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1. Ref Part Description Qty Used on 1 786710 6 5 gallon fuel tank assembly w cap 1 All 2A 785337 4 5mm fuel line 6 in 165601 7in 165601 2B 785337 4 5mm fuel line Sin 165603 165604 3 784959 Fuel valve 1 All 4 787295 Roll cage 1 All 5 784974 Exhaust pipe 1 165601 784975 165603 165604 6 785352 Muffler gasket 1 All 7 784699 Muffler 1 All 8 784792 Heat shield out muffler 1 All 9 785269 Heat shield side muffler 1 All 10 784795 Iso mount heat shield 1 All 11 784709 Muffler hanger 1 All 12 784791 Heat shield in muffler 1 All 13 784710 Mount muffler 1 All 14 782487 Strap muffler 1 All 15 777110 1 2 hose clip 1 165601 16 786712 Fuel cap with strainer 1 All 784971 165601 5 784972 FAI 165603 165604 777302 165601 E 782435 EAE 165603 165604 19 306459 Engine ground wire 1 All 784706 165601 A 782306 pum i 165603 165604 21 785291 Positive battery cable 1 165604 22 Northern 349920 Battery not included 12VDC 18AH n a 165604 23 785607 Battery stop 1 165604 24 785292 Negative battery cable 1 165604 25 82377 1 4 20 x 7 HHSC gr g zinc 2 165604 26 82083 1 4 20 wing nut 2 165604 27 787619 Battery tie plate 1 165604 28 30825 1 iso mount 5 All 29 32848 Upper iso bracket 4 All 30 783217 Carbon canister strap 1 All 31 32844 Lower iso bracket 4
2. 3798 RPM 3390 3798 RPM Fuel Type Non leaded automobile Non leaded automobile gasoline gasoline Fuel Capacity 6 5 gallons 6 5 gallons Oil Capacity 1 16 US quarts 1 16 US quarts Starting Method Recoil Recoil Dimensions Length U PS Width ph 21 25 Height DUAN PPN Dry Weight 174 Ib 200 Ib 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 120 240 Volt V Phase Single phase 4 wire Single phase 4 wire Frequency 56 5 63 3 Hertz Hz 56 5 63 3 Hertz Hz Power Factor 1 0 p f 1 0 p f Engine Honda GX390 Honda GX630 Engine Speed 3390 3798 RPM 3390 3798 RPM Fuel Type Non leaded automobile Non leaded automobile gasoline gasoline Fuel Capacity 6 5 gallons 11 gallons Oil Capacity 1 16 US quarts see Honda Manual Starting Method Electric Electric Battery not included 12VDC 18AH 12VDC 35AH Battery Dimensions Lx WxH 7 13 x 3 x 6 57 Lx WxH 7 69 x 5 13 x 7 Dimensions Length 25 75 32 38 Width 2125 24 38 Height 22 25 26 90 Dry Weight 206 Ib 209 Ib 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 120 240 Volt V Phase Single phase 4 wire Single phase 4 wire Frequency 56 5 63 3 Hertz Hz 56 5 63 3 Hertz Hz Power Factor 1 0 p f 1 0 p f Engine Honda G
3. If generator cannot be exercised on a regular basis prepare generator for long term storage e Periodic maintenance Perform periodic maintenance as directed in this manual to keep the generator in safe working condition Safety Inspection Maintenance Inspect and maintain your generator on a regular basis and repair as needed to keep it in safe working condition e Turn off generator Always turn off generator and remove spark plug s or spark plug wire s before working on the engine or generator to prevent accidental starting e Discharge capacitor When the generator is shut down the capacitor may maintain a charge Always discharge the capacitor before working on the generator head to prevent electrical shock e Replace guards shields Make sure all guards and shields are replaced after servicing the generator e Replacement parts If a part needs replacement only use parts that meet the manufacturer s specifications Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator and will void the warranty 42 oO l e e Lu kN P 19 AM N 165601 165603 amp 165604 C Item s Generator Exploded View Rev O 3 INCLUDED NOT e P ure eb ha Se V mu 43 Generator Exploded View Rev 0 3 Item s 165601 165603 amp 165604
4. 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 14 Power Load Planning amp 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 Greater of Device to be Powered 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 p
5. Reference 15 Choke Lever Used during cold starts Refer to the Honda engine manual for usage 10 Machine Component Identification Description Items 165605 165606 165607 Description Air Cleaner 11 Gallon Gas Tank Gasoline Tank Cap Choke Engine Key Switch Oil Drain Plug Oil Fill Port Battery not included Control Panel Vibration Isolation Mount Generator Head Carbon Canister Fuel Valve Lever 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
6. 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 120 240 Volt V Phase Single phase 4 wire Single phase 4 wire Frequency 56 5 63 3 Hertz Hz 56 5 63 3 Hertz Hz Power Factor 1 0 p f 1 0 p f Engine Honda GX270 Honda GX390 Engine Speed 3390
7. 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 13 Power Load Planning amp Management cont d Don Running Watts Starting Watts Continuous 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 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 80 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
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 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 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 12 Power Load Planning amp 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 po
9. Flowing gasoline Most people are not aware that gasoline accumulates static electric charge while flowing through a hose or pipe This charge then transfers to and accumulates in the gas tank or container that is being filled The total amount of charge accumulation depends on the amount of gas pumped into the container the speed with which it is pumped and whether or not the tank container is grounded If sufficient static electric charge accumulates in the fuel tank or container during the fueling process the tank container may discharge a spark to the grounded gasoline dispenser nozzle 3 Persons A person dispensing the gasoline can carry a static electric charge on their body typically resulting from contact with their car seat or electronics The static electricity can discharge as a spark between that person s hand and either the grounded dispenser nozzle or the fuel tank opening 27 Position Position generator in accordance with the instructions given in generator Installation amp Initial Set up Step 4 Select a Suitable Site of this manual Operate outside only on dry level ground with adequate clearance and ventilation AWARNING 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 ONLY run generator OUTDOORS and away from air intakes NEVER run generator inside any enclosed or semi enclosed spaces including ho
10. be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine Inspect the entire fuel system Look for e signs of leaks or deterioration e chafed or spongy fuel hose e loose connections e loose or missing fuel hose clamps e adamaged gasoline tank or e adefective gasoline shut off valve Personal 1 Hearing can be damaged from prolonged close range exposure to the type of Protection noise produced by this generator The use of ear plugs or other hearing protection device is recommended for persons working within 15 20 feet of the running generator for an extended period of time 2 Loose or dangling apparel can become entangled in moving parts Metal jewelry can conduct electricity Never wear jewelry or loose fitting clothing when starting or operating the generator 30 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 Pull the starter grip lightly until you feel resistance then pull the starter cord out briskly and rapidly Allow starter cord to return sl
11. follow manufacturer s service instructions Replace if damaged Keep generator Keep generator clean clean If dust or debris accumulates on the generator clean the generator with a damp cloth or soft bristle brush Do not allow air intakes to become blocked Note Do not spray generator with a garden hose or pressure washer Water may enter the generator and cause damage to the rotor stator or internal windings Recharge and Inspect recharge and maintain your battery according to your battery maintain battery manufacturer s instructions Only for those models equipped with electric if electric start start Do not store with battery charger always connected Batteries that are over charged can boil themselves dry and produce excessive amounts of hydrogen an explosive gas IMPORTANT If a part needs replacement only use parts that meet the manufacturer s specifications Replace ment parts that do not meet specifications may result in a safety hazard or poor operation of the generator Contact NorthStar Product Support at 1 800 270 0810 for any questions problems or parts orders 37 Troubleshooting Problem Engine will not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Engine shuts down during operation a Low oil level b Fouled spark plug c Outof fuel d Stop switch in OFF position a Engine speed too
12. information can be found in the Installation amp Initial Set up Steps 5 amp 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 A 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
13. keep a fire extinguisher nearby Avoid other generator hazards Read Owners Manual completely before using READ MANUAL BEFORE USE Serious injury or death can result if safety instructions are not followed Description Always make sure safety labels are in place and in Burn Hazard good condition If a safety label is missing or not Danger Warning legible order new labels or unsafe operation could result To order replacement safety labels call NorthStar Battery Hazard Product Support at 1 800 270 0810 Over Fill Warning Machine Component Identification Items 165601 165603 165604 Lt Lt 0914 Description Description ONDARON 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 Generator Head 6 5 Gallon Gas Tank Muffler Gasoline Tank Cap Carbon Canister Air Cleaner Choke Lever 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 th
14. oil filter 2 Air filter check replacement 3 Spark plug cleaning and replacement 4 Fuel filter check replacement 5 Fueltank cleaning Check receptacles before each use to make sure they are not cracked or broken If a receptacle is cracked or otherwise damaged do not use until replaced with an authorized factory part Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipment Inspect the fuel system and check for leaks on a regular basis 1 Inspect the entire fuel system Look for signs of leaks or deterioration chafed or spongy fuel hose loose connections loose or missing fuel hose clamps damaged gasoline tank or defective gasoline shut off valve 36 Maintenance amp Repair cont d Check GFCI Once a month test the Ground Fault Circuit Interrupter GFCT to if equipped 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 Restore power to the GFCI by firmly pressing the RESET button back into the receptacle until an audible click is heard Clean amp inspect Clean and inspect the spark arrestor muffler spark arrestor If the engine is equipped with a spark arrester muffler clean and inspect it if equipped regularly
15. such as electronics via surge protectors Plug devices such as TV s computers and microwaves into a UL listed voltage surge protector then plug the surge protector into the generator Using as a Each transfer switch installation will be unique Back up Power Source for a Building Proper instructions for how to safely bring the generator online with the building s electrical system should be provided by the installing electrician who should also provide personal instruction to the owner operator Failure to follow the proper procedure as provided by the electrician could expose persons to the hazards noted above 6 Stopping the Engine Stop the engine using the following steps 1 Disconnect all loads to the generator Turn engine on off switch to OFF position Turn gasoline line shut off valve to OFF position Sie Remove spark plug to prevent accidental starting of engine 33 7 Storage amp 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 provided below Disconnect loads amp When you are finished using the generator disconnect all loads and turn off fuel supply turn off fuel supply 1 Make sure all devices that were connected to the generator s outlets have bee
16. you have damaged components contact the freight company that delivered the unit and file a claim 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 amp Management section of this manual to review how to plan and manage power loads for the generator 16 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 Asa 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 Asa 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 Contact a licensed electrician to install an UL approved transfer sw
17. 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 PATATE Tec Removing all gasoline from the tank and carburetor OR Adding fuel stabilizer to the gasoline following manufacturer s instructions Fuel stabilizer steps Ensure gasoline tank is full Add fuel stabilizer to fuel tank Run engine at least 10 minutes after adding stabilizer to allow it to enter the fuel system Shut off engine Disconnect spark plug wire and remove spark plug Add one teaspoon oil through spark plug hole Place rag over spark plug hole and turn starter or pull the recoil a few times to lubricate the combustion chamber Replace spark plug but do not reconnect the spark plug wire 35 Maintenance amp 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 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 A WARNING Note The generator head is brushless and maintenance free The bearing is a heavy duty sealed ball bearing which requires no maintenance or lubrication Follow safety rules Perform engine maintenance Check receptacle
18. 0 NEMA L14 30 Receptacle All 165601 165603 165605 7 783053 NEMA 5 20 Receptacle 4 duplexes 165606 165607 nm 165603 165604 165605 8 783091 30 AMP Circuit Breaker 2 165606 165607 165603 165604 165605 9 783085 NEMA L5 30 Receptacle 1 165606 165607 10 783094 s Switch w key Electric 1 165604 11 783132 GFCI 5 20R Receptacle 4 duplexes 165604 12 783964 37 AMP Circuit Breaker 2 165605 13 31953 14 50 Receptacle 1 165605 165606 14 783965 45 AMP Circuit Breaker 2 165606 15 783966 58 AMP Circuit Breaker 1 165607 16 305619 14 60R Outlet 1 165607 17 783133 Grounding Post 1 All 18 786128 Panel Bolts 4 All 19 781830 Back Cover Small not shown 1 165601 165603 165604 783275 Back Cover Large not shown 165605 165606 165607 Throttle Control Module for 20 783134 Idle Control not shown behind 1 165604 panel 49 Generator Head Exploded Views Rev 0 3 Item s 165601 165603 165604 165605 50 FIGO3744 Generator Head Exploded Views Rev 0 3 Item s 165601 165603 165604 165605 Ref Part Description Qty Used On MA305522 165601 l Togia OO Pate Oe 5 165603 165604 165605 MA306404 165601 A T7956 165603 165604 165605 3 TI l 165601 719557 165603 165604 165605 MA306406 l 165601 3 770920 Tee i 165603 165604
19. 1 All 12 MA306416 Nyloc Nut and Star Washer 1 All 13 MA30997 Grill 1 All 14 MA31065 Securing Stud Cap 1 All 15 MA30999 Fixing Ring 1 All 16 MA30992 Rotor Assembly 1 All 17 MA307479 Diode 2 All 18 MA307481 Varistor 2 All 19 MA31021 Capacitor 31 5 uF 5 165606 MA9910303129 Capacitor 35 uF 165607 20 N A Frame and Stator Assembly 1 All 21 MS X 8 Nut 6 22 MA307478 Brass Jumper 2 All 23 Terminal Board 1 24 31022 Securing Stud 333mm 1 All 25 777129 Lead Wire 2 All 53 This page has intentionally been left blank 54 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 Please thoroughly read the instructions and understand the operation before using your product Always contact NorthStar Product Support at 1 800 270 0810 prior to having any service or warranty work performed as some services performed by parties other than NorthStar approved service centers may void this warranty This warranty is in lieu of any other warranty expressed or implied and NorthStar assumes no other responsibility or li
20. 165605 718954 165601 5 719786 Enclosing Band 1 165603 165604 779558 165605 305554 165601 6 777304 End Cover l 165603 165604 165605 MA306408 165601 d 38271 Cove Flug i 165603 165604 165605 786124 165601 8 786125 Stator 1 165603 165604 779787 165605 718956 165601 9 779788 Rotor w Diode and Varistor 1 165603 165604 719560 165605 10 MA307479 Diode 2 All 718957 165601 11 779790 Securing Stud 1 165603 165604 719561 165605 5 MA307485 ing l 165601 MA38276 165603 165604 165605 MA306417 165601 is MASIH DOS DUNS Ead bracket I 165603 165604 165605 15 MA34684 Capacitor 20 uF 1 165601 MA38279 Capacitor 40 uF 165603 165604 165605 718960 165601 16 779792 Bracket Securing Stud 4 165603 165604 719563 165605 17 MA307481 Varistor 2 All 18 783101 Rectifier 1 165601 165603 165604 51 Generator Head Exploded Views Rev O 3 Item s 165606 165607 Generator Head Exploded Views Rev O 3 Item s 165606 165607 Item Part Description Qty Used On 1 MA30991 Drive End Bracket 1 All 2 MA30994 Protection Screen 2 All 3 MA31013 Phillips Screw 10 All 4 MA30995 Fan 1 All 5 307489 Grommet 1 All 6 305605 Terminal Box Cover w grommet 1 All 7 N A M5 X 8 16mm Long 2 All 8 N A MS X 8 10mm Long Green 2 All 9 MA31015 MS X 8 10mm Long 4 All 10 N A Rubber Cup 2 All 11 MA306403 Rear Bearing
21. All 32 785768 3 8 x 1 4 hose mender 1 All 33 785755 3 8 fuel line 1 5 in All 34 782126 Carbon canister 1 All 784819 GX270 Honda engine red 165601 35 784820 GX390 Honda engine red 1 165603 784821 GX390 Honda engine electric start 165604 783072 165601 36 783075 Control Panel 1 165603 787668 165604 37 787300 Tank bolt bar 1 All 38 777345 1 4 fuel line hose 3 ft All 784707 165601 si 782524 hese 165603 165604 40 787306 Heat shield 1 All 41 787307 Adjustable bumper tab 6 All 42 787259 Grommet bumper 6 All Quei 3 165601 43 786123 3 8 Spring action hose clamp 1 165603 165604 44 Generator Exploded View Rev 0 3 Item s 165605 165606 amp 165607 45 Generator Exploded View Rev 0 3 Item s 165605 165606 amp 165607 Ref Part Description Qty Used on 1 786711 11 gallon fuel tank assembly w cap 1 All 2 787271 Channel roll cage 1 All f 2 0ft 165605 165607 4 785337 4 5mm fuel line 3 5ft 165606 5 787525 Fuel valve 1 All 6 787326 Roll cage 1 All 7 782127 Carbon canister 1 All 8 783214 Ring carbon canister 1 All 9 777345 1 4 fuel line 6 7ft All 10 783250 Header assembly muffler 1 All 11 783260 Upper mounting bracket muffler 1 All 12 783333 Gasket
22. DOORS never indoors c Stay away from all sources of heat sparks and flames Do not smoke 2 Turn generator engine off and allow to cool for at least two minutes before removing gas cap Note A running or still hot engine is hot enough to ignite fuel 3 Remove generator gasoline cap 4 Add gasoline through the fill opening Use only an UL approved portable gasoline container to transfer the gasoline to the generator s tank Follow the safety warning and instructions below for avoiding static electric sparking Do NOT overfill the gasoline tank Fill to bottom of fill neck to allow for fuel expansion A WARNING Static electric spark hazard A Static electric spark can explosively ignite gasoline vapor resulting in a flash fire that could cause serious injury or death To avoid static electric sparking while filling the gasoline tank the following steps must be followed to minimize and safely dissipate static electric charge build up before and during the fueling process e Always dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources Never fill the generator s gas tank directly from the fuel pump the generator s tank is not grounded and high velocity flow from the pump can cause static electricity build up Use an approved portable container to transfer gas to the generator s tank 29 e Never fill the p
23. Move generator away from spilled fuel on the ground Wipe fuel off engine and wait 5 minutes for excess fuel to evaporate before starting engine Gas soaked rags should be disposed of properly e Onskin clothes If gasoline is spilled on your skin or clothes change clothes and wash skin immediately e Inspect fuel system Check fuel system on a regular basis Look for signs of leaks deterioration chafed or spongy fuel hose loose or missing fuel hose clamps damaged fuel tank or a defective fuel shut off valve Do not start generator until needed repairs have been completed e Gasoline storage Store gasoline in a cool dry place in an UL approved tightly sealed container Safety During Use e 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 e 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 e Damaged Do not operate the generator with damaged missing or broken parts e Carbon monoxide exhaust The running engine gives off carbon monoxide a poisonous gas that can kill you You CANNOT smell it see it or taste it If you start to feel sick dizzy or weak while using the generator shut off the engine and get to fresh air RIGHT AWAY See a doctor You may have
24. NEMA 5 20P or 5 15P mating plugs 120 240 Volt 50 Amp straight blade receptacle NEMA 14 50R receptacle compatible with NEMA 14 50P mating plug 120 240 Volt 60 Amp straight blade receptacle NEMA 14 60R receptacle compatible with NEMA 14 60P mating plug ENGINE SWITCH 12VDC A nes a KOSI BA o OAC 120V o o AC 120Vo pe AC 120 240V LX zm G3 9 23 33 D D o GND e Sy 18 Installation Initial Set Up S Ee A 5 Item pu SM NA o 9 120V 9 165604 fon Item AC 120V0 Qo AC 120V0 165605 amp V 6 165606 D ODA o Qoo Item 165607 p E 3 E E n GO oed Qoo d gg 2 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 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 c
25. NORTH AN M1656010 3 Item Number 165601 165603 165604 b 165605 165606 165607 Serial Number Proven Performance Owner s Manual Instructions for Installation Set up Operation Servicing amp 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 AWARNING 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 e 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 generat
26. X630 Honda GX690 Engine Speed 3390 3798 RPM 3390 3798 RPM Fuel Type Non leaded automobile Non leaded automobile gasoline gasoline Fuel Capacity 11 gallons 11 gallons Oil Capacity see Honda Manual see Honda Manual Starting Method Electric Electric Battery not included 12VDC 35AH 12VDC 35AH Battery Dimensions Lx WxH 7 69 x 5 13 x 7 Lx WxH 7 69 x 5 13 x 7 Dimensions Length 32 38 32 38 Width 24 38 24 38 Height 26 90 26 90 Dry Weight 313 Ib 325 Ib An uestions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 Safety Label Locations Models 165601 165603 165604 Models 165605 165606 165607 A7 BURN HAZARD Do not touch hot muffler Fire amp Overheating Hazard DO NOT overfill fuel tank Fill fuel only to bottom of fill neck Expansion of fuel from heat of sun or normal operation may cause tank spillage if overfilled Wipe up fuel spills and allow to dry before starting engine I A WARNING BATTERY HAZARDS BATTERIES 4 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 es 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
27. ability outside that expressed within this warranty Limited Warranty NorthStar shall warranty any piece of equipment manufactured or parts of equipment manufactured to be free from defects in material or workmanship for a period of NorthStar Warranty Item Consumer Warranty Period Commercial Warranty Period 165601 165603 165604 165605 165606 165607 4 years from date of purchase by user 2 years from date of purchase by user Engine Warranty Item Consumer Warranty Period Commercial Warranty Period 165601 165603 165604 165605 165606 165607 3 years from date of purchase by user 3 years from date of purchase by user Consumer use means personal residential household use by a consumer Commercial use means all other uses including use for commercial income producing or rental purposes or when purchased by a business This warranty applies to the original purchaser of the equipment verification of purchase in the form of a receipt is the responsibility of the buyer is non transferable and covers parts and labor Parts will be replaced or repaired at no charge except when the equipment has failed due to lack of proper maintenance If a part is no longer available the part may be replaced with a similar part of equal function Any misuse abuse alteration or improper installation or operations will void warranty Determining whether a part is to be replaced or repaired is the sole decisi
28. as cooled at least two minutes e 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 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 e Adjusting repairing Always turn off generator and remove spark plug s or spark plug wire s before working on the generator to prevent accidental starting QOO OQ O O O O O Safety After use e Cool engine before storing Let engine cool for at least five minutes before storing A hot engine can be a fire hazard e Shut off fuel supply Make sure gasoline shut off valve is in the OFF position e 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 e Storage location Store the generator in a dry location away from sources of heat open flames sparks or pilot lights such as water heaters space heaters furnaces clothes dryers or other gas appliances EVEN IF the generator s gas tank is empty Residual gasoline could ignite e Exercise regularly Exercise generator every four weeks to dry out moisture that accumulates in the windings
29. be connecting the generator to your buildings 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 Hazard Signal Word Definitions This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER red indicates an imminently A DAN G E R hazardous situation which if not avoided will result in death or serious injury WARNING orange indicates a potentially AWARN N G hazardous situation which if not avoided could result in death or serious injury CAUTION yellow indicates a potentially Ah CAU TIO N hazardous situation which if not avoided may result in minor or moderate injury CAUTION yellow used without the safety CAUTIO N alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage fig01453 Table of Contents Hazard Signal Word Definitions Lalla ra iaia 2 ADo t Your Generator ilaele 4 Specifica tlon S essare a a Sa a aa aA 6 Safety Label Locatiomns issr teo ER oa oa dra edd a 8 Machine Component Identification anana anana an anana nne
30. carbon monoxide poisoning e Other exhaust dangers This product contains or emits chemicals known to the State of California to cause cancer birth defects or other reproductive harm Avoid inhalation of exhaust e Smoking sparks Never smoke near the running generator and never operate near sources of sparks or flames e Check output voltage Check output voltage to ensure the generator is working properly before connecting loads to the generator Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual Do not adjust output speed of engine to change voltage If voltage is not within specified range have generator repaired by factory authorized personnel e Stabilize before connecting loads Start generator and let engine stabilize before connecting electrical loads e Do not overload Do not overload the generator Make sure that combined starting and running loads do not exceed rated capacity of generator or damage will result e Protect sensitive electronics Some electronic equipment such as computers and audio video equipment can be damaged by small fluctuations in the flow of power Use a surge suppressor for any voltage sensitive electronic equipment you will be powering with the generator e Wet conditions Do not operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in the rain or snow Electric shock may re
31. ces of ignition e NEVER touch both battery terminals at the same time with your hand or any non insulated tools e If battery acid contacts skin or clothing flush immediately with water and neutralize with baking soda Connecting the battery Always connect the cables in the following sequence to avoid possible shock 1 Find the battery cables attached to the engine 2 Connect the red cable to the positive terminal of the battery 3 Then connect the black cable to the negative terminal of the battery Disconnecting the battery Always disconnect cables in the following sequence to avoid possible shock 1 First disconnect the black cable from the negative terminal of the battery 2 Next disconnect the red cable from the positive terminal of the battery 24 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 General Safety Rules for Operation Preparing for Operation Starting the Engine Checking Generator Output Connecting Electrical Loads Portable Power Generation Stopping Storage amp Exercise of Generator ARRESE Each of these procedures is discussed in detail below 1 General safety rules for operation Before starting the generator review the following general safety rules for operation WARNING Failure to fo
32. 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 A DANGER Using a generator indoors CAN KILL YOU IN MINUTES Electic Shock Fire Explosion Hazard Generator exhaust contains carbon monoxide Electrocution Hazard Fuel is flammable and explosive This is a poison you cannot see or smell High voltage electricity Exhaust is very hot Overloading the from generator can kill generator can cause fire NEVER plug generator directly into a wall outlet LP NG hookup must be completed by certified gas technician ANY connection to a building s electrical system NEVER fuel a running or hot engine CJ MUST ISOLATE GENERATOR FROM UTILITY POWER Ensure there are no fuel leaks before starting via a transfer switch Keep sources of sparks and flames away gt Besure generator is properly grounded Clean up fuel spills immediately Use only outdoor rated grounded extension cords Keep muffler at least 7 feet from all combustible objects NEVER use inside a home Only use OUTSIDE and 9f proper size f DO NOT overload generator c or garage EVEN IF doors far away from windows DO NOT operate in wet locations elisa ud adequate cooling ventilation so engine and windows are open doors and vents ALWAYS
33. done by factory authorized personnel e External fuel sources Never attempt to connect external gasoline diesel sources in order to increase engine run time Larger tank at pressure or higher elevation will cause gasoline to leak from carburetor during operation Fire or explosion could result 25 e Malfunction during operation Immediately turn off the generator if any of the following conditions arise during operation 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 o o o O OTO 00 0 0 e Adjusting repairing Always turn off generator and remove spark plug s or spark plug wire s before working on the generator to prevent accidental starting Always discharge the capacitor before working on the generator head to prevent electrical shock See Maintenance amp Repair section of this manual for instructions on how to do this e Carbon monoxide poisoning The running engine gives off carbon monoxide a poisonous gas that can kill you You CANNOT smell it see it or taste it Follow all instructions for site selection and positioning the generator and avoid inhaling the exhaust If you start to feel sick dizzy or weak while using the generator shut off the engine and get to fresh air RIGHT AWAY See a doctor You may have carbon monoxide p
34. e oil after the first 20 operating hours and at least every 100 operating hours thereafter or as directed in engine owner s manual Refer to the engine owner s manual for engine maintenance instructions Check fill Check the gasoline level in the generator s tank If needed fill tank with gasoline tank fresh unleaded gasoline from a portable container after first reading the warnings and instructions below 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 Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition e gas vapor collection inside enclosures static electric sparks sparks from electric wiring batteries or running engines sources of heat such as a hot engine or exhaust open flames including pilot lights 1 Before starting review the following general safety precautions for fueling a Never pump gasoline directly into the generator s gas tank at a gas station high velocity flow from the pump could result in a static electric build up in the generator s tank Always use a portable container to fill the tank See warning box about static electric spark hazards below b Fill gasoline tank OUT
35. edication e Intended use Carefully read about and understand the intended use of this generator Do not use for other purposes as unforeseen hazards or equipment damage may result Prohibition Against Modifications Never modify or alter the generator in any way Modifications can create serious safety hazards and will also void the warranty e Engine speed Never attempt to modify the engine speed setting The engine speed is preset at 3600 RPM for safe and optimal performance of the generator If speed needs adjusting it must be done by factory authorized personnel e Fuel exhaust system Never modify the exhaust system fuel tanks or fuel lines Carbon monoxide poisoning fire or explosion could result e Guards Do not operate generator unless all guards and cover shields which prevent access to moving parts and pinch points are in place Failure to guard the power transmission mechanisms may result in serious injury or death Safety Installation amp Set up Battery Safety Batteries are hazardous because they contain caustic acid can emit explosive gases and can cause electric shock Caution must be exercised when making connections to a battery to avoid shock and contact with the acid and to prevent any sparking that could lead to an explosion Follow safety rules carefully when connecting battery to generator e Eye skin protection Always wear eye protection and protective clothing when connecting or disconnecting batte
36. eeded Personal protective equipment e Hearing protection The use of ear plugs or other hearing protection device is recommended for those in close proximity to the generator while it is operating e Loose dangling Loose or dangling apparel can become entangled in moving parts Metal jewelry can conduct electricity Never wear jewelry or loose fitting clothing when operating the generator Gasoline Safety Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Use extreme care when handling e Fuel outdoors Fill fuel tank outdoors never indoors Gasoline vapors can ignite if they collect inside an enclosure Explosion can result 40 Summary of Important Safety Information for Operation cont d e 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 e Running hot engine A running engine is hot enough to ignite fuel Never add fuel or remove gas cap if engine is running or still hot Stop the engine and allow to cool at least two minutes before adding fuel e Heat flames sparks Stay away from sources of heat flame or sparks while adding fuel Don t overfill DO NOT overfill the gas tank Fill to bottom of fill neck to allow for fuel expansion e Replace cap Replace gas cap securely before starting engine e Spills Clean up fuel spills immediately
37. ene enne 9 Power Load Planning amp Management eee nene nenen an ananem awanane wanan enne enne nnns 13 Installation Initial Set Up l Unpackine amp Delivery Inspections su sorrento Na SABDA E pa NA Naga NAN sanita 16 2 Planning the Power Load s fesa illa ida ite lariana 16 3 Set up either as a BUILDING BACK UP or PORTABLE Power Source 17 4 Seleetins a Suitable Sites slitta elio 21 5 Grounding the Generator ay ach sis clot a Waa cra RM e psc ade deuten es ede ae 23 6 Battery Installation cadenti 24 Operation 1 General Safety Rules for Operation iure a a 25 2 Prepanps for penance sete at ie cal EN co E E E EE E EL ale ate 28 3 Starting the Englne cssc ak ere e bee AIAR E E Rca 31 A Ch cking Generator Op aces cues sirni QOO OR estier a KANGEN AAN RU HE URN Ga Aa Ka 32 3 Connectins Loads aoo icc teu qu iui ila E N a AA ir eus 33 6 Stopping the Engine attoriali 33 TA Storage K Exercise n i casen E aaa ee aa aaa gaga eS 34 Maintenance Repair ehibllazlic lase 36 Troubl sho0ting ospitali leto io 38 Summary of Important Safety Information for Operation eeae eaaa anane ane 39 Generator Exploded View stet ote bte ed ae aes 43 Control Panel Parts LIst Jac oec Ua tedio vade ded a didi DN t ene te 47 Generator Head Exploded View iii 50 Limited Warrant RE RR a PB Ree RL es s nia testibus 55 About Y
38. er tab 4 All 49 787259 Grommet bumper 7 All 46 ASSOLO X9 Proven Performance 6 Item 165601 It monia NA gt 6 4 165603 ey sa IS o a o AC 120Vo 4 300000 POST Item 165604 Control Panel Parts List Rev 0 3 QE ARE POPPE x Item 165605 Item 165606 Item 165607 48 Control Panel Parts List Rev 0 3 Ref Part Description Qty Used on 1 783063 Switch 2 pole red 1 165601 165603 165604 2 783060 8 AMP Circuit Breaker 1 165601 165603 165604 3 783058 300V Volt Meter 1 All 4 783059 12VDC Outlet 1 165601 165603 165604 2 165601 5 783061 20 AMP Circuit Breaker 165603 165604 165605 165606 165607 6 78305
39. es while filling Manually control the flow of gasoline do NOT use the nozzle s lock open device e Use a portable container made of metal or conductive plastic It will dissipate charge to ground more readily About static electricity and fueling Many common objects can accumulate and retain a static electric charge Objects made of non conductive materials e g plastics easily accumulate and retain static electric charge as can objects made of conductive material e g metal water if they are not electrically grounded The static electric charge on an object such as a human body or plastic fuel tank container can reach as high as several thousand volts A static electric spark can be generated if the static electric charge stored on an object jumps to another less charged object Such a spark can ignite invisible gasoline vapors that are present during fueling situations Typical sources of static electric hazards during fueling The following objects can accumulate a static electric charge and cause an ignition spark in typical fueling situations 1 Ungrounded tanks containers Any ungrounded fuel tank or container can accumulate a static electric charge as a result of contact with other objects or friction during transportation This static electricity can discharge as a spark to the grounded gasoline dispenser nozzle as the nozzle is first brought close to the tank container at the beginning of the fueling process 2
40. ge as motors connected to the generator cycle on or off The slight variation has no appreciable effect in the operation of motors lights and most appliances 32 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 Asa 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 Overloading the generator can cause damage to the generator and attached electrical devices and may result in fire Using as a Portable Power Source Connect electrical loads one at a time according to the following instructions 1 Allow engine to reach operating speed by allowing it to warm up for approximately 5 minutes before connecting electrical devices 2 After engine is warmed up begin by connecting the items that require the highest wattage first The recommended sequence is as follows a Connect items with motors such as refrigerators freezers air conditioners or small hand tools one at a time Let each motor stabilize before connecting the next device b Connect any lights you are planning on powering c Connect voltage sensitive equipment
41. igned or approved for use in vehicles or marine applications Never run the generator inside RVs or other vehicles on boats or on pick up truck beds e Cooling ventilation The generator needs adequate unobstructed flow of air to allow for proper cooling of engine and generator head Situate so there is adequate clearance around generator to allow for cooling airflow Do not allow debris to accumulate and block airflow e Grounding Always ensure generator is properly grounded to prevent electrical shock This generator is equipped with a grounding post Always complete the grounding path from the generator to a copper pipe rod driven into moist earth to a sufficient depth Check with an electrician for local grounding requirements If a 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 buildings grounding system e Isolate connection to building s electrical circuit 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 an UL approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes If the generator is not isolated from the utility power system by such means generator output will back feed into the utility power grid This may result in injury or death to utilit
42. ine applications Never run the generator inside RVs or other vehicles on boats or on pick up truck beds A WARNING Never attempt to attach ductwork to the muffler system to allow for installation inside an enclosure This could cause hot air deflection heat build up and increased exhaust back pressure resulting in possible exhaust leakage or damage to the generator 21 Installation Initial Set Up Adequate cooling The generator needs adequate unobstructed flow of air to allow for ventilation proper cooling of engine and generator head A WARNING Heat build up from inadequate ventilation can result in fire posing a serious risk to nearby persons and structures e Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up e Never place the generator immediately adjacent to a building or other structure allow at least a 7 clearance e Do notrun the generator in close proximity to other heat generating equipment such as another generator The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation e Do notallow debris to accumulate and block airflow e Do not operate with a tarp blanket or cover surrounding the generator No wet conditions Choose a location where the generator will NOT be exposed to rain snow or direct sunlight Exposure to water can cause electric
43. is 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
44. itch if Back up Power you want to use your generator as a back up power source for a building Source for a pee What does a transfer switch do It Building 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 A 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 additi
45. llow safety rules may result in serious injury or death to the operator or bystanders e Know proper use 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 see Operation Step 6 Stopping the Engine e Instruct operators The generator owner must instruct all operators in safe generator set up and operation Only trained adults should set up and operate the generator Do not let children operate e Intended use Carefully read about and understand the intended use of this generator Do not use for other purposes as unforeseen hazards or equipment damage may result e Under the influence Never operate or let anyone else operate the generator while under the influence of alcohol drugs or medication e Safety equipment controls Do not operate the generator unless all safety covers guards and barriers are in place and in good working order and all controls are properly adjusted for safe operation e Damaged Do not operate the generator with damaged missing or broken parts e Modifications Do not modify the generator in any way Modifications can create serious safety hazards and will also void the warranty e Engine speed Never attempt to modify the engine speed setting The engine speed is preset at 3600 RPM for safe and optimal performance of the generator If speed needs adjusting it must be
46. mes garages basements sheds boxes pick up truck beds RVs or boats These spaces can trap poisonous gases EVEN if you run a fan or open windows Carbon monoxide exhaust is given off whether you are using gasoline natural gas or propane to power the generator Ground Make sure the generator is grounded in accordance with instruction given in generator Installation amp Initial Set up Step 5 Grounding the Generator of this manual AWARNING Electric shock hazard Always ensure generator is properly grounded to prevent electrical shock Perform Make sure that any regular maintenance has been performed as prescribed scheduled in this manual in the Maintenance amp Repair section maintenance as needed Check add oil Check the oil level using the dipstick and add oil as needed Using a funnel add oil up to the FULL mark on the dip stick with the recommended oil type for your engine and expected ambient conditions See engine Owner s Manual for oil type and capacity and more detailed oil check fill instructions AWARNING Burn hazard Never open oil port while engine is running Hot oil can spray over face and body Notes o Low oil shutdown feature prevents the generator from starting without sufficient oil o Engine is shipped without oil You must add oil before first use IMPORTANT Under long continuous run operating conditions be prepared to e Check engine oil level every time you refuel the engine e Chang
47. muffler 1 All 13 783410 Canister muffler 1 All 14 781341 Spark arrestor 1 All 15 780061 Heat shield muffler 1 All 16 783264 Lower mounting bracket muffler 1 All 17 784957 Shim muffler 1 All 18 787502 Heat shield 1 All 19 777110 1 2 hose clip 1 165605 778532 165605 20 778553 Generator head 1 165606 785268 165607 21 786712 Fuel cap with strainer 1 All 22 30981 Lower iso mount bracket gen head 1 All 23 306459 Engine ground wire 1 All 24 787370 Base 1 All 25 82377 1 4 20 x 7 HHSC gr g zinc 2 AII 26 777164 Battery cable positive 1 All 27 785609 Battery stop 1 All 28 Northern 349900 Battery not included 12VDC 35AH n a All 29 777108 Battery cable negative 1 All 30 82083 1 4 20 wing nut 2 All 31 787620 Battery tie plate 1 All 32 785299 Deflector 1 1 All 33 787375 Lower iso bracket 1 All 34 30825 1 iso mount 4 All 35 787376 Upper iso bracket 1 All 36 785322 Deflector 2 1 All 37 785768 3 8 x 1 4 hose mender 1 All 38 785755 3 8 fuel line 3 in All 39 783226 GX630 Honda engine 1 165605 165606 185264 GX690 Honda engine 165607 786109 165605 40 786110 Control panel 1 165606 786111 165607 41 777834 1 4 hose clamp 2 All 42 31881 3 4 heat reflective sleeving 1 75 ft All 783277 165605 43 783278 NorthStar decal 2 165606 783279 165607 44 787328 Tank heat shield 1 All 45 787331 Heat shield mount 1 All 46 anni Upper iso mount bracket gen head 1 165 TORIS 607 47 787302 Bumper tank 3 All 48 787307 Adjustable bump
48. n disconnected 2 Checkto be sure gasoline line shut off valve is in OFF position Cool engine before Let engine cool for at least five minutes before storing A hot engine can storing be a fire hazard Choose a storage Store the generator in a location that is location o Clean and dry o Away from sources of heat open flames sparks or pilot lights even if the generator s fuel tank is empty Residual fuel in the tank could ignite o Away from extreme high or low temperatures Prevent accidental Remove key from starter for electric start engines and secure key in a starting safe location or remove spark plug s in order to ensure the generator cannot be started accidentally in a storage location or by untrained persons Exercise generator The generator should be exercised regularly every 4 weeks At least every four weeks start the engine and let it run for 10 to 15 minutes with a small load plugged in such as a lamp or fan Monthly exercising of the generator will o Dry out any moisture that has accumulated in the windings If left this moisture can cause corrosion in the winding o Ensure that the unit is operating properly should it be needed in an emergency Perform regular Perform periodic maintenance as directed in this manual to keep the maintenance generator in safe working condition 34 Prepare engine for long term storage if needed If you will not be able to exercise the generator regularly
49. nd other moving parts Never remove any drive belt or fan guard while the unit is operating 26 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 To avoid static electricity while fueling certain steps must be followed before and during the fueling process in order to minimize and safely dissipate static charge build up e Touch a grounded metal object before starting Always dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance away from fuel sources e Use a portable container to fill tank Never fill the generator s gas tank directly from the fuel pump the generator s tank is not grounded and the high velocity flow of gasoline from a fuel pump can cause static electric build up Use an approved portable container to transfer gasoline to the generator s tank e Fill container on the ground 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 e Keep nozzle in contact with container Keep nozzle in contact with the portable container at all tim
50. ng property caused by failure of any part Repair or replacement of parts does not extend the warranty period The engine warranty is covered under the terms and conditions as outlined by the engine manufactures warranty contained herein and is the sole responsibility of the engine manufacture Normal engine maintenance such as spark plugs air filters adjustments fuel system cleaning and obstruction due to build up is not covered by this NorthStar warranty Please fill in the following information and have it on hand when you call in on a warranty claim Customer Number Date of Purchase NorthStar Serial Number Item Number 33 NORTH STAR Proven Performance Assembled by Northern Tool 4 Eguipment Company Inc Burnsville MN 55306 NorthernTool com 56
51. oisoning e Other exhaust dangers This product contains or emits chemicals known to the State of California to cause cancer birth defects or other reproductive harm Avoid inhalation of exhaust e Wet conditions Do not operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in the rain or snow Electric shock may result e Ground fault circuit interrupter Always use a ground fault circuit interrupter GFCI protected extension cord or outlet if generator is equipped in damp or highly electrical conductive areas and on construction jobsites to prevent electrical shock e Avoid contact Avoid contact with bare wires terminals connections etc while the unit is running e Electric shock accident If an electric shock accident occurs immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor Avoid direct contact with victim Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor Apply first aid and get immediate medical help e Smoking sparks Never smoke near the running generator and never operate near sources of sparks or flames e Hot muffler Never touch hot muffler hot exhaust manifold or engine cooling fins Exhaust and engine parts can be very hot and will burn you e Moving parts Keep hands feet and apparel away from drive belts fans a
52. on of NorthStar NorthStar will not provide for replacement of complete products due to defective parts Any costs incurred due to replacement or repair of items outside of a NorthStar approved facility is the responsibility of the buyer and not covered under warranty Transportation costs to and from service center is the responsibility of the customer In addition to the normal warranty NorthStar shall warrant any normal wear item from defects in material or workmanship for a period of 90 days from the date of purchase by user Normal wear items include but are not limited to filter elements This warranty specifically excludes the following failure of parts due to damage caused by accident fire flood windstorm acts of God applications not approved by NorthStar in writing corrosion caused by chemicals use of replacement parts which do not conform to manufacturer s specifications damage to accessory parts such as starting batteries damage related to rodent and or insect infestation and damage caused by vandalism Additional exclusions loss of running time inconvenience loss of income or loss of use including any implied warranty of merchantability of fitness for a specific use Also Outdoor Power Equipment needs periodic parts and service to perform well and this warranty does not cover instances when normal use has exhausted the life of a component or the engine This warranty does not cover any personal injury or damage to surroundi
53. on 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 17 Installation Initial Set Up Using as a Portable Power Source Item 165601 Item 165603 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 See the previous section of this manual entitled Power Load Planning amp Management for more information on load application and selection When using the generator as a portable power source you can plug electric devices and appliances directly into the generator s electrical outlets There are different kinds of electrical outlets on your generator 1 120 240 Volt 30 Amp locking receptacle NEMA L14 30R locking receptacle compatible with L14 30P mating plug 2 120 Volt 20 Amp duplex straight blade receptacles NEMA 5 20R duplex receptacle compatible with NEMA 5 20P or 5 15P mating plugs 120 Volt 30 Amp locking receptacle NEMA L5 30R receptacle compatible with NEMA L5 30P mating plug 120 Volt 20 Amp duplex GFCI protected straight blade receptacles NEMA 5 20R duplex receptacles compatible with
54. or is properly grounded Use only UL listed outdoor rated grounded extension cords of proper size e 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 e 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 e 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 e ALWAYS keep a fire extinguisher rated ABC nearby STOP CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS See the Power load Planning amp 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 amp 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
55. ords 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 19 Installation Initial Set Up Table 2 Current Power Maximum Extension Cord Length 240V watts Cord Cad Cord Cord 10 2400 250 150 100 75 30 no e 35 25 19 A WARNING Use of under sized extension cords can cause electric shock fire or damage to connected devices 3 Allextension and appliance cords must be in good condition and not worn bare frayed or otherwise damaged WARNING Use of damaged electric cords can cause electric shock or fire Note If an extension cord becomes hot to the touch it is overloaded or damaged and must be replaced Northern Tool is NOT responsible for damage or injury resulting from customer use of inadequate extension cords 20 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 A 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 Dry level surface The generator should be positioned on a dry firm level s
56. ortable 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 gt If possible move the generator away from spilled gasoline on the ground Wipe up spilled gasoline and wait 5 minutes for excess gasoline to evaporate before starting engine Gasoline soaked rags are flammable and should be disposed of properly If gasoline is spilled on your skin or clothes change clothes and wash skin immediately 6 Replace gasoline cap securely before starting engine 7 Store extra gasoline in a cool dry place in an UL approved tightly sealed container IMPORTANT For continuous operation be prepared to check and refuel the engine on a regular basis A tank of gasoline should last about 4 hours under 100 load and about 8 hours under 50 load Inspect Fuel Inspect fuel system amp check for leaks BEFORE starting generator System Check Do not start generator until all needed repairs have been completed for Leaks AWARNING Fuel leak hazard Gasoline is highly explosive and fuel leaks can result in fire or explosions You can
57. our 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 Asa portable power source You can plug appliances directly into the generator s electrical outlets 2 Asaback up standby power source for a building A licensed electrician can connect the generator to your buildings electrical system via the installation of an UL approved transfer switch See the Installation amp 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 amp 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
58. owly b Electric Turn the engine key switch to the START position and hold it there until the engine starts NOTE Ifthe engine fails to start after 5 seconds release key and wait 10 seconds before attempting to start again Cranking the electric starter for more than 5 seconds continuously can overheat and damage the starter motor Release the key when the engine starts 5 When engine starts move choke lever to RUN position 6 Under long continuous run operating conditions be prepared to a Check and refuel the engine on a regular basis A tank of gas should last about 4 hours under 100 load and about 8 hours under 50 load See engine owner s manual for more detail WARNING A running engine is hot enough to ignite fuel Never add fuel or remove gas cap if engine is running or still hot Let cool at least 2 FEDERAL LAW prohibits the use of minutes E15 in small engines Per the EPA i A E15 should ONLY be used in 2001 b Check engine oil level each time you refuel and newer passenger vehicles c Change oil after the first 20 operating hours and at least every 100 operating hours thereafter as directed in the engine owner s manual WARNING Never open oil port while engine is running Hot oil can spray over face and body 31 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 outpu
59. ry e Sparks Smoking Never smoke or work near sparks or other sources of ignition e Electric shock Never touch both battery terminals at the same time with your hand or any non insulated tools e Connection disconnection sequence ALWAYS connect and disconnect cables to the correct battery terminals in the proper sequence o When CONNECTING the battery connect the RED cable to the POSITIVE terminal FIRST o When DISCONNECTING the battery disconnect the BLACK cable from the NEGATIVE terminal FIRST e Acid skin contact If battery acid contacts skin or clothing flush immediately with water and neutralize with baking soda 39 Summary of Important Safety Information for Operation cont d Installation Initial Set up Safety e 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 e 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 ONLY run generator OUTDOORS and away from building air intakes NEVER run generator inside homes garages sheds or other semi enclosed spaces These spaces can trap poisonous gases EVEN if you run a fan or open windows Carbon monoxide is given off whether you are using gasoline natural gas or propane to power the generator e No vehicle marine use This generator is NOT des
60. s Inspect fuel system check for leaks Maintenance amp Repair Read and follow these safety rules whenever you will be servicing the generator e Turnoff generator Always turn off generator and remove spark plug s or spark plug wire s before working on the engine or generator to prevent accidental starting e Discharge capacitor When the generator is shut down the capacitor may maintain a charge Always discharge the capacitor before working on the generator head to prevent electrical shock Discharge using a screwdriver with an insulated handle While wearing safety glasses touch opposite terminals of the capacitor together with the tip of the screwdriver If there is stored charge in the capacitor a spark will be generated thereby discharging the capacitor e Replace guards Make sure all guards and shields are replaced after servicing the generator e Repair Major service including the installation or replacement of parts should be performed only by a qualified electrical service technician Obtain factory approved parts from NorthStar Product Support at 1 800 270 0810 e Replacement parts If a part needs replacement only use factory approved repair parts Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator and will void the warranty Perform engine maintenance as specified in the engine owner s manual Engine maintenance items include 1 Changing oil and
61. s could cause hot air deflection heat build up and increased exhaust back pressure resulting in possible exhaust leakage or damage to the generator 22 Installation Initial Set Up 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 3 4 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 2 Connect an approved ground clamp to the pipe 3 Run a 10 gauge items 165601 165603 165604 or an 8 gauge items 165605 165606 165607 wire from the clamp to the generator grounding post located on the electrical panel 4 Do not connect the generator grounding post to a water pipe or a ground used by a radio system Copper Pipe Rod 10 or 8 Ga wire Grounding Post fp ef Ground T4 a PART a ege a LIL LEL IAA If a licensed electrician installs the generator with a connection to your buildings electrical circuit for use as a back up po
62. shock You may operate the generator under an outdoor canopy like structure of heat resistant material that is open on all sides Make sure that all parts of canopy are at least 7 from exhaust and allow for adequate clearance above generator so that heat does not build up Hot exhaust The exhaust gas from your generator is extremely hot and can cause clearance combustible materials to catch on fire e Make sure your generator s exhaust system is at least 7 feet from all combustible materials and buildings structures e Equip the engine with a spark arrestor if the generator will be used near any ignitable forest brush or grassy land See the Specifications section of this manual to determine if your generator is already equipped Make sure you comply with applicable local state and federal codes e Keep a fire extinguisher rated ABC nearby Keep it properly charged and be familiar with its use Away from Do not use the generator in extremely dusty or dirty conditions dust dirt Excessive dust and dirt can cause premature failure of the machine Hearing Generators can produce noise levels of up to 95 dB in close proximity protection 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 A WARNING Never attempt to attach ductwork to the muffler system to lower noise levels Thi
63. slow b Generator is overloaded a Defective load connected to generator b Defective receptacle c Generator overloaded a Engine speed too high a Generator is overloaded b Insufficient ventilation a Defective load connected to generator b Broken or loose wire c Defective receptacle d Defective stator e Defective rotor f Defective capacitor g Circuit breaker tripped a Generator is overloaded b Dirty air filter a Outof fuel b Low oil level 38 Possible Causes Possible Remedies a Fill crankcase to proper oil level b Clean or replace spark plug c Fill fuel tank d Place switch in ON position a Bring generator to a qualified technician for adjustment b Reduce the load See Power Load Planning amp Mgt section of this manual a Disconnect load b Replace receptacle c Reduce the load See Power Load Planning amp Met section of this manual a Bring generator to a qualified technician for adjustment a Reduce the load See Power Load Planning amp Met section of this manual b Make sure there is at least 7 feet of clearance on all sides of generator a Disconnect load b Bring generator to a qualified technician for repair c Replace receptacle d Bring generator to a qualified technician for repair e Bring generator to a qualified technician for repair f Bring generator to a qualified technician for repair g Reset circ
64. sult e Ground fault circuit interrupter Always use a ground fault circuit interrupter GFCI protected extension cord or outlet if generator is equipped in damp or highly electrical conductive areas and on construction jobsites to prevent electrical shock e Electrical cords Use only UL listed outdoor rated three prong extension cords of the proper size All extension and appliance cords must be in good condition and not worn bare frayed or otherwise damaged Use of inadequate or damaged electric cords can cause electric shock or fire e Avoid contact Avoid contact with bare wires terminals connections etc while the unit is running e Electric shock accident If an electric shock accident occurs immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor Avoid direct contact with victim Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor Apply first aid and get immediate medical help e Hot muffler Never touch hot muffler hot exhaust manifold or engine cooling fins Exhaust and engine parts can be very hot and will burn you e 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 41 Summary of Important Safety Information for Operation cont d e Refueling DO NOT refuel the engine until it h
65. t 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 Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual Output voltage should be checked with a portable voltage meter 1 Startengine and allow to warm up for five minutes Do not connect any loads 2 Use voltage meter to check output voltage at the generator s outlets receptacles 3 Measured voltage should be within the following ranges a 120V 10 at 120V receptacles b 240V 10 at 240V receptacles 4 If measured voltage is not within the specified range have generator adjusted by factory authorized personnel Do not attempt to adjust the engine speed yourself NOTE All engines have a tendency to slow down when a load is applied When Slight variation in electrical loads are connected to the generator the engine is more heavily voltage speed with loaded and as a result the speed drops slightly changing electrical lowe This slight decrease in speed together with the voltage drop within the generator itself results in a slightly lower voltage when the generator is loaded to its full capacity than when it is running with no load Additionally there may be small brief surges and drops in volta
66. uit breaker and reduce loads connected to the generator a Reduce the load See Power Load Planning amp Mgt section of this manual b Clean or replace air filter a Fill fuel tank b Fill crankcase to proper oil level 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 Carefully read and make sure you understand the following safety information before using the generator Improper use or maintenance of the generator can result in serious injury or death from carbon monoxide poisoning electric shock fire explosion or burns General e Read manual Read this Owner s Manual and the engine Owner s Manual completely before attempting to set up and use the generator Serious injury or death can result if safety instructions are not followed e Instruct operators The generator owner must instruct all operators in safe generator set up and operation Do not allow anyone to operate the generator who has not read the Owner s Manual and been instructed on its safe use e Adults only Only trained adults should set up and operate the generator Do not let children operate e Under the influence Never operate or let anyone else operate the generator while under the influence of alcohol drugs or m
67. ump 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 STAGGERING LOADS 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 15 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 amp 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 a Grounding 6 Battery installation electric start models only Each of these steps is discussed in detail below 1 Unpacking amp 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 e If you have missing components contact Product Support at 1 800 270 0810 e If
68. urface Ensure that the generator sits level and will not slide or shift during operation If applicable block the generator s wheels to prevent sliding and shifting Outdoors only dangerous carbon monoxide exhaust AWARNING Carbon monoxide poisoning hazard The exhaust from your generator contains carbon monoxide CO a poisonous gas that can kill You cannot smell it see it or taste it Carbon monoxide exhaust is given off whether you are using gasoline natural gas or propane as the fuel source to power the generator Follow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning The location you choose to operate the generator must be OUTDOORS and away from all air intakes e Never run the generator inside any closed or semi enclosed spaces even if outdoors including homes garages basements sheds or boxes These spaces can trap poisonous gases even if you run a fan or open windows e Never place the generator immediately adjacent to a building or other structure allow at least 7 feet clearance e Place the generator so that the exhaust fumes will not be directed towards people or building air intakes e Ensure that working battery operated or battery back up carbon monoxide alarms are used in any dwelling structure that is in close proximity to the running generator e Note that this generator is NOT designed or approved for use in vehicles or mar
69. wer system grounding may alternatively be completed through the buildings grounding system Ask your electrician If the generator is not grounded through your building s electrical system follow the procedure above A WARNING Operating the generator when it is not properly grounded can result in electrical shock 23 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 AWARNING Battery hazards Batteries are hazardous because they contain caustic acid can emit explosive gases and can cause electric shock Caution must be exercised when making connections to a battery to avoid shock and contact with the acid and to prevent any sparking that could lead to an explosion ALWAYS follow the general battery safety rules and instructions listed below L J Positive battery terminal Negative battery terminal TA fr 1 4 20 wing nut JM 1 4 20 x 7 bolt Tie plate Battery Base __ v General Battery Safety Rules e ALWAYS use eye protection when handling batteries e NEVER smoke or work near sparks or other sour
70. wering 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 e Devices without electric motors such as light bulbs radios and televisions have the same running and starting wattage e 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 Starting Watts Continuous Surge 10in Table Saw 1800 4500 7 1 4in Circular Saw 1400 2300 8in Bench Grinder 1400 2500 Air Conditioner Central 24
71. y power workers or others who contact the lines during a power outage It may also cause the generator to explode or cause fires when utility power is restored e Wet conditions Water conducts electricity Do not operate generator where it is wet Operate on a dry surface under an open canopy like structure e CO alarms Ensure that working battery operated or battery back up carbon monoxide alarms are used in any dwelling structure that is in close proximity to the running generator e Hot exhaust fires Exhaust from engine can be extremely hot and cause fire Position muffler at least 7 from combustible objects during operation e Spark arrestor Equip engine with a spark arrestor if generator will be used near any ignitable forest brush or grassy land See the Specifications section of this manual to determine if your generator is already equipped Make sure you comply with applicable local state and federal codes e Fire extinguisher Keep a fire extinguisher rated ABC by the National Fire Protection Association nearby Keep it properly charged and be familiar with its use Safety Before Use Know how to operate e Review safety rules Before each use of this generator review the Rules for Safe Operation Failure to follow these rules may result in serious injury or death e Know how to operate Be thoroughly familiar with all controls and with the proper use of the equipment Know how to stop the generator quickly if n

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