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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Industrial Gasoline Generator
6,600 Watt Continuous (8,000 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
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165920S
ITEM NUMBER: 165920
SERIAL NUMBER: _____________
®
WARNING
CO Poisoning
Fire / Explosion
STOP!
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Summary of Contents for North Star M165920S
- Page 1 M165920S ITEM NUMBER: 165920 SERIAL NUMBER: _____________ ® Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Industrial Gasoline Generator 6,600 Watt Continuous (8,000 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. Planning the Power Load......................12 3. -
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 8000 Watts of electrical power (6600 watts continuous, 8000 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) 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.
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Page 6: Specifications
Specifications SPECIFICATIONS Item Number 165920 Maximum Output 8000 Watts (W) Continuous Output 6600 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 13 HP Honda GX390 Engine Speed 3390 - 3798 RPM Fuel Type... -
Page 7: Safety Label Locations
Safety Label Locations WARNING BURN HAZARD Do not touch • Commercial-grade electric start engine hot muffler. • Extend run 6.5 gallon fuel tank • Maintenance-free brushless alternator design ©2005 NT+E 1-800-270-0810 PN 39260 • Smooth running focus mount isolation system WARNING - BATTERY HAZARDS BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock... -
Page 8: Machine Component Identification
Machine Component Identification - Item #165920S Figure 1 (Ref. 1-13) Ref. Description Ref. Description Air Cleaner Gas Cap with Gauge Oil Drain Plug 6.5 Gallon Gas Tank Full Power Switch Super Silent Muffler Voltmeter Generator Head Idle Control On/Off Switch Battery Box Hour Meter Vibration Isolation Mount... - Page 9 Machine Component Identification - Item #165920S REFERENCE GUIDE Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care. Reference 2 – Oil Drain Plug Refer to your Honda engine manual for oil change recommendations. Reference 3 – Full Power Switch The switch reconnects the two generator windings from parallel (120V only) to series (120/240V).
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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 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) Hand drill (1”) 1100...
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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 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 8000W 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 ♦ Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet. ♦ Extension cords may be used to power devices that are located at a distance from the generator.
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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: Battery Installation
Installation / Initial Set-Up 6. Battery Installation Your generator’s engine is equipped with an electric starter which requires the installation of a 12- volt lawn tractor size battery (Group U1). See the “Specifications” section of this manual for more specific battery requirements for this generator model, such as minimum amperage or CCA rating. The battery is to be supplied by the customer and should be installed in the protective battery box located near the engine. -
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 (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 22 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 23: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation generator & 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 24 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 25 Operation (cont’d) 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; do NOT use the nozzle’s lock-open device. •...
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Page 26: 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 27: 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 28: 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 29: Storage & Exercise
Operation (cont’d) 7. 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 (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: f) Removing all gasoline from the tank and carburetor g) 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) Inspect fuel system / Inspect the fuel system and check for leaks on a regular basis. check for leaks Inspect the entire fuel system. Look for: signs of leaks or deterioration, chafed or spongy fuel hose, loose connections, loose or missing fuel hose clamps, damaged gasoline tank, or defective gasoline shut-off valve.
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Page 33: 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) Stop switch in OFF 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) Installation / Initial Set-up Safety • Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. •...
- Page 36 Summary of Important Safety Information for Operation (cont’d) • Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel. Use an UL approved fuel container to transfer gas to the engine. •...
- Page 37 Summary of Important Safety Information for Operation (cont’d) • Hot muffler. Never touch hot muffler, hot exhaust manifold, or engine cooling fins. Exhaust and engine parts can be very hot and will burn you. • Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never remove any drive belt or fan guard while the unit is operating.
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Page 38: Generator Exploded View
Exploded View Rev - S... - Page 39 Exploded View Rev - S Diag # Part # Description 38759 Fuel Tank Assembly 33321 Fuel Cap Battery Warning Decal 779396 30754 Leather Washer 779422 Decal 777834 Fuel Clamp, 1/4” 30755 Fuel Filter 32833 Cradle Weldment 38184 Engine Cover 39260 Hot Muffler Sticker 31335 13 HP Honda Engine...
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Page 40: Wiring Diagram
Wiring Diagram Rev - S... - Page 41 Wiring Diagram Rev - S Diag # Part # Description 31344 GFCI Duplex Receptacle, NEMA 5-20R, 20A-120V 31211 Mounting Clip 306422 Receptacle, NEMA L14-30R, 30A-120/240V 306429 Binding Post 31084 Rocker Switch 31085 Thermal Circuit Breaker, 20 Amp 31086 Thermal Circuit Breaker, 30 Amp 306423 Receptacle, NEMA L5-30R, 30 Amp-120 Volt 31334...
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Page 42: Generator Head Exploded View
Generator Head Exploded View Rev - S Item # Part # Description 779919 Mount Plate (J609B) 779556 Fan Bolts 779557 779920 Drive End Bracket 779786 Enclosing Band 777304 End Cover 38271 End Cover Plug 779787 Stator 779788 Rotor 307481 Varistor 779789 Diode 779790... -
Page 43: 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 44 ® Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...
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