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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
4,500 Watt Continuous (5,500 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.
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 AWAY from building air intakes. 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.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
WARNING
CO Poisoning
Electric shock / Electrocution
Fire / Explosion
Call NorthStar Product Support 1-800-270-0810
M165911V
ITEM NUMBER: 165911
SERIAL NUMBER: _____________
®
STOP!
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Related Manuals for North Star M165911V
Summary of Contents for North Star M165911V
- Page 1 M165911V ITEM NUMBER: 165911 SERIAL NUMBER: _____________ ® Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 4,500 Watt Continuous (5,500 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 5500 Watts of electrical power (4500 watts continuous, 5500 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: Warranty Registration
About Your Generator (cont’d) NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture. -
Page 6: Specifications
Specifications – Item #165911 SPECIFICATIONS Item Number #165911 Maximum Output 5500 Watts (W) Continuous Output 4500 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency 56.5-63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 9 Hp Honda GX270 Engine Speed 3390 - 3798 RPM Fuel Type... -
Page 7: Safety Label Locations
Safety Label Locations – Item #165911 WARNING BURN HAZARD Do not touch • hot muffler. Commercial-grade electric start engine • Extend run 6.5 gallon fuel tank • Maintenance-free brushless alternator design PN 39260 ©2005 NT+E 1-800-270-0810 • Smooth running focus mount isolation system •... -
Page 8: Machine Component Identification
Machine Component Identification – Item #165911V Figure 1 (Ref. 1-7) Ref. Description Ref. Description Circuit Breakers Gas Cap with Gauge 120/240V 20A Locking 6.5 Gal. Gas Tank Receptacle 120V 20A Duplex Receptacle Generator Head Oil Drain Plug Vibration Isolation Mount Engine On/Off Switch Recoil Air Cleaner... - Page 9 Machine Component Identification – Item #165911V REFERENCE GUIDE Reference 1 – Circuit Breakers This portable single phase generator has 2, 20 amp (A) push to reset circuit breakers to protect against electrical overloads. The device is a 120/240V 20A NEMA L14-20R Reference 2 –...
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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 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 1200 Submersible pump (1/2 HP) 1500 (a)
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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 Either As A Building Back-Up Or Portable Power Source
Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 5500W 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 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. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator.
- Page 15 Installation / Initial Set-Up ♦ 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 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 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 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 generator “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with adequate clearance and 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.
- Page 24 Operation (cont’d) • Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled. • Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline;...
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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) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position. -
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) Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Shut off fuel supply o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. - Page 29 Operation (cont’d) Prepare engine for If you will not be able to exercise the generator regularly, you must long term storage if prepare the engine for long term storage to prevent gum deposits from 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 (if equipped) protect against electrical shock due to failure of the GFCI. (Only for 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 a) Low oil level. a) Fill crankcase to proper oil level. start. b) Fouled spark plug. b) Clean or replace spark plug. c) Out of fuel. c) Fill fuel tank. d) Stop switch 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. • Shut off fuel supply. Make sure gasoline shut-off valve is in the OFF position. •...
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Page 37: Generator Exploded View
Generator Exploded View Rev- V... - Page 38 Generator Exploded View Rev- V Diag # Part # Description 38759 Fuel Tank Assembly 33321 Fuel Cap 777345 Fuel Line 2.75’ 30754 Leather Washer 779422 Decal 777834 Hose Clamp 30755 Fuel Filter 32833 Roll Cage 39260 Hot Muffler Sticker 305493 Honda Engine 778529 Generator...
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Page 39: Wiring Diagram
Wiring Diagram Rev- V Diag # Part # Description 30974 Control Panel Face Plate 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 306446 Locking Receptacle, 20 Amp-120/240 Volt (NEMA L14-20R) 306429 Grounding Post 31085 Thermal Circuit Breaker 38191 Wire Harness 82004 #8-32 X ½... -
Page 40: Generator Head Exploded View
Generator Head Exploded View Rev- V Diag # Part # Description 305522 Mount Plate (J609B) 306404 Fan Bolts 778953 306406 Drive End Bracket 778954 Enclosing Band 305554 End Cover 306408 End Cover Plug 778955 Stator 778956 Rotor 778959 Diode 778957 Securing Stud 307485 Bearing... -
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 ® Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...