Page 2 - Hazard Signal Word Definitions
Page 3 - Table of Contents
Table of Contents 3 Hazard Signal Word Definitions ................................................................................................. .2 About Your Generator ................................................................................................................. .4 Specificat...
Page 4 - Thank you for purchasing your NorthStar portable generator!; About Your Generator; It can supply power:; You must select a generator adequately sized for your power needs.; You need to; Read this Manual; WARNING; Improper use or maintenance of this generator can result in; from
About Your Generator 4 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. Yo...
Page 6 - SPECIFICATIONS
Specifications – Item #165957K 6 SPECIFICATIONS Item Number #165957 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 3390-3800 RPM Fuel Type...
Page 7 - If a safety label; To order replacement safety labels; , call NorthStar Product Support at; On-Product Warning Labels; Part numbers; Warning
Safety Label Locations – Item #165957K 7 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. On-Produc...
Page 8 - Machine Component Identification - Item #165957K
Machine Component Identification - Item #165957K 8 Figure 1 (Ref. 1-8) 00591 Ref. Description Ref. Description 1 Circuit Breakers 10 Gas Cap with Gauge 2 120/240V 30A Locking device Receptacle 11 6.5 Gallon Gas Tank 3 Grounding Post 12 Generator Head 4 120V 20A Duplex Receptacle 13 Battery Box 5 120...
Page 9 - REFERENCE GUIDE
Machine Component Identification - Item #165957K 9 REFERENCE GUIDE Reference 1 – Circuit Breakers This portable single phase generator has 1, 15 amp (A) 2, 20A, and 2, 30A push to reset circuit breakers to protect against electrical overloads. Reference 2 – 120/240V Receptacle The locking device is ...
Page 10 - Power Load Planning & Management; NEVER exceed the rated wattage capacity of your generator.; Example conversion to watts:; Running
Power Load Planning & Management 10 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 (su...
Page 11 - Table 1
Power Load Planning & Management (cont’d) 11 Device Running Watts Device Running 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 Sump pump 600 (a) Han...
Page 12 - If you have; Planning the Power Load
Installation / Initial Set-Up 12 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. 3. Sett...
Page 13 - Set-up either as a BUILDING BACK-UP or PORTABLE Power Source; As a portable power source; transfer switch installed by a licensed electrician
Installation / Initial Set-Up 13 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 ...
Page 14 - Power Load Planning &
Installation / Initial Set-Up 14 Please read your owner's manual before operating, if you do not have a manual or have questions, call customer service at 1-800-270-0810 GROUNDING POST NEMA L14-30R NEMA 5-20R Duplex NEMA 5-15R FIG02679 that have been chosen as critical to operate during a power outa...
Page 15 - Table 2; Maximum Extension Cord Length; Use of damaged electric cords can cause electric shock or fire.
Installation / Initial Set-Up 15 ♦ 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 ...
Page 16 - Select a Suitable Site; Before using the generator, you must select a suitable; OUTDOOR; location for installation and; The generator should be positioned on a dry, firm, level surface.; WARNING: Carbon monoxide poisoning hazard; These
Installation / Initial Set-Up 16 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 avoi...
Page 17 - Do not use the generator in extremely dusty or dirty conditions.
Installation / Initial Set-Up 17 • Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build 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 clo...
Page 18 - Grounding the generator
Installation / Initial Set-Up 18 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...
Page 19 - Battery Installation; WARNING: Battery hazards; red
Installation / Initial Set-Up 19 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 gen...
Page 20 - Operation; Each of these procedures is discussed in detail below:; General safety rules for operation; Be thoroughly familiar with proper use of the equipment and all
Operation 20 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. Starting the Engine 4. C...
Page 22 - Static electricity and filling the gasoline tank:; from persons carrying a static electric charge; . Always dissipate static charge from your body; . Never fill the generator’s gas tank directly from the fuel pump –; . Keep nozzle in contact with the portable container at all times; It will dissipate charge to ground more
Operation (cont’d) 22 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 d...
Page 23 - Preparing for Operation; battery manufacturer’s instructions.; WARNING: Burn hazard; Engine is shipped without oil. You must add oil before first use.
Operation (cont’d) 23 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “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 24 - See warning box about static electric spark hazards below.; WARNING: Static electric spark hazard
Operation (cont’d) 24 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 w...
Page 26 - Starting the Engine; To start the engine:
Operation (cont’d) 26 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...
Page 27 - Checking Generator Output; output voltage should be checked periodically to; Use voltage meter to check output voltage
Operation (cont’d) 27 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...
Page 28 - Connecting Loads; Stop the engine using the following steps:
Operation (cont’d) 28 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 g...
Page 31 - Maintenance & Repair; Follow safety rules; Always turn off generator and remove spark plug(s) or; Engine maintenance items include:; Check receptacles
Maintenance & Repair 31 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 cle...
Page 32 - Clean and inspect the spark arrestor muffler.; (Only for those models; Keep generator clean.; (Only for those models equipped with electric
Maintenance & Repair (cont’d) 32 Check GFCI (if equipped) Once a month, test the Ground Fault Circuit Interrupter (GFCI) to 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. Depress the...
Page 33 - Troubleshooting; TROUBLESHOOTING; Problem
Troubleshooting 33 TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Stop switch in OFF position. e) Battery is not charged. a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) Fill fuel t...
Page 34 - Summary of Important Safety Information for Operation; memory about how to safely use your generator.; General; Battery Safety
Summary of Important Safety Information for Operation 34 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 Carefu...
Page 35 - Summary of Important Safety Information for Operation (cont’d); Safety – Before Use; Know how to operate
Summary of Important Safety Information for Operation (cont’d) 35 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. • Operate OUTSIDE only ...
Page 36 - Gasoline Safety; Safety – During Use
Summary of Important Safety Information for Operation (cont’d) 36 Gasoline Safety Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use extreme care when handling: • Fuel outdoors . Fill fuel tank outdoors – never indoors. Gasoline vapors can igni...
Page 37 - Safety – After use
Summary of Important Safety Information for Operation (cont’d) 37 • Avoid contact . Avoid contact with bare wires, terminals, connections, etc. while the unit is running. • Electric shock accident. If an electric shock accident occurs, immediately shut down the source of electrical power. If this is...
Page 38 - Generator Exploded View Rev - K
Page 39 - Description
Generator Exploded View Rev - K 39 Ref # Part # Description Qty 1 38759 Fuel Tank Assembly 1 2 33321 Fuel Cap 1 3 777352 Battery Box 1 4 30754 Leather Washer 4 5 779422 Decal 1 6 777834 Hose Clamp 3 7 779423 Warning Decal 1 8 32833 Roll Cage 1 9 39260 Hot Muffler Sticker 1 10 31335 Honda GX390 Engin...
Page 40 - Wiring Diagram Rev - K
Wiring Diagram Rev - K 40 Diag # Part # Description Qty 1 306438 15 Amp, 120 Volt Receptacle (NEMA 5-15R) 1 2 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 1 3 306422 30 Amp, 120/240 Volt Locking Receptacle (NEMA L14-30R) 1 4 306429 Grounding Post 1 5 306433 Thermal Circuit Breaker, 15 Amp 1 6 3819...
Page 41 - Generator Head Exploded View Rev - K
Generator Head Exploded View Rev - K 41 Item # Part # Description Qty 1 38266 Mount Plate (J609B) 1 2 38267 Fan Bolts 2 3 38268 Fan 1 4 38269 Drive End Bracket 1 5 38270 Enclosing Band 1 6 777304 End Cover 1 7 38271 End Cover Plug 1 8 38272 Stator 1 9 38273 Rotor 1 10 307479 Diode 2 11 38275 Securin...