North Star 10500 SBG User manual

Proven
ITEM #165952
MODEL 10500 SBG
Stand By Generator
Installation and Operation Manual
DANGER
ONLY A QUALIFIED CONTRACTOR OR ELECTRICIAN SHOULD INSTALL THIS PRODUCT.
ITMUST BE INSTALLEDIN ACCORDANCEWITH APPLICABLE REGULATIONS, CODES,
ANDSTANDARDS.
M165952F

1
THANKYOU
Thankyouforpurchasing a NorthStar Standby Generator. Your machine is designed forlong
life,dependability,andthe 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 NorthStarproduct.
IMPORTANT INSTRUCTIONS
Make certain:
- The operator andinstaller read and understand thismanual.
- If anyportionof thismanual isunclear, orportionsof thismanual aremissing 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
Throughoutthismanual and on safetydecalslocated on themachinery,DANGER, WARNING,
and CAUTION headingsare used toidentifyspecial instructionthatmust beunderstood prior
toinstallation, repair,or operation of thisgenerator. Observe the DANGER, WARNING, and
CAUTION blockscarefully. Their definitionsareasfollows:
DANGERindicatesanimminently hazardoussituation which,ifnot avoided,
will result in death or serious injury. This signal word is to be limited to the most
extreme situations.
WARNINGindicatesa potentiallyhazardoussituation which,ifnotavoided, could resultina
death or seriousinjury.
CAUTIONindicatesa potentiallyhazardoussituation, which ifnotavoided, may resultin minor
ormoderate injury. Itmayalso be used to alert against unsafe practices.
After the DANGER, WARNING,and CAUTION headings, appropriate instructionsare relayed
about specific functionsor installationproceduresthatmaybe hazardousifthe safetyinstructions
are not followed. HOW TO OBTAINSERVICE
When your NorthStarproduct requiresservice or repair, simply call our NorthStar Customer
Service Department. We will locate thenearest 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
specificationsatany timewithoutincurring any obligationtoinstall them on unitspreviously sold.

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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 transferswitch.
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 recommendsthatinstallation, initial start-up,
and maintenance should issues be addressed by
professionals who are familiar with installation and
operationof standby generator sets.
DANGER •Never operate this generator in
an enclosed area. Exhaust gases contain carbon
monoxide,anodorlessanddeadly poison.
DANGER •Never install the generator in
such alocationthat exhaust gasescan seep back into
closed rooms. Gases can seep into closed rooms
through windows, doors, and floors.
DANGER •Neverinstall thisproductindoors,
or modify the exhaust system for indoorinstallation.
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
independentof the stand by generator.
DANGER •Always remove the spark plugs
or spark plug wires before working on the engine or
generator.Theengine 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 whenin operation.Avoid anycontact 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 •Neverhandleany kind ofelectrical
device while standing in water,while barefoot, or while
handsor feet arewet. Dangerouselectrical shockwill
result.
DANGER •The National Electrical Code (NFPA
70) requiresthe frame and externally conductive parts
of the generator tobe connectedto an approved earth
ground.
DANGER •Thishome stand by electrical system
may start without warning. When the generator starts
load circuits automatically can transfer by the transfer
switch. 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
incomingutilitypoweratthe mainline circuitbreaker.
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 ordeath.
DANGER •LPGand NG arelethal and explosive
gases. If yousmell gas, exittheareaimmediately.
DANGER •Do not smoke around the generator.
Wipe upanyfuel or oil spills immediately. Ensure that
no combustible materials are left in the generator
compartment, or near the generator. Keep area
around thegenerator cleanand free of debris. Keep a
fireextinguisher rated “ABC” near the generator.

3
Table of Contents
Introduction Page 1
Thankyou Page 1
Important Instructions Page 1
How to Obtain Service Page 1
Notice Page 1
Safety Rules Page 2
Table of Contents Page 3
Section1 - Specifications Page 3
1.1 Engine Page 3
1.2 Generator Page 3
1.3 Control System Page 4
Section2 - Installation Page 4
2.1 Introduction Page 4
2.2 Assistance Page 4
2.3 Unpacking the Product Page 5
2.4 InstallationPreparation Page 5
2.5 GeneratorLocation 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
2.9.1A.C. Wiring Connections Page 11-12
2.9.2Battery Charger Connections Page 12
2.9.3AutomaticStart Connections Page 13
2.10 Fuel MixtureReconfiguration Page 13
2.11Battery 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
Section4- Theory of Operation Page 18-19
Section 5- Maintenance Page 19
5.1 SparkArrester 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
[BoreX Stroke] 37.5 cu-in (614 cc) [3.03X2.60in (77X66mm)]
Number ofCylinders 2
Cylinder Block Cast Aluminum
ValveArrangement 4--Stroke, Overhead Valve
Ignition System TransistorizedMagneto
Compression Ratio 8.3:1
MaxTorque 32.5 lb-ft @2500 rpm
CoolingSystem Forced Air
PTOShaftRotation Counterclockwise
(viewed from PTOside)
SparkPlugGap 0.028 -0.031 in.
RecommendedSparkPlug 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
RecommendedOil Filter
Honda # 15400-POH-305PE
Recommended Air Filter
Honda # 17010-ZJ1-000
Starter 12 Vdc,SolenoidShift
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
ContinuousPower (Watts) 9600 (LPG) / 8000 (NG)
Voltage (Volts) 120/240
ContinuousCurrent(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

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1.3 Control System
Battery Charger
InputSpecification
Output Specification
Charging
Maintaining
115Vac, 1.0 Amp
12.0 Vdc, 2.0Amp
13.3 Vdc, 0.1Amp
Battery Charger Fuse Bussman AGX6
32Vdc,6 Amp
1/4” X1” Non-Time Delay
Convenience Receptacle 125Volt,20Amp,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 CrankShutdown
12 Vdc
4080 rpm (68 Hz.)
300°F
14.22 psi (98 kPa)
3 AttemptsatStarting
Engine Controller Fuse 12 Vdc,20Amp
ATOSeries
(Automotive Style)
Fuel Lockoff Solenoid 12 Vdc.
Cooling Fan 12 Vdc.
Section 2: Installation
2.1 Introduction
DANGER •Only qualifiedelectricians or
contractors should attempt installation of
either the stand bygenerator or transfer
switch. The installation must complywith all
applicable codes, regulations, or standards.
Note: Please read the entire manual before
attemptingtoinstall the stand by generatoror
transfer switch.
NorthStar designsproductsthatare safeto
operateand easilyinstalled. We cannotpredict all
installation proceduresor methodsrequired to
install our products. Itistheinstaller’s
responsibilitytofollow safe workprocedures, and
to correctlyidentify potential hazardswhile
installingthisproduct.
2.2 Assistance
1: For Home or Business installation, a certified
electrician or contractorisrequired. 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: Lookin your local
phone book under the classification “ Heating
Contractors” or “Air Conditioning Contractors.”
•Call Customer Service at1-800-270-0810
between the hours of 7:30 a.m. and 5:00 p.m.
CST. Our Customer Service Department will
assist in finding thenearest qualified installer.
2: For installation by a Certified Electrician or
Contractor: all requiredinformationiscontained
within this manual for proper installation and
startup. Iffurtherinformation 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 thenearest 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 damagedue to bumping, dropping,
or collision. Always store the generator with the
proper sideup.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 thefreight bill.
Afterunpacking the stand bygenerator, inspect all
contentsfor 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 tomachine.
2.4 Installation Preparation
Prior to installation of this equipment check the
ratings of both the generator set and transfer
switch. The generatorand 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 bygeneratorisfastenedto the shipping
palletby four 1/4” X 1.5” lagbolts. A 1/2” wrench is
required to remove the lag bolts from the pallet
(Figure 01164).
2.5 Generator Location
DANGER •Neveroperate thisgeneratorin
anenclosedarea.Exhaust gasescontain carbon
monoxide,anodorlessanddeadly poison.
DANGER •Neverinstall thegeneratorin
a locationthat exhaust gasescan seep back
into closed rooms. Gasescan seepinto closed
roomsthrough windows, doors, and floors.
Install the stand by generator set outdoors where
thereisan adequate supplyof fresh cooling air.To
help ensure trouble free operation, the following
suggestionsshould beconsidered:
1: Neverinstall the generator inareasprone to the
collectionof rainwater.
2: Never install the generator in an area that is
prone toflooding.
3: Neverlocate the generator ona 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
placementof the gaspipe.
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 resultin 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 thebase.
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 bya minimum of 3incheson all sides.
The concrete slab must be level. For further
details concerning concrete slab dimensions and
details, see FIG01168.
LAGBOLT
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 followinginformationisonly to assist the
gaseousfuel technician withinstallation andset-
up. ALWAYS follow LOCALandFEDERAL gas
codeswhen installing thisproduct. Consult your
local fuel supplier or FireMarshall if questionsor
installation problemsoccur.
When installingthe fuel system, place a flexible
length of fuel line between the generator fuel
connection pointand the rigidpiping.The section
of flexible fuel line must beapproved for gaseous
fuel use, and meet the requirementsasdictated by
LOCALand FEDERALgascodes.
It isadvised that amanual fuel shutoff valvebe
placedin-line with the rigidpiping.
Thisproductisdesigned tooperate on either
Natural Gas(NG) or Liquid Petroleum Gas(LPG).
Onlyuse a vapor withdrawal system to deliver fuel
to the engine. A vapor withdrawal system uses
the vaporsthatare formed on topof theliquidfuel.
Note: Thisengine onlyburnsvapor fuel.
The fuel system isfactory presetforNG. If the fuel
source isLPG,followthefuel reconfiguration
directionsin Section 2.10.
To achievemaximum horsepower from the
engine,the recommended fuelsshould havea
minimum BTU contentof1,000 BTU per cubic foot
for Natural Gas(NG) and 2516 BTU per cubicfoot
for Liquid Petroleum Gas (LPG). See Table 1.5 for
fuel
LPG Conversion Factors:
1 lb. =8.58 cubic feet
1 gallon =36.39 cubicfeet
Table 1.5 - Inlet Fuel Requirements
NG LPG
Pressure 4-6 oz. 7-11” Water Column
Flow 3.25 CFM 9.33lb/hr, 2.2 gal /hr
BTU/HR 161374 201718
2.7 FuelSystem Components
The fuel system iscomposed offour main
components: fuel lockoff, demand regulator,load
block, and carburetoradapter. See Figure01174.
The fuellock-off isa safety device that
electricallyoperateswith12Vdc.Thevalveis
open while 12 Vdcispresentatitstwo electrical
terminals. Ifthe engine should fail while
unattended,thisdevicepositively shutsoff the flow
of fuel. Thefuel lock-off has3/4” NPT inletpipe
thread,labeled “inlet”. Thisisthe fuel inlet
connection point.
The demand regulator allowslow-pressure fuels
to passthrough if 4ouncesof vacuum isapplied
to the outlet side ofthe regulator.
Thisdevice issometimescalleda “zero governing”
or “secondary”. The regulatorisa vacuum
demand device,whichisnormallyshut whenthe
engineisnotrunning.Venturi vacuum causesthe
secondary regulator toopen andallow the flowof
fuel at a zeroor negative pressure. This device is
not to be considered as a satisfactory fuel
lock-offvalve, or a pressure regulator.
The load block isa device thatadjuststhe fuel
mixture.Ifthisdevice isset incorrectly, the engine
will experiencedifficultyin starting, and cause
poorengineperformance.
The adaptermountsbetween the engine
carburetor and the air cleaner. Inside theadapter
isa venturi.The venturi isa symmetrical restriction
thatproducesapressure drop (vacuum)and
drawsfuel into theair stream.The amount of fuel
drawnin isproportional tothe volume andspeed
of the airpassing throughtheventuri.
FIG 01174 - Fuel System Components
VENTURI
ADAPTER
FUEL LOCKOFF
(fuel inlet)
DEMAND
REGULATOR
LOAD BLOCK

9
2.8 Generator Winding Connections
Figure 01175 representsa simplifiedpictorial of
thegenerator stator AC connection system.This
system isdescribed asa 60-Hertz, single phase,
four-wiredesign.The generator stator produces
120/240 voltsby meansoftwoindependent
stationary coil groups(windings), with twoleads
broughtoutofeach winding.Each winding can
nominally produce120 Voltsat60Hertz.
Combiningboth windingsin seriesproduces240
Voltsat 60 Hertz.Generator outputleads1 and4
are ”HOT”.Generator outputleads2 and 3 are
“Neutral”.
Fig. 01175 - Generator AC ConnectionSystem
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
independentof the stand-bygenerator.
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
throughtheconcrete pad, see theRightSide 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
screwscan be removedwith 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 boxaspictured in Figure01189.
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). Alwaysuse 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 withthelead 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
connectionlug, and torqueto35in-lbs.
Helpful Hint: Check that the lead wire has
adequateinsulation removed prior to insertion into
the connection lug. A lead wire that is inserted
into a compression connection without adequate
insulation removedmaycreate anopen circuit .
Inside most transfer switches, the generator
contacts are designated as EMERGENCY
POWER, andlabeledasconnectionpointsE1 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 forlead 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 thefunnel.Theset 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

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FACTORY CONNECTIONS
CUSTOMER CONNECTIONS
LEAD WIRESTOTHE GFCI RECEPTACLE
DO NOT DISTURB
LEAD WIRES TO THE GENERATOR HEAD
DO NOT DISTURB
MAINLINE 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” - TOTRANSFER SWITCHTERMINALE1
“HOT” - TOTRANSFER SWITCHTERMINALE2
NEUTRAL - TO TRANSFER SWITCH NEUTRAL
CONNECTIONPOINT
GROUND - TO TRANSFERSWITCH 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 blocklocation#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 groundlead wire into the terminal block,
rotatethe set screw counterclockwise to open the
funnel (Figure01198).
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 thefunnel.Theset screw has a
torque specification of 16 inch-pounds minimum.
Fig. 01198 - Terminal Block
2.9.2 A.C. BatteryCharger 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
125volt,20-amp circuit breaker, protectstheGFCI
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 adjacentto the GFCI receptacle.
The battery charger electrical requirements are
115VoltsA.C. with a current ratingof0.8 Amps.
For the battery charger to operate, separate power
must berouted 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 isdesignated 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
SELECTORSWITCH

13
2.9.3 Automatic Start Connections
Thisgeneratorisequipped witha automatic
engine start feature. Ifitisdesiredtoenable this
feature, the Auto/Off/Manual selector switch
(Figure 01199) islocated onthe control panel and
must be in the Auto position. The generator will
then start when terminals#5and #6 (Figure
01192)are connected to a remote set of contacts.
The remote contactsmust beconfigured assuch:
close to start the engine,and open tostop the
engine. Generally, all transfer switcheshave a set
of remote engine start contacts. These contacts
close upon lossof utilitypower, and openonce
utilitypower isrestored. If your transfer switchisa
General Electric ZTX100 (Northern Tool &
Equipment item #165969) or General Electric
ZTX200 (NorthernTool & Equipment item #
165970) the engine start contactsare labeledas
X1 and X2inside the transferswitch enclosure.
Refer to your Transfer Switch owners’ manual for
furtherinformation.
2.10 Fuel Mixture Reconfiguration
Thisgenerator set isdesigned to operateon 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
thefuel mixture. To adjust the fuel mixture, locate
the fuel regulator assembly (Figure 01201). The
following toolsare required to reconfigure the fuel
mixture: (1) 11/16” open-end wrench and (1)
straightblade screw driver.
Fig. 01201 - Regulator Assembly
The loadblockadjusts 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.Oncethe proper setting is achieved turn
thebrasslocknut to secure the adjustmentscrew.
Fig. 01202 - Load Block Adjustment
FUEL REGULATOR ASSEMBLY
A
DJUSTMENT
SCREW
SCRE
W
DRIVER
11/16” WRENCH
DEMAND
REGULATOR

14
2.11 Battery Introduction
Installationor 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 ofthe battery. Ifthe 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 BatteryWarnings
DANGER
•ALWAYS be sure that the utility power is
turned off to the battery charger, orsparks will
occur at the battery posts as the battery cables
are connected ordisconnected.
•Always wear safety glasses.
•Shieldeyes-explosive gases cancause
blindness.
•Sulfuric acid can cause blindness or severe
burns.
•Flush eyes immediately with w ater. Seek
medical help immediately.
•Never install orcharge a visibly damaged or
frozen battery.
•Never dispose ofa battery ina fire.The
battery is capable ofexploding.
WARNING
•Spilled electrolyte or sulfuric acid is to be
washed down with an acid-neutralizing agent. A
common neutralizing agentisa mixture of1 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 presenta 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 BatterySize
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
“lawnand 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 BatteryInstallation
The battery compartment is located behind an
accesspanel located on the frontofthe generator.
The accesspanel isremoved by loosening the (4)
5/16 hex bolts with a 1/2” socket wrench (Figure
01204and Figure 01205).

15
Figure 01204 - Battery Location
2.11.3 BatteryInstallation-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.
Failuretodisconnect 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
batteriesduring 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 coverplate.The cover plate issecured with
four bolts.
Reference 2: Fuel Inlet. The fuel inletisthe fuel
connection pointbetween thegenerator set and
thefuel deliverypipe.Thefuel inletistapped for
3/4” NPT pipe. Always use a section ofapproved
flexible gaspipebetween the fuel inletand rigid
gaspipe.
Reference 3: Door and Door Lock.There are
two locking doors. The doorsare designed tolift
completelyout ofthe housing.To open the door,
pressthe key lockportion ofthe doorlatch.Each
door canbelocked with the provided keys. Two
setsof keysare included withthe generator.
Reference 4:Spark Arrester. The exhaust
system incorporatesa removable sparkarrester.
The sparkarresterisa safety feature thatinsures
thatsparkswill not exitthe muffler and cause a
fire.The sparkarrester isUSDA approved.The
sparkarrester should be cleaned after every 50
hoursofengineuse. See Section 5.1of this
manual for furtherdetails.
Reference 5: Generator Head.The electricity
producingportion of thegenerator.
Reference 6: Dipstick. Use theoil dipstickto
monitortheengineoil level. Consult the Honda
engineowners’ manual forfurtherinformation.
Reference 7: Remote Oil Drain and Plug. The
remoteoil drain providesa cleanand convenient
method to change engineoil.
Reference 7: (Continues)The oil drain plug
preventsaccidental lossof engineoil. A5/16” hex
key (Allan Wrench)isrequired to remove theoil
drain plug.
Reference 8:Engine Oil Drain Valve. The
engineoil drain valveprovidesa convenient
method to change oil.Byopening the valve engine
oil flowsto the remote oil drain (Reference 7).
Reference 9: Demand Regulator Assembly.
SuppliesLP or NGfuel ata negative pressure
whenthe engine isrunning.The regulator is
sometimesreferred to asa Secondary.The
Secondary regulatorgaugesthe fuel flowor
amount of fuel delivered to the engine.
Reference 10: Engine. The engine is a 20 H.P.
Honda GX620 K1VXA. Refer tothe Honda engine
owner’smanual for maintenance intervals. Refer
tooSection1.1ofthismanual for general engine
information.
Reference 11: Battery Charger. The battery
chargerisofa “3-stage”electronicdesign.The 3
charging stagesarebulk, absorption,and float.
Thischarger isnot of the “trickle” designthat can
boil off theelectrolyte and destroy abattery.The
battery charger plugsintotheGFCI convenience
receptacle, which islocated on the control panel.
When thebattery chargerisoperating,a green
LEDlight on the front of the charger will be lit.
Reference 12: Spark Plug. The Honda engine
hastwo sparkplugs. One islocated on each side
of the engine.Referto the Honda engineowners’
manual formaintenance.
Reference 13: Engine Oil Fill Cap. Remove cap
to add oil tothe engine. Referto the Honda engine
owners’ manual for oil recommendations.
Reference 14: Engine Air Cleaner.Referto 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
STARTSWITCH
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
protectsthe generatorfromelectrical overloads. If
the circuit breaker trips, reset thebreaker by
moving theleverto the OFFposition andthen
backto theONposition.
Reference 17: ON/OFF/AUTO. Thisswitch will
start theengineifplacedinthe ONposition. When
the switchisin theAUTO position, thegenerator
will start whenthe transfer switch senseslossof
utilitypower.The OFF positionshutsdown the
engine.
WARNING •With the switch set in the
AUTO position, the engine can crank and start
withoutwarning. Automatic starting can occur
with loss of normal utility power orduring a
normal exercise initiated by the transfer
switch. To prevent accidental engine starting,
place the switch in the OFF positionand
disconnect the battery prior to working on or
around the generator.
Reference 18: Maintenance Interval Reset
Switch.Themaintenanceinterval meter can be
instantly reset to zero by depressing the switch.
Reference 19: Total Hour Meter.The total hour
meter measureshoursthe enginehas
accumulatedwhile running.Thisportion of the
meter cannot reset.
Reference 20: Maintenance Interval Meter.
Thelowermeterisa maintenanceinterval meter.
It isused tomeasure hoursbetween scheduled
maintenance.To reset thismeter,depressthe
maintenanceinterval reset switch (Reference18).
Thismeter providesa convenient waytomonitor
oil changeintervals.
Reference 21: System Controller. The system
controller starts, stops, andmonitorsthegenerator
set. Thereare fivealarmlampsassociated with
theengine controller.Their functionsareas
follows:
Low Oil Pressure- In the event of low engine oil
pressure, the “lowoil pressure” lamp will glow red,
andthe engine will shutdown.To reset the system
controller, place the ON/OFF/AUTO switch in the
OFF position. Checktheengine 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 theON/OFF/AUTO switch
in the OFF position. Check for leaves or debris
blocking air inletsand outlets.
High Engine Speed- The system controller will
shut downthe engine in the event that the engine
operatingspeedexceeds4080 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 OFFposition.
Engine Over crank- The system controller will
engage the starter for 15 seconds. If the engine
doesnot 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 OFFposition.
System Normal-Thislampindicates everything is
normal. The lamp will glow while the unit is
running, or in automaticmode.
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 seriousinjury.A ground fault is defined as
a condition where electricity does not follow its
normal path, but passes through a person’s body
to reachground.A defectivepower 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 froma separate circuit-not the generator,
and will not work during a utility power outage.
This receptacle is rated for 125 volts at 20 amps
andwill powermost portablehandtools.
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 theGFCI receptacleeverymonth.
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
blackpost beakinto thehousing.
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 eventsoccur:
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 wiringharness.
2: If the three position switch is in the manual
mode,12 volts(dc) isthen deliveredto the system
control board which is located inside the control
box via lead wire “01A”.
3: Simultaneoustodelivering 12 voltsvialead 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
locatedinside theengine wiringharness.
Trouble Shooting Hint: When the system control
boardinputs(leads “O7 and O6A”) are connected
together, theengine will attempt to start if 12 volts
ispresent betweenleadwires“01A”and “G2B”.
SystemControl Board
4: Atthe same time theengineiscranking,both
theLP/NGfuel lockoff valve andcompartmentfan
are energizedby 12 voltsvialead wire “O4”.Lead
wire “O4”exitsthe control boxinsidethe engine
wiring harness.
5: Asthe engine cranks, thepistonscreate
vacuum.The vacuumwill influence the secondary
gasregulator to open and allow fuel to flow. The
secondary regulator reactsto a minimum of 4
ouncesper squareinch of vacuum.
Trouble Shooting Hint: It iscrucial tohave both
correct gasinletpressure andfuel mixture for
quickstarting. There isa1/8” NPT porton the side
of the regulator thatprovidesa convenientpoint to
measure inletpressure.
6: As the engine comes up to operating speed
(3600rpm),the engine continually sendsan
electrical signal througha blackwith red stripe
lead wire that exitsthe engine.Theblackwith red
stripelead wireisconnectedintolead wire “O5A”.
Lead wire “O5A” islocated insideof theengine
wiringharnessand terminatesat the system
control board.Theimportance ofthissignal isthat
oncea stable frequencyismeasured from the
magneto,the system control board takesthe
engine starteroffline. Secondly,ifthe frequency
exceeds4080rpm fora timeinterval of5 seconds
or greater, the system control board will alarmand
shutdownthe engine downasa resultofanover
speed condition.
7: Duringstart up, the control board disregardslow
oil pressure for 15 seconds. If after that period of
time,oil pressure hasnotdeveloped, the system
control board will alarmand shutdownthe engine
asa resultoflowoil pressure.
1/8” NPT PORT

19
The oil pressure sender islocatedon themuffler
side of theengine,andisconnected to the system
controller vialead wire “O9”. Theoil pressure
sender isnormally closed whenthe engineisnot
running. Anormally closed sender will complete
aninternal circuittothe engine block, whichisthe
system ground. An ohmmeterisuseful for
checkingif the senderisfunctioning correctly.
Trouble Shooting Hint: If lead wires“G8 andO9”
are connected together,the system control board
will alwaysshut downthe engineasa resultoflow
oil pressure. Lead wire“G8”isa system ground
wire,and if theoil pressure sender isclosed, lead
wire “O9” will beconnected toground.
8:The system control board can shutdown the
generator at anytime due tohighengine
temperature.Ahightemperatureconditionis
monitored bya thermo-diskmountedto the
engine.Thethermo-diskisnormally open and
closesif the compartmentair temperature
becomesexcessive. The thermo-diskisconnected
to the system control boardvia thetwolead wires
“O10 andO11”.
Trouble Shooting Hint: The system control board
will shutdown theengineiflead wires“O10 and
O11” are connected together.If thethermo-diskis
closed,lead wires“O10 and O11”are connected
together.
Section 5
Maintenance
Toinsure reliableand troublefreeoperationof
your standbygenerator,itisimportanttofollow
recommendedmaintenance schedules. Consult
your Honda engine owner’s manual for
maintenance schedules.
5.1 Spark Arrester Maintenance
The sparkarrester shouldbe removedand
cleaned witha wirebrush every50hoursof
engineoperation.
1: Removethesetscrew and cleanit with a
brush.
2:Pull the sparkarrester out of theoutlet
tube.
3: Cleanthe screen assembly witha wire brush.
Ifbreaksin the screenarediscovered, the
screen assembly must be replaced.
4: Returnthe screen assembly to themuffler
outlettube andrefastenwith the set screw.
Muffler Assembly
Spark Arrester
5.2 Oil Drain Valve Operation
The engineoil drain valve canbeopened with
eithera 10mmmetric socket, ora pairofpliers.
Simply turn thevalve counterclockwise toopenthe
valve.Turn the valve clockwise to close.
SET SCRE
W
SPAR
K
ARRESTER
MUFFLE
R
OUTLETTUBE
SCREEN
VALVE