c) Generator overloaded.
a) Disconnectload.
b) Replacereceptacle.
c) Reduce theload.(See Load
Application section ofthismanual.)
Voltage too high. a) Engine speed too high. a) Bring generator to a qualified
technician for adjustment.
Generatoroverheating. a) Generatorisoverloaded.
b) Insufficient ventilation.
a) Reduce the load.(SeeLoad
Application section ofthismanual.)
b) Make sure there isatleast 3 feetof
clearance on all sides of generator.
No output voltage. a) Defectiveload connected to generator.
b) Broken orloose wire.
c) Defective receptacle.
d) Defectivestator.
e) Defective rotor.
f) Defective capacitor.
a) Disconnectload.
b) Bring generator to a qualified
technician for repair.
c) Replacereceptacle.
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.
Enginelackspower. a) Generatorisoverloaded.
b) Dirty air filter.
a) Reduce the load.(SeeLoad
Application section ofthismanual.)
b) Clean or replace air filter.