North Star M165601AD.1, 165601, 165603, 165604, 165605 Owner’s Manual

...

M165601AD.1

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).

WARNING

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:

CO Poisoning

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 at least 20 feet from the home, away from windows, vents and air intakes, to

allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. 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).

Electric shock / Electrocution

• 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.

Fire / Explosion

• 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.

STOP!

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

Call NorthStar Product Support 1-800-270-0810

Item Number: 165601, 165603, 165604,

165605, 165606, 165607

Serial Number: _____________

Hazard Signal Word Definitions

Table of Contents

Hazard Signal Word Definitions ................................................................................................... 2

About Your Generator ................................................................................................................... 4

Specifications ................................................................................................................................... 6

Safety Label Locations .................................................................................................................... 8

Machine Component Identification ............................................................................................... 9

Power Load Planning & Management .......................................................................................... 13

Installation / Initial Set-Up:

1. Unpacking & Delivery Inspection .......................................................................................... 16

2. Planning the Power Load ........................................................................................................ 16

3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source ............................ 17

4. Selecting a Suitable Site ......................................................................................................... 21

5. Grounding the Generator ........................................................................................................ 23

6. Battery Installation ................................................................................................................. 24

Operation:

1. General Safety Rules for Operation ....................................................................................... 25

2. Preparing for Operation .......................................................................................................... 28

3. Starting the Engine ................................................................................................................. 31

4. Checking Generator Output .................................................................................................... 32

5. Connecting Loads ................................................................................................................... 33

6. Stopping the Engine ............................................................................................................... 33

7. Storage & Exercise ................................................................................................................. 34

Maintenance & Repair .................................................................................................................. 36

Troubleshooting ............................................................................................................................. 38

Summary of Important Safety Information for Operation ....................................................... 39

Generator Exploded View ............................................................................................................ 43

Control Panel Parts List ............................................................................................................... 47

Generator Head Exploded View .................................................................................................. 50

Limited Warranty ......................................................................................................................... 55

California Proposition 65 Information ........................................................................................ 56

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. As a portable power source. You can plug appliances directly into the generator’s electrical

outlets.

2. As a back-up, standby power source for a building. A licensed electrician can connect the

generator to your building’s electrical system via the installation of an UL-approved transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn more about

specific requirements and precautions relating to wiring the generator to your building’s electrical

system.)

You must select a generator adequately sized for your power needs. You need to determine the power needs of all the appliances/tools you wish to power at the same time and choose a generator rated

to provide at least that power level. See the “Power Load Planning & Management” section of this

manual to determine your specific power load requirements and then compare them to this generator’s rated capacity. You must not overload the generator. Overloading will cause damage to the generator and attached electrical devices, and may also result in fire.

Be sure to read about site selection and grounding requirements for running this generator. More detailed information can be found in the “Installation & Initial Set-up, Steps 5 & 6 of this manual.

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 cover for storage, UL-approved transfer switches, and extension cords.

Contact NorthStar Product Support at 1-800-270-0810 with questions about optional accessories or to order.

Read this Manual

WARNING

Improper use or maintenance of this generator can result in serious injury or death from carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.

Read this manual completely before using the generator and follow all instructions and safety rules.

You must follow all instructions and safety precautions presented throughout this manual. A summary of important safety information can be found at the end of the manual. Keep this manual for reference and review.

Proper preparation, operation, and maintenance will result in operator safety, as well as best performance and long life of the generator. For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator.

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.

Contact NorthStar Product Support at 1-800-270-0810 for any questions about the appropriate use of this generator.

Warranty Registration

Please fill in the warranty registration information in the back of this manual and have it on hand when you call in on a warranty claim or replacement parts.

ATTENTION:

All Rental Companies and Private Owners who loan this

equipment to others!

All persons to whom you rent/loan this generator must have access to and read this manual.

Keep this owner’s manual with the generator at all times and advise all persons who will operate the machine to read it. You must also provide personal instruction on how to safely operate the generator and remain available to answer any questions a renter/borrower might have.

Specifications

Item Number

#165601

#165603

Maximum Output

5500 Watts (W)

8000 Watts (W)

Continuous Output

4500 Watts (W)

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

Honda GX270

Honda GX390

Engine Speed

3390 - 3798 RPM

Fuel Type

Non-leaded automobile

gasoline

Non-leaded automobile

gasoline

Fuel Capacity

6.5 gallons

Oil Capacity

1.16 US quarts

Starting Method

Recoil

Spark Arrester

Included on muffler

Dimensions

Length

27”

Width

21.25”

Height

22.63”

Dry Weight 174 lb.

200 lb.

Item Number

#165604

#165605

Maximum Output

8000 Watts (W)

10000 Watts (W)

Continuous Output

6600 Watts (W)

8500 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 GX390

Honda GX630

Engine Speed

3390 - 3798 RPM

Fuel Type

Non-leaded automobile

gasoline

Non-leaded automobile

gasoline

Fuel Capacity

6.5 gallons

11 gallons

Oil Capacity

1.16 US quarts

see Honda Manual

Starting Method

Electric

Battery (not included)

12VDC. 18AH

12VDC. 35AH

Battery Dimensions

(L x W x H) 7.13” x 3” x 6.57”

(L x W x H) 7.69” x 5.13” x 7”

Spark Arrester

Included on muffler

Included in manual bag

Dimensions

Length

27”

32.38”

Width

21.25”

24.38”

Height 22.63”

26.90”

Dry Weight 206 lb.

209 lb.

Specifications

Item Number

#165606

#165607

Maximum Output

13000 Watts (W)

15000 Watts (W)

Continuous Output

10500 Watts (W)

13500 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 GX630

Honda GX690

Engine Speed

3390 - 3798 RPM

Fuel Type

Non-leaded automobile

gasoline

Non-leaded automobile

gasoline

Fuel Capacity

11 gallons

Oil Capacity

see Honda Manual

Starting Method

Electric

Battery (not included)

12VDC. 35AH

Battery Dimensions

(L x W x H) 7.69” x 5.13” x 7”

Spark Arrester

Included in manual bag

Dimensions

Length

32.38”

Width

24.38”

Height 26.90”

26.90”

Dry Weight 313 lb.

325 lb.

Any Questions, Comments, Problems, or Parts Orders

Call NorthStar Product Support 1-800-270-0810

Safety Label Locations

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.

Part #

Description

Qty

786635

Burn Hazard

785265

Danger Warning

786837

Over Fill Warning

782397

Battery Hazard

Models: 165601, 165603, 165604

Models: 165605, 165606, 165607

ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns. NO smoking, sparks, or flames. NEVER touch both battery terminals at the same time with your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing. CONNECT cables in correct sequence: FIRST RED to POSITIVE terminal, then BLACK to NEGATIVE terminal. When disconnecting, DISCONNECT BLACK cable first, then RED. NEVER charge a visibly damaged or frozen battery. ALWAYS read and follow charger instructions.

BATTERIES:

1) contain caustic acid, 2) emit explosive gases,

3) can cause electric shock

WARNING - BATTERY HAZARDS

782397

Machine Component Identification

Items: 165601, 165603, 165604

Ref.

Description

Ref.

Description

Recoil

Generator Head

Fuel Valve Lever

6.5 Gallon Gas Tank

Engine Key Switch (165604 only)

Muffler

Vibration Isolation Mount

Gasoline Tank Cap

Oil Drain Plug

Carbon Canister

Oil Fill Port

Air Cleaner

Battery (not included, 165604 only)

Choke Lever

Control Panel

Machine Component Identification

Items: 165601, 165603, 165604

REFERENCE GUIDE

Reference 1 – Recoil

Grasp firmly when starting engine.

Reference 2 – Fuel Valve Lever

The Honda engine has an ON-OFF valve. Always keep this valve closed when the generator is not in use. Always keep this valve closed while transporting the generator.

Reference 3 – Engine Key Switch

The engine key switch is located on the control panel. Always locate this switch and be familiar with its location before operating the generator.

Reference 4 – Vibration Isolation

Mount

The engine and generator are mounted on rubber cylinders that absorb most of the engine vibration. This feature eliminates the tendency of the machine to “walk” which is common in engine-powered equipment.

Reference 5 – Oil Drain Plug

Refer to your Honda engine manual for oil change recommendations.

Reference 6 – Oil Fill Port

Refer to your Honda engine manual for oil change recommendations.

Reference 7 – Battery (not included)

Type required: 12VDC. 18AH

Reference 8 – Control Panel

An electrical device that contains outlets and meters for controlling other electrical devices

Reference 9 – Generator Head

The electricity producing part of the generator.

Reference 10 – 6.5 Gallon Gas Tank

Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full.

Reference 11 – Muffler

An acoustic device installed onto the exhaust system that is designed to reduce noise.

Reference 12 – Gasoline Tank Cap

The gasoline tank cap is extra-large, creating a large hole for refilling and a comfortable grip.

Reference 13 – Carbon Canister

Prevents gasoline vapors from exiting the fuel system.

Reference 14 – Air Cleaner

Refer to your Honda engine manual for air cleaner care.

Reference 15 – Choke Lever

Used during cold starts. Refer to the Honda engine manual for usage.

Machine Component Identification

Items: 165605, 165606, 165607

Ref.

Description

Ref.

Description

Air Cleaner

Battery (not included)

11 Gallon Gas Tank

Control Panel

Gasoline Tank Cap

Vibration Isolation Mount

Choke

Generator Head

Engine Key Switch

Carbon Canister

Oil Drain Plug

Fuel Valve Lever

Oil Fill Port

Muffler

Machine Component Identification

Items: 165605, 165606, 165607

REFERENCE GUIDE

Reference 1 – Air Cleaner

Refer to your Honda engine manual for air cleaner care.

Reference 2 – 11 Gallon Gas Tank

Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full.

Reference 3 – Gasoline Tank Cap

The gasoline tank cap is extra-large, creating a large hole for refilling and a comfortable grip.

Reference 4 – Choke

Used during cold starts. Refer to the Honda engine manual for usage.

Reference 5 – Engine Key Switch

The engine key switch is located on the engine. Always locate this switch and be familiar with its location before operating the generator.

Reference 6 – Oil Drain Plug

Refer to your Honda engine manual for oil change recommendations.

Reference 7 – Oil Fill Port

Refer to your Honda engine manual for oil change recommendations.

Reference 8 – Battery (not included)

Type required: 12VDC. 35AH

Reference 9 – Control Panel

An electrical device that contains outlets and meters for controlling other electrical devices

Reference 10 – Vibration Isolation

Mount

Reference 11 – Generator Head

The electricity producing part of the generator.

Reference 12 – Carbon Canister

Prevents gasoline vapors from exiting the fuel system

Reference 13 – Fuel Valve Lever

The Honda engine has an ON-OFF valve. Always keep this valve closed when the generator is not in use. Always keep this valve closed while transporting the generator.

Reference 14 – Muffler

An acoustic device installed onto the exhaust system that is designed to reduce noise.

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. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously. The sum of the running and starting wattages of the devices being powered must not exceed the continuous output rating of your generator. (The continuous output rating of your generator is listed in the “Specifications” section of this manual.) Note that:

• Devices without electric motors such as light bulbs, radios, and televisions have the same

running and starting wattage.

• Devices with electric motors such as refrigerators, compressors, and hand tools typically

require a starting wattage that is 3 to 5 times greater than the running wattage.

The running and starting wattage requirements are often listed on a device’s nameplate. If wattage

is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate

voltage by nameplate amperage, Watts = Volts X Amps.

Example conversion to watts:

120 Volts X 5 Amps = 600 Watts

If only the running voltage is given on the nameplate for a device with an electric motor, the starting wattage can be approximated to be three to five times the running wattage.

Estimates for the running wattage requirements for common devices are listed in Table 1 below. Guidance for starting wattages is provided in the table’s footnotes.

Table 1

Device

Running Watts

(Continuous)

Starting Watts

(Surge)

10in. Table Saw

1800

4500

7-1/4in. Circular Saw

1400

2300

8in. Bench Grinder

1400

2500

Air Conditioner - Central (24,000 BTU)

3800

4950

Air Conditioner - RV (13,500 BTU)

1500

3000

Air Conditioner - Window (10,000 BTU)

1200

2200

Battery Charger: 100 Amp with 300 Amp Boost

2400

7800

Battery Charger: 15 Amp

380

Battery Charger: 60 Amp with 250 Amp Boost

1500

5750

Belt Sander

1200

2400

Ceiling Fan

800

1200

Clock Radio

100

Clothes Dryer (electric)

1800

5750

Power Load Planning & Management (cont’d)

Device

Running Watts

(Continuous)

Starting Watts

(Surge)

Clothes Dryer (gas)

700

1200

Clothes Washer

1150

2300

Coffee Maker

1750

Deep Freezer

700

1000

Desktop Computer w/ 17" monitor

800

Dishwasher (Hot Dry)

1500

Drill: 1/2in., 5.4 Amps

600

900

Drill: 3/8in., 4 Amps

440

600

DVD/CD Player

100

Electric Fence: 25 Miles

2500

Electric Fry Pan

1300

Electric Range: 8in. Element

2100

Furnace Fan (Gas or fuel oil): 1/2 HP

875

2350

Furnace Fan (Gas or fuel oil): 1/4 HP

600

1000

Furnace Fan (Gas or fuel oil): 1/8 HP

300

500

Garage Door Opener

750

1200

Hair Dryer

1250

Hot Plate

2100

Inkjet Printer

Iron

1200

Laser Printer

950

Lights (Ten 75 Watt light bulbs)

750

Microwave Oven 1000W

1000

Milk Cooler

1100

1800

Milker (Vacuum Pump): 2 HP

1000

2300

Miter Saw - 10"

1650

2400

Oscillating Fan

200

400

Portable Heater (Kerosene, Diesel: 150,000 BTU

625

1000

Pressure Washer: 1 HP

1200

3600

Quartz Halogen Work light

1000

Reciprocating Saw

1200

2000

Refrigerator Freezer

700

1500

Security System

500

Space Heater

1800

Stereo Receiver

450

Sump Pump: 1/2 HP

1050

2150

Sump Pump: 1/3 HP

800

1300

Television 27"

500

VCR

100

Water Heater (Electric 40gal)

4000

Water Well Pump (1/3hp 220v)

1000

2000

(a) Hard-starting motors require 3-5 times the rated running watts (b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to

determine maximum wattage

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. List the greater of the running or starting wattage next to each device as obtained from the

devices’ nameplate or Table 1. If only the running wattage for a device with an electric motor is known, the starting wattage can be estimated to be at least 3 times the running wattage.

3. Add the wattages for all devices on your list. This total must be lower than the continuous

output rating of your generator.

Example:

Device to be Powered

Greater of

Starting/Running Wattage

Light Bulbs (10 – 75 watt)

750 W

Refrigerator Freezer

1500 W

Microwave Oven 1000W

1000 W

Air Conditioner, Window (10,000 BTU)

2200 W

Sump pump (1/3 hp)

1300 W

Total

6750W

In this example, the generator must have a continuous output of at least 6750 watts in order to power all of the devices simultaneously.

You can increase the number of devices your generator can power by staggering the load on the generator. For example, you could alternately power your refrigerator and air conditioner for limited periods of time -- powering only one of the devices at a time and never powering both at the same time.

STAGGERING LOADS

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.

3. Setting up generator for the type of power generation you need: a. portable power source, or

b. connected to a building as a back-up power source.

4. Selecting a site for using the generator.

5. Grounding.

6. Battery installation (electric start models only).

Each of these steps is discussed in detail below:

1. Unpacking & Delivery Inspection

You should inspect the generator immediately after you receive delivery.

See the “Machine Component Identification” section of this manual for a

diagram of the generator and its components.

• If you have missing or damaged components, contact Product Support at 1-800-270-0810.

2. Planning the Power Load

Plan your power load so that you do not exceed the generator’s rated capacity. See the “Power Load Planning & Management” section of this manual to review how to plan and

manage power loads for the generator.

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. The transfer switch must be installed in accordance with building electrical code and guidelines supplied by your power company.

2. As a portable power source. You can plug appliances or tools directly into the generator’s

electrical outlets.

Specific requirements for each are given below.

Note: Regardless of whether you use your generator as a back-up power source connected to a

building or as a portable power source, you must not overload the generator. Overloading may cause serious damage to the generator and attached electrical devices.

Using as a Back-up Power Source for a Building

Contact a licensed electrician to install an UL-approved transfer switch if

you want to use your generator as a back-up power source for a building. What does a transfer switch do? It:

a) Safely connects the generator to your building’s electrical system by

isolating your generator from your utility company’s power lines,

AND

b) Connects your generator to a critical subset of your building’s circuits

that are needed for emergency power needs.

If your generator will be connected to your building’s electrical system, it

MUST ALWAYS be isolated from the utility power grid with a UL-approved transfer switch installed by a licensed electrician in compliance with all

applicable building and electrical codes, and in accordance with guidelines supplied by your power company.

DANGER:

A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise:

 When your generator is running, it’s output will back feed into

the utility power line and transformer that are normally used to provide you with power. The transformer will step up the current to the normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated line could be electrocuted.

 If your generator is connected (running or not) when utility

power is restored, your generator will be destroyed. It could also explode or cause fire.

In addition to isolating your generator from the utility system, the transfer 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.

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