M165650D.2 ITEM NUMBER: 165650 SERIAL NUMBER: _____________ Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 2,400 Watt Continuous (2,700 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.
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 2700 Watts of electrical power (2400 watts continuous, 2700 watts surge). 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 (continued) 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. NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation.
Specifications SPECIFICATIONS Item Number Maximum Output Continuous Output Generator Type Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Capacity Starting Method 120 V Receptacle Circuit Breaker Dimensions Length Width Height Dry Weight Gross Weight #165650 2700 Watts (W) 2400 Watts (W) Brush Style 120 Volt (V) Single phase 56.5 - 63.3 Hertz (Hz) 1.0 p.f. Honda GC160 AVXA 3390 - 3798 RPM Unleaded gasoline 2.12 quarts (2.0 L) 0.55 US quarts (0.
Safety Label Locations CAUTION BURN HAZARD Do not touch hot muffler. PN 39260 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.
Machine Component Identification – 165650 Figure 1 (Ref. 1-6) Ref. 1 2 3 4 5 6 Description Ref. Circuit Breaker 120V 20A Duplex Receptacle Generator Head Oil Drain Plug Vibration Isolation Mount Muffler 7 8 9 10 11 Figure 2 (Ref.
Machine Component Identification – 165650 (cont’d) REFERENCE GUIDE Reference 1 – Circuit Breaker Reference 2 – (1) 120V 20A Duplex Receptacle Reference 3 – Generator Head Reference 4 – Oil Drain Plug Reference 5 – Vibration Isolation Mount Reference 6 – Muffler Reference 7 – Choke Lever Reference 8 – Ignition Switch Lever Reference 9 – Recoil Reference 10 – Gas Tank Reference 11 – Air Cleaner This portable single phase generator has 1, 20 amp (A) push to reset circuit breaker to protect against electric
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 Electric range (1 element) Electric skillet Furnace fan (1/3 HP) Freezer Hair dryer Hand drill (1”) Hand drill (1/2”) Hand drill (3/8”) Hand drill (1/4”) Hedge trimmer Home computer Impact wrench Running Watts 1500 1250 1200 (a) 800 (b) 1200 1100 875 500 250 450 150 500 Device Refrigerator Slow cooker Submersible pump (1-1/2 HP) Submersible pump (1 HP) Submersible pump (1/2 HP) Sump pump Table saw Television Toaster Vacuum cleaner VCR Water Heater Weed trim
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. 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 (cont’d) 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 2700W 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 (cont’d) 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. 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.
Installation / Initial Set-Up (cont’d) 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 amperage of the device being used and the length of the cord. Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga.
Installation / Initial Set-Up (cont’d) 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 (cont’d) 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 (cont’d) 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 the ground close to the generator. The pipe/rod must penetrate moist earth – the depth required will be dictated by local soil conditions. Consult with an electrician.
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 (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 o Excessive vibration o Flame or smoke o Abnormal noise • Adjusting / repairing.
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.
Operation (cont’d) 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.
Operation (cont’d) 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 (cont’d) • • 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. • • • • If possible, move the generator away from spilled gasoline on the ground.
Operation (cont’d) 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) Adjust choke: a) To start a cold engine, pull the choke rod to the CLOSED position. b) To restart a warm engine: i) If the engine has run out of fuel, pull choke rode to the CLOSED position after refueling. ii) If the engine has not run out of fuel, leave the choke rod in the OPEN position.
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.
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: Do not overload generator.
Operation (cont’d) 7. Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Store the generator properly o 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, make sure all devices that were connected to the generator’s outlets have been disconnected.
Operation (cont’d) 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, disconnect the spark plug(s) and discharge the capacitor 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 that 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 – See the “Specifications” section.) 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 NorthStar for replacement parts. 2.
Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) b) c) d) a) b) c) d) Voltage too low. a) Engine speed too slow. a) b) Generator is overloaded. b) Circuit breaker trips. a) Defective load connected to generator. b) Defective receptacle. c) Generator overloaded. a) b) c) Voltage too high. a) Engine speed too high. a) Generator overheating. a) Generator is overloaded. a) b) Insufficient ventilation.
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) • • • • • • licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a standby power system, grounding will be complete through the building’s grounding system. Isolate connection to building’s electrical circuit. Never plug the generator directly into a wall outlet.
Summary of Important Safety Information for Operation (cont’d) Safety – During Use • Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation. • Know how to stop. Be thoroughly familiar with proper use of the equipment and all generator controls, output receptacles, and connections. Know how to stop the generator quickly if needed. • Damaged.
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. • Prevent accidental starting. When generator is not in use, remove key from starter (key start engines) and secure in a safe location, or remove spark plug(s) in order to ensure that generator cannot be started in a storage location or by untrained persons. • Storage location.
Generator Exploded View 165650 - Rev D.
Generator Exploded View 165650 – Rev D.2 Diag # Part # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 305491 796590 796596 796572 796570 39260 306459 794922 305587 794921 798402 796577 794613 796092 796585 798401 795997 795994 N/A N/A N/A 82681 796000 796564 796566 797951 798400 Honda 5 HP Engine 168 Engine Adapter Rotor Flat Washer Hexagon Flange Bolt 5/16-24 x 6.
Wiring Diagram 165650 - Rev D.
This page has intentionally been left blank.
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 www.northerntool.