North Star 165957 Owner's Manual

Manual is about: Portable, Outdoor Use-Only, Gasoline Generator 6600 Watt Continuous (8000 Watt Surge) Capacity

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M165957K

Owner’s Manual

Instructions for Installation/Set-up, Operation, Servicing, & Storage

Portable, Outdoor Use-Only, Gasoline Generator

6600 Watt Continuous (8000 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.

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 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).

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’ 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: 165957

SERIAL NUMBER: _____________

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Summary of 165957

Page 1
M165957k owner’s manual instructions for installation/set-up, operation, servicing, & storage portable, outdoor use-only, gasoline generator 6600 watt continuous (8000 watt surge) capacity can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up conne...
Page 2
Hazard signal word definitions 2.
Page 3
Table of contents 3 hazard signal word definitions ..................................................................................................2 about your generator ..................................................................................................................4 specificatio...
Page 4: About Your Generator
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 5: Warranty Registration
About your generator (cont’d) 5 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...
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: On-Product Warning Labels
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-product...
Page 8
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 ...
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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 (surge)...
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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) hand dr...
Page 12
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. Setting ...
Page 13
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 ...
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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...
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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
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...
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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
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
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 ge...
Page 20
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 21
Operation (cont’d) 21 • 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 ...
Page 22
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
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. Warn...
Page 24
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 25
Operation (cont’d) 25 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. • a portable container made of metal or conductive plastic is preferred because it dissipates charge to ground m...
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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
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
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...
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Operation (cont’d) 29 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. Detailed instructions are pr...
Page 30
Operation (cont’d) 30 prepare engine for long term storage if needed 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 forming and causing malfunction of the engine. Prepare engine for long term storage by: o r...
Page 31
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 cleanin...
Page 32
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 tes...
Page 33: Troubleshooting
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 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) 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
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 ignit...
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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 38.
Page 39
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 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 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...