M165601AB Item Number: 165601, 165603, 165604, 165605, 165606, 165607 Serial Number: _____________ 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).
Hazard Signal Word Definitions 2
Table of Contents Hazard Signal Word Definitions ................................................................................................... 2 About Your Generator ................................................................................................................... 4 Specifications ................................................................................................................................... 6 Safety Label Locations ..................................................
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.
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.
Specifications Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method Spark Arrestor Dimensions Length Width Height Dry Weight Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method Battery (not included) Battery Dimensions Spark Arrestor Dimensions Length Width Height Dry Weight #165601 5500 Watts (W) 4500 W
Specifications Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method Battery (not included) Battery Dimensions Spark Arrestor Dimensions Length Width Height Dry Weight #165606 13000 Watts (W) 10500 Watts (W) 120 / 240 Volt (V) Single phase (4-wire) 56.5-63.3 Hertz (Hz) 1.0 p.f. Honda GX630 3390 - 3798 RPM Non-leaded automobile gasoline 11 gallons see Honda Manual Electric 12VDC. 35AH (L x W x H) 7.69” x 5.
Safety Label Locations Models: 165601, 165603, 165604 Models: 165605, 165606, 165607 WARNING - BATTERY HAZARDS BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock 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.
Machine Component Identification Items: 165601, 165603, 165604 Ref. 1 2 3 4 5 6 7 8 Description Ref. Recoil Fuel Valve Lever Engine Key Switch (165604 only) Vibration Isolation Mount Oil Drain Plug Oil Fill Port Battery (not included, 165604 only) Control Panel 9 10 11 12 13 14 15 9 Description Generator Head 6.
Machine Component Identification Items: 165601, 165603, 165604 REFERENCE GUIDE Reference 1 – Recoil Reference 2 – Fuel Valve Lever Reference 3 – Engine Key Switch Reference 4 – Vibration Isolation Mount Reference 5 – Oil Drain Plug Reference 6 – Oil Fill Port Reference 7 – Battery (not included) Reference 8 – Control Panel Reference 9 – Generator Head Reference 10 – 6.
Machine Component Identification Items: 165605, 165606, 165607 Ref. 1 2 3 4 5 6 7 Description Ref.
Machine Component Identification Items: 165605, 165606, 165607 REFERENCE GUIDE Reference 1 – Air Cleaner Reference 2 – 11 Gallon Gas Tank Reference 3 – Gasoline Tank Cap Reference 4 – Choke Reference 5 – Engine Key Switch Reference 6 – Oil Drain Plug Reference 7 – Oil Fill Port Reference 8 – Battery (not included) Reference 9 – Control Panel Reference 10 – Vibration Isolation Mount Reference 11 – Generator Head Reference 12 – Carbon Canister Reference 13 – Fuel Valve Lever Reference 14 – Muffler Refer t
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.
Power Load Planning & Management (cont’d) Device Clothes Dryer (gas) Clothes Washer Coffee Maker Deep Freezer Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles Electric Fry Pan Electric Range: 8in.
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.
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: 1. 2. 3. 4. 5. 6. Steps for Installation / Initial Set-Up Unpacking & delivery inspection. Planning the power load to stay within the generator’s rated capacity. 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. Selecting a site for using the generator. Grounding.
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.
Installation / Initial Set-Up The generator may not 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. Using as a Portable Power Source (See the previous section of this manual entitled “Power Load Planning & Management” for more information on load application and selection.
Installation / Initial Set-Up Item # 165604 Item # 165605 & 165606 Item # 165607 1. 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. 2. Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoorrated, grounded extension cords of the proper size.
Installation / Initial Set-Up Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga. 240V (watts) Cord Cord Cord Cord 10 2400 250' 150' 100' 75' 20 4800 125' 75' 50' 25' 30 7200 60' 35' 25' 10' 40 9600 30' 15' 10' * 50 12000 15' * * * WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices. 3. All extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise damaged.
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. Choose a site that meets all of the criteria specified.
Installation / Initial Set-Up Adequate cooling ventilation The generator needs adequate, unobstructed flow of air to allow for 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. • Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.
Installation / Initial Set-Up Hearing protection Generators can produce noise levels of up to 95 dB in close proximity, which can be dangerous to human hearing with prolonged exposure. Hearing protection may be required for persons working within 15-20 feet of the running generator for an extended period of time. WARNING: Never attempt to attach ductwork to the muffler system to lower noise levels.
Installation / Initial Set-Up 6. Battery Installation Your generator’s engine may be equipped with an electric starter, which requires the installation of a battery (see Specifications section of manual). The battery is to be supplied by the customer and should be installed with the battery securing brackets located near the engine. Follow the instructions detailed below for connecting and disconnecting the battery.
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. 1. 2. 3. 4. 5. 6. 7. Operation Procedures General Safety Rules for Operation Preparing for Operation Starting the Engine Checking Generator Output Connecting Electrical Loads (Portable Power Generation) Stopping Storage & Exercise of Generator Each of these procedures is discussed in detail below: 1.
Operation • Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o o o o o o o o o Excessive change in engine speed, slow or fast Overheating in load connecting devices Sparking or arcs from generator Loss of electrical output Receptacle damage Engine misfire Excessive vibration Flame or smoke Abnormal noise • Adjusting / repairing.
Operation 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.
Operation 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 at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it.
Operation 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.
Operation • • • Never fill the portable gas container while it is sitting inside a 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. A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily. 5) Clean up gasoline spills /splashes immediately.
Operation 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. To restart a warm engine, move choke lever to half choke or to RUN position. 4) Start the engine: a. Recoil: - Move the engine on/off switch to the ON position.
Operation 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.
Operation 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: Do not overload generator. Make sure that combined starting and running loads do not exceed rated capacity of generator.
Operation 7. Storage & Exercise When you are finished using the generator, you must: o o o o Disconnect all loads Shut off fuel supply Store the generator properly Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below. Disconnect loads & When you are finished using the generator, disconnect all loads and turn off fuel supply turn off fuel supply: 1.
Operation 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 Removing all gasoline from the tank and carburetor OR o Adding fuel stabilizer to the gasoline (following manufacturer’s instructions) Fuel stabilizer steps: 1. Ensure gasoline tank is full. 2.
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 and disconnect the spark plug(s) before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using. Note: The generator head is a brush style head and requires maintenance.
Maintenance & Repair (cont’d) 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.) To test the GFCI: 1. Depress the TEST button. The RESET button should extend from the receptacle. If the RESET button does not extend, contact Northern Tool for replacement parts. 2.
Troubleshooting Problem Possible Causes Possible Remedies Engine will not start. a) b) c) d) a) a) b) c) d) a) Voltage too low. Low oil level. Fouled spark plug. Out of fuel. Stop switch in OFF position. Engine speed too slow. b) Generator is overloaded. Circuit breaker trips. Voltage too high. Generator overheating. c) Defective AVR (165601, 165603, 165604 only) a) Defective load connected to generator. b) Defective receptacle. c) Generator overloaded. a) Engine speed too high.
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.
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. • Operate OUTSIDE only – dangerous carbon monoxide exhaust! Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it.
Summary of Important Safety Information for Operation (cont’d) • Fuel outdoors. Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. • 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. • Running / hot engine. A running engine is hot enough to ignite fuel.
Summary of Important Safety Information for Operation (cont’d) • 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. • Refueling. DO NOT refuel the engine until it has cooled at least two minutes. • Malfunction during operation.
Generator Exploded View Rev – AB Item #s 165601, 165603, & 165604 43
Generator Exploded View Rev – AB Item #s 165601, 165603, & 165604 Part # Description Qty Used on 1 2A 791171 801492 6 gallon fuel tank assembly w/cap 4.5mm fuel line, Hose 2B 801492 4.
Generator Exploded View Rev – AB Item #s 165605, 165606, & 165607 45
Generator Exploded View Rev – AB Item #s 165605, 165606, & 165607 Ref # Part # Description 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 791699 795073 801492 787525 795183 11 gallon fuel tank assembly w/cap Channel, roll cage 4.
Control Panel Parts List Rev – AB Item # 165601 Item # 165603 Item # 165604 47
Control Panel Parts List Rev – AB Item # 165605 Item # 165606 Item # 165607 48
Control Panel Parts List Rev – AB Ref # 1 2 3 4 Part # 790409 783060 783058 783059 Description Switch – 2 pole, red 8 AMP Circuit Breaker 300V Volt Meter 12VDC Outlet 5 783061 20 AMP Circuit Breaker Qty 1 1 1 1 Used on 165601, 165603, 165604 165601, 165603, 165604 All 165601, 165603, 165604 2 165601 4 6 783050 NEMA L14-30 Receptacle 7 783053 NEMA 5-20 Receptacle (4) duplexes 8 783091 30 AMP Circuit Breaker 2 9 783085 NEMA L5-30 Receptacle 1 10 783094 11 12 13 14 15 16 17 18 78313
Generator Head Exploded Views Rev – AB Item #s 165601, 165603, 165604 50
Generator Head Exploded Views Rev – AB Item #s 165601, 165603, 165604 Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part # 796591 796580 796578 796551 796550 796586 796567 796568 796576 796557 796553 795996 796564 796583 796563 795999 796581 796573 796558 796559 796556 796555 796588 796594 796574 796593 Description Engine Adapter Qty 1 Cover Band 1 Stator Assembly 1 Bearing Support Hexagon Flange Bolt M6 x 140 Hexagon Flange Bolt M6 x 180 Bridge Rectifier Outer Hexagon Bolt M5 x 20 Ter
Generator Head Exploded Views Rev – AB Item #s 165605, 165606, 165607 52
Generator Head Exploded Views Rev – AB Item #s 165605, 165606, 165607 Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part # 796592 796579 796916 796917 796597 796599 796601 796587 796569 796565 796571 795998 796564 796584 796563 796554 795995 796560 796561 796562 796575 796598 796600 796602 796589 796582 Description Engine Adapter Qty 1 Cover Band 1 Stator Assembly 1 Bearing Support Hexagon Flange Bolt M8 x 160 Hexagon Flange Bolt M8 x 185 Hexagon Flange Bolt M8 x 195 Carbon Brush Hexagon Flange Bolt
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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. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
WARNING: This product can expose you to chemicals including gasoline engine exhaust, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.