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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
Can be used to power individual appliances plugged directly into the generator's outlets, or as a back-up
connection to a building's power supply (via a professionally installed UL-approved transfer switch.
READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up,
operate, and maintain this generator could result in serious injury or death from carbon monoxide poisoning,
electric shock, fire/explosion, or burns. In particular, be aware of the following hazards:
Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
ONLY run generator OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to allow
proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air
RIGHT AWAY. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes, basements,
garages, sheds, boxes, RVs, boats or pick-up truck beds. These spaces can trap poisonous gases, EVEN if you run a fan or
open windows.
Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly grounded.
Use only UL-listed, outdoor-rated grounded extension cords of proper size.
NEVER plug the generator directly into a wall outlet. ANY connection to a building's electrical system MUST ISOLATE
THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed electrician.
Otherwise, back feed from the generator into the power grid could kill utility workers.
DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so
engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7' from all combustible objects.
All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use
approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
ALWAYS keep a fire extinguisher rated "ABC" nearby.
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the "Power load Planning & Management" section of
this manual to determine your power load requirements and then compare to the generator's rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the "Unpacking &
Delivery Inspection" section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to
your building's electrical system. See the "Installation/Initial Set-Up" section for more information about this
requirement.
Owner's Manual
2,400 Watt Continuous (2,700 Watt Surge) Capacity
Electric shock / Electrocution
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
M165912I.4
ITEM NUMBER: 165912
SERIAL NUMBER: _____________
WARNING
CO Poisoning
Fire / Explosion
STOP!
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Related Manuals for North Star M165912I.4
Summary of Contents for North Star M165912I.4
- Page 1 M165912I.4 ITEM NUMBER: 165912 SERIAL NUMBER: _____________ Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 2,400 Watt Continuous (2,700 Watt Surge) Capacity Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up connection to a building’s power supply (via a professionally installed UL-approved transfer switch.
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Page 2: Hazard Signal Word Definitions
Hazard Signal Word Definitions... -
Page 3: Table Of Contents
Table of Contents Hazard Signal Word Definitions ....................2 About Your Generator ......................... 4 Specifications ..........................6 Safety Label Locations ........................7 Machine Component Identification ..................... 8 Power Load Planning & Management ..................10 Installation / Initial Set-Up: 1. Unpacking & Delivery Inspection ..................12 2. -
Page 4: About Your Generator
About Your Generator Thank you for purchasing your NorthStar portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to 2700 Watts of electrical power (2400 watts continuous, 2700 watts surge). It can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. - Page 5 About Your Generator (cont’d) Proper preparation, operation, and maintenance will result in operator safety, as well as best performance and long life of the generator. For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator. NorthStar is constantly improving its products.
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Page 6: Specifications
Specifications SPECIFICATIONS Item Number #165912 Maximum Output 2700 Watts (W) Continuous Output 2400 Watts (W) Generator Type Brushless Voltage 120 Volt (V) Phase Single phase Frequency 56.5 - 63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 5 Hp Honda GC160 AVXA Engine Speed 3390 - 3798 RPM Fuel Type... -
Page 7: Safety Label Locations
Safety Label Locations CAUTION BURN HAZARD Do not touch hot muffler. PN 39260 Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810. -
Page 8: Machine Component Identification
Machine Component Identification – 165912I.4 Figure 1 (Ref. 1-7) Ref. Description Ref. Description Circuit Breaker Choke Lever 120V 20A Duplex Receptacle Ignition Switch Lever Generator Head Recoil Oil Drain Plug Gas Tank Vibration Isolation Mount Air Cleaner Muffler Figure 2 (Ref. 7-11) - Page 9 Machine Component Identification – 165912I.4 (cont’d) REFERENCE GUIDE Reference 1 – Circuit Breaker This portable single phase generator has 1, 20 amp (A) push to reset circuit breaker to protect against electrical overloads. Reference 2 – (2) 120V 20A The generator has a control panel with two 120V Duplex Receptacles duplex (two receptacles in a common housing) receptacles.
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Page 10: Power Load Planning & Management
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. - Page 11 Power Load Planning & Management (cont’d) Running Running Device Watts Device Watts Electric range (1 element) 1500 Refrigerator 600 (b) Electric skillet 1250 Slow cooker Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer...
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Page 12: Installation / Initial Set-Up
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. -
Page 13: Set-Up As A Portable Or Building Back-Up Power Source
Installation / Initial Set-Up (cont’d) 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 2700W of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch. - Page 14 Installation / Initial Set-Up (cont’d) In addition to isolating your generator from the utility system, the transfer switch connects your generator to a limited set of circuits in your building that have been chosen as critical to operate during a power outage. The generator cannot power your entire home -- you must work with the installing electrician to determine which devices/appliances you wish to power during an outage.
- Page 15 Installation / Initial Set-Up (cont’d) Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoor-rated, grounded extension cords of the proper size. Use Table 2 below to choose an adequately sized extension cord according to the amperage of the device being used and the length of the cord.
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Page 16: Selecting A Suitable Site
Installation / Initial Set-Up (cont’d) 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet all of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. - Page 17 Installation / Initial Set-Up (cont’d) Adequate cooling The generator needs adequate, unobstructed flow of air to allow for ventilation proper cooling of engine and generator head. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. ...
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Page 18: Grounding The Generator
Installation / Initial Set-Up (cont’d) 5. Grounding the generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –... -
Page 19: Operation
Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. - Page 20 Operation (cont’d) Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire...
- Page 21 Operation (cont’d) Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
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Page 22: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” generator of this manual. Operate outside only, on dry, level ground with at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. - Page 23 Operation (cont’d) WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite gasoline vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Use extreme care when handling gasoline. Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: ...
- Page 24 Operation (cont’d) Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device. A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily. 5) Clean up gasoline spills /splashes immediately.
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Page 25: Starting The Engine
Operation (cont’d) 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Adjust choke: a) To start a cold engine, pull the choke rod to the CLOSED position. b) To restart a warm engine: i) If the engine has run out of fuel, pull choke rode to the CLOSED position after refueling. -
Page 26: Checking Generator Output
Operation (cont’d) 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. -
Page 27: Connecting Loads
Operation (cont’d) 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING:... -
Page 28: Storage & Exercise
Operation (cont’d) 7. Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below. Disconnect loads When you are finished using the generator, make sure all devices that were connected to the generator’s outlets have been disconnected. - Page 29 Operation (cont’d) Prepare engine for If you will not be able to exercise the generator regularly, you must prepare the engine for long term storage to prevent gum deposits from long term storage if needed forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carburetor o Adding fuel stabilizer to the gasoline (following manufacturer’s...
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Page 30: Maintenance & Repair
Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the generator. - Page 31 Maintenance & Repair (cont’d) Check GFCI Once a month, test the Ground Fault Circuit Interrupter (GFCI) to protect against electrical shock due to failure of the GFCI. (Only for (if equipped) those models equipped with GFCI – See the “Specifications” section.) To test the GFCI: 1.
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Page 32: Troubleshooting
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. a) Fill crankcase to proper oil level. b) Fouled spark plug. b) Clean or replace spark plug. c) Out of fuel. c) Fill fuel tank. d) Ignition switch lever in OFF position. -
Page 33: Summary Of Important Safety Information For Operation
Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator. - Page 34 Summary of Important Safety Information for Operation (cont’d) licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a standby power system, grounding will be complete through the building’s grounding system. Isolate connection to building’s electrical circuit. Never plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST ISOLATE THE GENERATOR FROM UTILITY POWER via an UL-approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes.
- Page 35 Summary of Important Safety Information for Operation (cont’d) Safety – During Use Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation. ...
- Page 36 Summary of Important Safety Information for Operation (cont’d) Safety – After use Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine can be a fire hazard. Prevent accidental starting. When generator is not in use, remove key from starter (key start engines) and secure in a safe location, or remove spark plug(s) in order to ensure that generator cannot be started in a storage location or by untrained persons.
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Page 37: Generator Exploded View
Generator Exploded View 165912 - Rev I.4... - Page 38 Generator Exploded View 165912 – Rev I.4 Diag # Part # Description 305491 Honda 5 hp Engine 780422 Engine Adapter Plate 780423 Fan & bolts 31193 Drive End Bracket 780424 Enclosing Band 306426 120V, 20A, NEMA 5-20R Receptacle 30643 20A Circuit Breaker 31177 End Cover 30815...
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Page 39: Wiring Diagram
Wiring Diagram 165912 - Rev I.4 Diag # Part # Description 305555 Connector Wire Harness 306496 Wire Assembly (W43, G41, G42) 306571 Black Terminated Wire 305556 Black Terminated Wire 305557 White Terminated Wire... - Page 40 This page has intentionally been left blank.
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Page 41: Limited Warranty
Limited Warranty Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. - Page 42 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com...