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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Triple Fuel 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.
Carbon monoxide is given off whether you are using gasoline, natural gas, or propane to power the generator.
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.
LPG/NG hook-ups must be completed by a certified gas technician and comply with all federal and local requirements.
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 transfer switch and/or NG/LPG hook-ups, if they will be used.
See the "Installation/Initial Set-Up" section for more information about these requirements.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165938R
ITEM NUMBER: 165938
SERIAL NUMBER: _____________
®
WARNING
CO Poisoning
Fire / Explosion
STOP!
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Summary of Contents for North Star M165938R
- Page 1 M165938R ITEM NUMBER: 165938 SERIAL NUMBER: _____________ ® Owner's Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Triple Fuel 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 ..................11 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 8,000 Watts of electrical power (6,600 watts continuous, 8,000 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) This generator is too heavy for one person to lift without mechanical assistance. An optional wheel kit is available from NorthStar and is recommended if you will be moving the generator unassisted. Other optional accessories available from NorthStar include a vinyl cover for storage, UL-approved transfer switches, and extension cords. -
Page 6: Specifications
Specifications SPECIFICATIONS Item Number 165938 Maximum Output 8000 Watts (W) Continuous Output: Gasoline 6600 Watts (W) Liquid Petroleum Gas (LPG) 6200 Watts (W) Natural Gas (NG) 5200 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency Regulation 56.5 - 63.3 Hertz (Hz) Voltage Regulation 110-129V... -
Page 7: Safety Label Locations
Safety Label Locations 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 ©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 #165938R Figure 1 (Ref. 1-12) Ref. Description Ref. Description Gas Cap with Gauge Super Silent Muffler 6.5 Gallon Gas Tank Air Cleaner Battery Box Engine Key Switch Circuit Breakers Fuel Valve 120V 15A Duplex Receptacle Choke Lever Fuel Selector Switch Recoil... - Page 9 Machine Component Identification - Item #165938R REFERENCE GUIDE Reference 1 – Gas Cap with The gas cap is extra large, creating a large hole for Gauge refilling and a comfortable grip. You can always monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap.
- Page 10 Machine Component Identification - Item #165938R This feature eliminates the tendency of the machine to "walk" which common engine-powered equipment. Reference 10 – Oil Drain Plug Refer to your Honda engine manual for oil change recommendations. Reference 11 – Super Silent Noise level is 8 dB less than Honda's standard muffler.
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Page 11: 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 12 Power Load Planning & Management (cont’d) Running Running Device Watts Device Watts Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1") 1100 Sump pump 600 (a) Hand drill (1/2") Table saw 2000 (a) Hand drill (3/8")
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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: Gas Hook-Up Installation For Natural Gas Or Propane (Lpg) - If Using
Installation / Initial Set-Up 3. Gas Hook-up Installation for Natural Gas or LPG (if needed) You can power this generator with gasoline, natural gas (NG), or propane (LP) gas. The generator is designed so that it is easy to switch between fuel sources. However, there are special initial hook-up requirements for natural gas and propane: WARNING: If you choose to operate the generator on NG or LPG, you must have the fuel line system... - Page 15 Installation / Initial Set-Up This product is designed to operate at an LPG gas pressure range of 7" to 11" of water column and requires a minimum LPG gas flow rate of 5.7 lb/hr, 1.34 Gal/hr, or 122,865 BTU/hr. Note: All gas cylinders produce gas pressure in excess of 11"...
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Page 16: Set-Up As A Portable Or Building Back-Up Power Source
Installation / Initial Set-Up 4. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 8,000W 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 17 Installation / Initial Set-Up 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 18 Installation / Initial Set-Up 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. Table 2 Current/Power Maximum Extension Cord Length...
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Page 19: Selecting A Suitable Site
Installation / Initial Set-Up 5. 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 20 Installation / Initial Set-Up Never place the generator immediately adjacent to a building or other structure – allow at least a 7' clearance. Do not run the generator in close proximity to other heat-generating equipment, such as another generator. The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation.
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Page 21: Grounding The Generator
Installation / Initial Set-Up 6. 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 22: Battery Installation
Installation / Initial Set-Up 7. 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 23: 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 24 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 25 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 26: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in "Installation & Initial Set-up, Step 5: Select a Suitable Site" of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. - Page 27 Operation (cont’d) Check the gasoline level in the generator's tank if you will be operating Fill gasoline tank the generator on gasoline. (if using gasoline) If needed, fill tank with fresh unleaded gasoline from a portable container, after first reading the warnings and instructions below. WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive.
- Page 28 Operation (cont’d) Always dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources. Never fill the generator's gas tank directly from the fuel pump – the generator's tank is not grounded and high velocity flow from the pump can cause static electricity build-up.
- Page 29 Operation (cont’d) Inspect Fuel Inspect fuel system & check for leaks BEFORE starting generator. Do not start generator until all needed repairs have been completed. System / Check for Leaks WARNING: Fuel leak hazard Gasoline, LP gas (propane) and NG (natural gas) are highly explosive and fuel leaks can result in fire or explosions.
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Page 30: 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. The following directions detail how to start the engine with either LP/NG or Gasoline as the fuel source: Using LP/NG To start engine using LP or Natural Gas: WARNING: DO NOT start engine if you smell gas. - Page 31 Operation (cont’d) 5) Under long, continuous-run operating conditions, be prepared to: a) Check engine oil level every 24 operating hours, Change oil after the first 20 operating hours, and at least every 100 operating hours thereafter, as directed in the engine owner's manual. WARNING: Never open oil port while engine is running.
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Page 32: 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 33: 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 34: Switching Fuels (During Operation)
Operation (cont’d) 6. Switching Fuels (during operation) You can switch fuel sources (from gasoline to LP/NG, or from LP/NG to gasoline) while the generator is running. Follow the instructions below: Switching from 1. Disconnect all loads to the generator. Leave the engine running. LP/NG to Gasoline 2. -
Page 35: Storage & Exercise
Operation (cont’d) 8. 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 36 Operation (cont’d) Perform periodic maintenance as directed in this manual to keep the Perform regular generator in safe working condition. maintenance 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.
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Page 37: 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 38 Maintenance & Repair (cont’d) Inspect fuel system / Inspect the fuel system and check for leaks on a regular basis. check for leaks 1) 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 39: 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 40: 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 41 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 42 Summary of Important Safety Information for Operation (cont’d) Personal protective equipment Hearing protection. The use of earplugs or other hearing protection device is recommended for those in close proximity to the generator while it is operating. Loose / dangling. Loose or dangling apparel can become entangled in moving parts. Metal jewelry can conduct electricity.
- Page 43 Summary of Important Safety Information for Operation (cont’d) Carbon monoxide exhaust. The running engine gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY.
- Page 44 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. Turn off propane tank valve or shut NG line valve, as applicable.
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Page 45: Generator Exploded View
Generator Exploded View Rev - R... - Page 46 Generator Exploded View Rev - R Diag # Part # Description 777834 1/4" Hose Clamp 777164 Positive Battery Cable 38759 Fuel Tank Assembly 30754 Leather Washer 779422 Decal 32833 Roll Cage 33482 6mm Stud and Coupler Nut 36297 Load Block 31770 Engine Adapter 32811...
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Page 47: Wiring Diagram
Wiring Diagram Rev - R Diag # Part # Description 31086 Thermal Circuit Breaker, 30 Amp 30643 Thermal Circuit Breaker, 20 Amp 306433 Thermal Circuit Breaker, 15 Amp 30975 Control Panel Face 306429 Binding Post 306438 15 Amp, 120 Volt Receptacle (NEMA 5-15R) 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 31824... -
Page 48: Generator Head Exploded View
Generator Head Exploded View Rev - R 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 49: 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 50 ® Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...
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