Table of Contents
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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
Can be used to power individual appliances plugged directly into the generator's outlets, or as a back-up
connection to a building's power supply (via a professionally installed UL-approved transfer switch).
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:
Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or
semi-enclosed spaces, including homes, basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These
spaces can trap poisonous gases, EVEN if you run a fan or open windows.
Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly
grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.
NEVER plug the generator directly into a wall outlet. ANY connection to a building's electrical system MUST
ISOLATE THE GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed
electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.
DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so
engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7 feet from all combustible objects.
All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use
approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
ALWAYS keep a fire extinguisher rated "ABC" nearby.
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the "Power load Planning & Management" section
of this manual to determine your power load requirements and then compare to the generator's rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the "Unpacking
& Delivery Inspection" section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to
your building's electrical system. See the "Installation/Initial Set-Up" section for more information about this
requirement.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
WARNING
Electric shock / Electrocution
Call NorthStar Product Support 1-800-270-0810
M165601O.3
Item Number: 165601, 165603, 165604,
Serial Number: _____________
CO Poisoning
Fire / Explosion
STOP!
165605, 165606, 165607
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Table of Contents
Related Manuals for NorthStar 165601
Summary of Contents for NorthStar 165601
- Page 1 M165601O.3 Item Number: 165601, 165603, 165604, 165605, 165606, 165607 Serial Number: _____________ Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up connection to a building’s power supply (via a professionally installed UL-approved transfer switch).
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Page 2: Hazard Signal Word Definitions
Hazard Signal Word Definitions... -
Page 3: Table Of Contents
Table of Contents Hazard Signal Word Definitions ....................2 About Your Generator ........................4 Specifications ........................... 6 Safety Label Locations ........................8 Machine Component Identification ....................9 Power Load Planning & Management ..................13 Installation / Initial Set-Up: 1. Unpacking & Delivery Inspection ..................16 2. -
Page 4: About Your Generator
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. -
Page 5: Warranty Registration
About Your Generator NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user shall assume liability for any modification and/or alterations of this equipment from original design and manufacture. -
Page 6: Specifications
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) - Page 7 (L x W x H) 7.69” x 5.13” x 7” Battery Dimensions Dimensions 32.38” 32.38” Length 24.38” 24.38” Width 26.90” 26.90” Height Dry Weight 313 lb. 325 lb. Any Questions, Comments, Problems, or Parts Orders Call NorthStar Product Support 1-800-270-0810...
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Page 8: Safety Label Locations
If a safety label is missing or not 786635 Burn Hazard legible, order new labels or unsafe operation could 785265 Danger Warning result. 786837 Over Fill Warning To order replacement safety labels, call NorthStar 782397 Battery Hazard Product Support at 1-800-270-0810. -
Page 9: Machine Component Identification
Machine Component Identification Items: 165601, 165603, 165604 Ref. Description Ref. Description Recoil Generator Head Fuel Valve Lever 6.5 Gallon Gas Tank Engine Key Switch (165604 only) Muffler Vibration Isolation Mount Gasoline Tank Cap Oil Drain Plug Carbon Canister Oil Fill Port... - Page 10 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.
- Page 11 Machine Component Identification Items: 165605, 165606, 165607 Ref. Description Ref. Description Air Cleaner Battery (not included) 11 Gallon Gas Tank Control Panel Gasoline Tank Cap Vibration Isolation Mount Choke Generator Head Engine Key Switch Carbon Canister Oil Drain Plug Fuel Valve Lever Oil Fill Port Muffler...
- Page 12 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.
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Page 13: Power Load Planning & Management
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. - Page 14 Power Load Planning & Management (cont’d) Running Watts Starting Watts Device (Continuous) (Surge) Clothes Dryer (gas) 1200 Clothes Washer 1150 2300 Coffee Maker 1750 Deep Freezer 1000 Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) 1500 1500 Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles...
- Page 15 Power Load Planning & Management (cont’d) To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps: 1. Make a list of all electrical devices you will be powering at the same time with the generator. 2.
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Page 16: Installation / Initial Set-Up
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. -
Page 17: Set-Up Either As A Building Back-Up Or Portable Power Source
Installation / Initial Set-Up 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to its rated amount of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this application, you must arrange for a licensed electrician to connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch. - Page 18 5-15P mating plugs) 5. 120/240 Volt, 50 Amp straight-blade receptacle (NEMA 14-50R receptacle compatible with NEMA 14-50P mating plug) 6. 120/240 Volt, 60 Amp straight-blade receptacle (NEMA 14-60R receptacle compatible with NEMA 14-60P mating plug) Item # 165601 Item # 165603...
- Page 19 Installation / Initial Set-Up Item # 165604 Item # 165605 & 165606 Item # 165607 1. Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet.
- Page 20 Installation / Initial Set-Up Table 2 Current/Power Maximum Extension Cord Length Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga. 240V (watts) Cord Cord Cord Cord 2400 250' 150' 100' 4800 125' 7200 9600 12000 WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.
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Page 21: Selecting A Suitable Site
Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet all of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, electric shock, or fire. - Page 22 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. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. ...
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Page 23: Grounding The Generator
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. -
Page 24: Battery Installation
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. -
Page 25: Operation
Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. - Page 26 Operation Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire...
- Page 27 Operation Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
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Page 28: Preparing For Operation
Operation 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” generator of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. - Page 29 Operation WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite gasoline vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Use extreme care when handling gasoline. Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: ...
- Page 30 Operation Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled. Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline;...
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Page 31: Starting The Engine
Operation 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position. -
Page 32: Checking Generator Output
Operation 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. -
Page 33: Connecting Loads
Operation 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING:... -
Page 34: Storage & Exercise
Operation Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Shut off fuel supply o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. - Page 35 Operation Prepare engine for If you will not be able to exercise the generator regularly, you must prepare the engine for long term storage to prevent gum deposits from long term storage if needed forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carburetor o Adding fuel stabilizer to the gasoline (following manufacturer’s...
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Page 36: Maintenance & Repair
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. Replacement parts. If a part needs replacement, only use factory approved repair parts. - Page 37 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.
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Page 38: Troubleshooting
Troubleshooting Problem Possible Causes Possible Remedies Engine will not a) Low oil level. a) Fill crankcase to proper oil level. start. b) Fouled spark plug. b) Clean or replace spark plug. c) Out of fuel. c) Fill fuel tank. d) Stop switch in OFF position. d) Place switch in ON position. -
Page 39: Summary Of Important Safety Information For Operation
Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator. - Page 40 Summary of Important Safety Information for Operation (cont’d) Installation / Initial Set-up Safety Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. ...
- Page 41 Summary of Important Safety Information for Operation (cont’d) 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. ...
- Page 42 Summary of Important Safety Information for Operation (cont’d) Refueling. DO NOT refuel the engine until it has cooled at least two minutes. 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...
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Page 43: Generator Exploded View
Generator Exploded View Rev – O.3 Item #s 165601, 165603, & 165604... - Page 44 Generator Exploded View Rev – O.3 Item #s 165601, 165603, & 165604 Ref # Part # Description Used on 786710 6.5 gallon fuel tank assembly w/cap 785337 4.5mm fuel line 6 in 165601 7 in 165601 785337 4.5mm fuel line...
- Page 45 Generator Exploded View Rev – O.3 Item #s 165605, 165606, & 165607...
- Page 46 Control panel 165606 786111 165607 1/4” hose clamp 777834 3/4” heat reflective sleeving 31881 1.75 ft 783277 165605 783278 NorthStar decal 165606 783279 165607 787328 Tank heat shield 787331 Heat shield mount 787374 165605 Upper iso mount bracket, gen head 787371...
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Page 47: Control Panel Parts List
Control Panel Parts List Rev – O.3 Item # 165601 Item # 165603 Item # 165604... - Page 48 Control Panel Parts List Rev – O.3 Item # 165605 Item # 165606 Item # 165607...
- Page 49 Control Panel Parts List Rev – O.3 Ref # Part # Description Used on Switch – 2 pole, red 783063 165601, 165603, 165604 783060 8 AMP Circuit Breaker 165601, 165603, 165604 783058 300V Volt Meter 783059 12VDC Outlet 165601, 165603, 165604...
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Page 50: Generator Head Exploded View
Generator Head Exploded Views Rev – O.3 Item #s 165601, 165603, 165604, 165605... - Page 51 Generator Head Exploded Views Rev – O.3 Item #s 165601, 165603, 165604, 165605 Ref # Part # Description Used On MA305522 165601 Mount Plate (J609B) 779919 165603, 165604, 165605 MA306404 165601 Fan Bolts 779556 165603, 165604, 165605 778953 165601 779557...
- Page 52 Generator Head Exploded Views Rev – O.3 Item #s 165606, 165607...
- Page 53 Generator Head Exploded Views Rev – O.3 Item #s 165606, 165607 Item # Part # Description Used On MA30991 Drive End Bracket MA30994 Protection Screen MA31013 Phillips Screw MA30995 307489 Grommet 305605 Terminal Box Cover w/grommet M5 X .8, 16mm Long M5 X .8, 10mm Long, Green MA31015 M5 X .8, 10mm Long...
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Page 55: Limited Warranty
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 decision of NorthStar. NorthStar will not provide for replacement of complete products due to defective parts. - Page 56 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com...