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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 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 feet 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
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165610B.3
Item Number: 165610
Serial Number: _____________
CO Poisoning
Fire / Explosion
STOP!
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Related Manuals for North Star M165610B.3
Summary of Contents for North Star M165610B.3
- Page 1 M165610B.3 Item Number: 165610 Serial Number: _____________ Owner’s Manual 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).
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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 ..................13 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 its rated amount of electrical power. (See specifications section of this manual for model specific ratings) It can supply power: 1. -
Page 5: Warranty Registration
About Your Generator 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. Before using, the user shall determine the suitability of this product for its intended use and assumes liability therein. -
Page 6: Specifications
Specifications Item Number #165610 Maximum Output 5000 Watts (W) Continuous Output 4000 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 Honda GX240 Engine Speed 3390 - 3798 RPM Fuel Type Non-leaded automobile gasoline Fuel Capacity... -
Page 7: Safety Label Locations
Safety Label Locations Part # Description Always make sure safety labels are in place and in 786635 Burn Hazard good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. 785265 Danger Warning 786837 Over Fill Warning To order replacement safety labels, call NorthStar... -
Page 8: Machine Component Identification
Machine Component Identification Ref. Description Ref. Description Air Cleaner Generator Head Recoil 6.5 Gallon Gas Tank Fuel Valve Lever Muffler Vibration Isolation Mount Gasoline Tank Cap Oil Drain Plug Carbon Canister Oil Fill Port Choke Lever Control Panel... - Page 9 Machine Component Identification REFERENCE GUIDE Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care. Reference 2 – Recoil Grasp firmly when starting engine. Reference 3 – Fuel Valve Lever The Honda engine has an ON-OFF valve. Always keep this valve closed when the generator is not in use.
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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 Watts Starting Watts Device (Continuous) (Surge) Clothes Washer 1150 2300 Coffee Maker 1750 Deep Freezer 1000 Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) 1500 1500 Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles 2500...
- Page 12 Power Load Planning & Management (cont’d) To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps: 1. Make a list of all electrical devices you will be powering at the same time with the generator. 2.
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Page 13: 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 14: 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 its rated amount 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 15 Installation / Initial Set-Up The generator may not 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 16 Installation / Initial Set-Up Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga. 240V (watts) Cord Cord Cord Cord 2400 250' 150' 100' 4800 125' 7200 9600 12000 WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.
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Page 17: 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 18 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 19: 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 3/4” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –... -
Page 20: 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 21 Operation 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 22 Operation 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 23: Preparing For Operation
Operation 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 adequate clearance and ventilation. - Page 24 Operation 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 25 Operation 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 26: Starting The Engine
Operation 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 27: Checking Generator Output
Operation 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 28: Connecting Loads
Operation 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 29: Storage & Exercise
Operation 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 30 Operation 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 31: 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 32 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.) To test the GFCI: 1.
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Page 33: 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. d) Place switch in ON position. -
Page 34: 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 35 Summary of Important Safety Information for Operation (cont’d) 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 36 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 37 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 38: Generator Exploded View
Generator Exploded View 165610 Rev – B.3... - Page 39 Generator Exploded View 165610 Rev – B.3 Part # Description Ref # 786710 6.5 gallon fuel tank assembly w/cap 785337 4.5mm fuel line 2 ft 784959 Fuel valve 787295 Roll cage Exhaust pipe 784974 785352 Muffler gasket Muffler 784699 Heat shield, out - muffler 784792 785269 Heat shield, side - muffler...
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Page 40: Control Panel Parts List
Control Panel Parts List 165610 Rev – B.3 Ref # Part # Description Switch – 2 pole, red 783063 783060 8 AMP Circuit Breaker 783058 300V Volt Meter 783059 12VDC Outlet 783061 20 AMP Circuit Breaker 783050 NEMA L14-30 Receptacle 783053 NEMA 5-20 Receptacle (4) duplexes... -
Page 41: Generator Head Exploded View
Generator Head Exploded Views 165610 Rev – B.3... - Page 42 Generator Head Parts List 165610 Rev – B.3 Ref # Part # Description MA305522 Mount Plate (J609B) MA306404 Fan Bolts 778953 MA306406 Drive End Bracket 778954 Enclosing Band 305554 End Cover MA306408 End Cover Plug 786124 Stator 778956 Rotor w/ Diode and Varistor MA307479 Diode 778957...
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Page 43: California Emission Control Warranty Statement
California Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Northern Tool and Equipment Co, Inc. are pleased to explain the Evaporative Emission Control System (EECS) warranty on your Small Off Road Equipment (SORE). In California, new SORE must be designed, built and equipped to meet the State’s stringent anti-smog standards. - Page 44 California Emission Control Warranty Statement subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period. (2) Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above.
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Page 45: 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 46 Manufactured by Northern Tool + Equipment Co., Ltd Burnsville, MN 55306 NorthernTool.com...