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North Star M165957K - page 1
M165957K Owner’s Manual Instructions for Installation/Set-u p, Operation, Serv icing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 6600 Watt Continuous (8000 Watt Surge) Capacity Can be used to power individual ap pliances plugged direc tly into the generato r’s outlets, or as a back-up connection to a building’s power supply ...
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North Star M165957K - page 2
Hazard Signal Word Definitions 2 ...
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North Star M165957K - page 3
Table of Contents 3 Hazard Signal Word Definitions ................................................................................................. .2 About Your Generator ................................................................................................................. .4 Specifications ............................................. ...
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North Star M165957K - page 4
About Your Generator 4 Thank you for purchasing your NorthStar portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to 8000 Watts of electrical power (6600 watts continuous, 8000 watts surge). It can supply power: 1. As a portable power source . You can plug appliances di rectly into the generato ...
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North Star M165957K - page 5
About Your Generator (cont’d) 5 NorthStar is constantly improving its products. The specifications outline d herein are subject to change without prior notice or obligation. Th e purchaser and/or user shall assume liability for any modification and/or alterations of this equipm ent from original design and manufacture. Before using, the user shal ...
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North Star M165957K - page 6
Specifications – Item #165957K 6 SPECIFICATIONS Item Number #165957 Maximum Output 8000 Watts (W) Continuous Output 6600 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency 56.5-63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 13 HP Honda GX390 Engine Speed 3390-3800 RPM Fuel Type Unleaded gasoline Fuel Capacity 6.5 gallons (24 ...
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North Star M165957K - page 7
Safety Label Locations – Item #165957K 7 Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new la bels or unsafe operation could result. To order replacement safety labels , call NorthStar Product Support at 1-800-270-0810. On-Product Warning Labels Part numbers Description 39260 ...
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North Star M165957K - page 8
Machine Component Identification - Item #165957K 8 Figure 1 (Ref. 1-8) 00591 Ref. Description Ref. Description 1 Circuit Breakers 10 Gas Cap with Gauge 2 120/240V 30A Locking device Receptacle 11 6.5 Gallon Gas Tank 3 Grounding Post 12 Generator Head 4 120V 20A Duplex Receptacle 13 Battery Box 5 120V 15A Duplex Receptacle 14 Vibration Isolation Mou ...
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North Star M165957K - page 9
Machine Component Identification - Item #165957K 9 REFERENCE GUIDE Reference 1 – Circuit Breakers This portable single phase generator has 1, 15 amp (A) 2, 20A, and 2, 30A push to reset circuit breakers to protect against electrical overloads. Reference 2 – 120/240V Receptacle The locking device is a 120/240V 30A NEMA L14-30R receptacle. This r ...
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North Star M165957K - page 10
Power Load Planning & Management 10 WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROP ERLY to provide both the running and starting (surge) wattage of the devices you will be powering. ...
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North Star M165957K - page 11
Power Load Planning & Management (cont’d) 11 Device Running Watts Device Running Watts Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1”) 1100 Sump pump 600 (a) Hand drill (1/2”) 875 Table saw 2000 (a) Hand d ...
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North Star M165957K - page 12
Installation / Initial Set-Up 12 There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / In itial Se t-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity. 3. Setting up generator for the type of power generat ...
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North Star M165957K - page 13
Installation / Initial Set-Up 13 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 8000W of electrical power. It can supply electricity in two ways: 1. As a back-up, standby power source for a building. For this applicatio n, you must arrange for a licensed electrician to connect the generat ...
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North Star M165957K - page 14
Installation / Initial Set-Up 14 Ple ase re ad you r owner's manu al bef ore op eratin g, if you do not have a m anual or ha ve qu esti ons, cal l cu stomer servi ce a t 1-800-270-0810 GROUNDING PO ST N EMA L14-30R NEMA 5-20 R Duplex NEMA 5-15 R FIG02679 that have been chosen as critical to operate during a power outage. The generator cannot p ...
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North Star M165957K - page 15
Installation / Initial Set-Up 15 ♦ Extension cords may be used to pow er devices that are located at a distance from the generator. Howeve r, use only UL-listed, outdoor-rated, grounded extension cords of the proper size. Use Table 2 below to choose an adequately sized extension cord according to the amperage of the device being used and the leng ...
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North Star M165957K - page 16
Installation / Initial Set-Up 16 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This location should meet al l of the criteria listed below. WARNING: You must choose a suitable site for operating your generator to avoid equipm ent damage and/or injury and possible de ...
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North Star M165957K - page 17
Installation / Initial Set-Up 17 • Situate so there is adequate clear ance around generator to allow for cooling airflow so that heat does not build up. • Never place the generato r imm ediately adjacent to a building or other structure – allow at least a 7’ clearance. • Do not run the generator in close proximity to other heat-generating ...
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North Star M165957K - page 18
Installation / Initial Set-Up 18 5. Grounding the generator Always ensure the generator is properly grou nded to prevent electrical shock. You must always ground the generator by the fo llowing method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pip ...
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North Star M165957K - page 19
Installation / Initial Set-Up 19 6. Battery Installation Your generator’s engine is equipp ed with an electric starter which require s the installation of a 12- volt lawn tractor size battery (Gr oup U1). See the “Specifications” section of this manual for m ore specific battery requirements for this generator model, such as minimum amperage ...
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North Star M165957K - page 20
Operation 20 Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessa ry for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3. Starting the Engine 4. Checking Generator Output 5. Connecting Electrical ...
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North Star M165957K - page 21
Operation (cont’d) 21 • Malfunction during operation. Immediately turn off the generator if an y 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 m isfire o Exces ...
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North Star M165957K - page 22
Operation (cont’d) 22 Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasolin e tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapor s that are present during the fueling process, resulting in seriou ...
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North Star M165957K - page 23
Operation (cont’d) 23 2. Preparing for Operation Position generator Position generator in accordance with the instructions g iven in “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level gr ound with adequate clearance and ventilation. WARNING: Carbon monoxide poisoning hazard ...
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North Star M165957K - page 24
Operation (cont’d) 24 WARNING : Gasoline fire/explosion hazard Gasoline is highly flammable and expl osive. 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 injur y or death. Use extreme care when hand ling gasoline. Carefully follow all t ...
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North Star M165957K - page 25
Operation (cont’d) 25 ground to be filled. • Keep nozzle i n contact with portabl e 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 ...
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North Star M165957K - page 26
Operation (cont’d) 26 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all load s to the generator. 2) Turn the gasoline line valve to the ON positio n. 3) For cold engine, move choke lever to full chok e position. To restart a warm engine, m ...
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North Star M165957K - page 27
Operation (cont’d) 27 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator . WARNING : The generator must ...
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North Star M165957K - page 28
Operation (cont’d) 28 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are prov ided below for connecting loads wh en you are using the generator: o As a portable power source o Conne ...
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North Star M165957K - page 29
Operation (cont’d) 29 7. Storage & Exercise When you are finished usin g 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 & turn o ...
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North Star M165957K - page 30
Operation (cont’d) 30 Prepare engine for long term storage if needed If you will not be able to exercis e the generato r regularly, you must prepare the engine for long term storage to prevent gum deposits from forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carbure ...
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North Star M165957K - page 31
Maintenance & Repair 31 Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety ru les and recom mended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the ge nerator. M ...
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North Star M165957K - page 32
Maintenance & Repair (cont’d) 32 Check GFCI (if equipped) Once a month, test the Ground Faul t Circuit Interrupter (GFCI) to protect against electrical shock due to failure of the GFCI. (Only for those models equipped with GFCI – See the “Specifications” section.) To test the GFCI: 1. Depress the TEST button. The RESET button should ext ...
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North Star M165957K - page 33
Troubleshooting 33 TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Stop switch in OFF position. e) Battery is not charged. a) Fill crankcase to proper oil level. b) Clean or replace spark plug. c) Fill fuel tank. d) Place switch in ON position. e) Charge Bat ...
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North Star M165957K - page 34
Summary of Important Safety Information for Operation 34 This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summ ary 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 followi ...
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North Star M165957K - page 35
Summary of Important Safety Information for Operation (cont’d) 35 Installation / Initial Se t-up Safety • Dry, level surface . Situate generator on a dry, firm, level surf ace. Ensure generat o r sits level and will not slide or shift during operation. Block wheels if applicable. • Operate OUTSIDE only – dangero us carbon mono xide exhaust ...
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North Star M165957K - page 36
Summary of Important Safety Information for Operation (cont’d) 36 Gasoline Safety Gasoline is highly flam mable and expl osive. Y ou can be burne d or seriously inju red when handling fuel . Use extreme care when handling: • Fuel outdoors . Fill fuel tank outdoors – never indoors. Gasoline vapors can ignite if they collect inside an enclosure ...
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North Star M165957K - page 37
Summary of Important Safety Information for Operation (cont’d) 37 • Avoid cont act . Avoid contact with bare wires, terminals, connections, etc. while the unit is running . • Electric shock accident. If an electric shoc k accident occurs, imme diately shut down the source of electrical power. If this is not possible, attempt to free the vi ct ...
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North Star M165957K - page 38
Generator Exploded View Rev - K 38 ...
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North Star M165957K - page 39
Generator Exploded View Rev - K 39 Ref # Part # Description Qty 1 38759 Fuel Tank Assembly 1 2 33321 Fuel Cap 1 3 777352 Battery Box 1 4 30754 Leather Washer 4 5 779422 Decal 1 6 777834 Hose Clamp 3 7 779423 Warning Decal 1 8 32833 Roll Cage 1 9 39260 Hot Muffler Sticker 1 10 31335 Honda GX390 Engine, 13 HP 1 11 778530A Generator Head 1 12 777304 G ...
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North Star M165957K - page 40
Wiring Diagram Rev - K 40 Diag # Part # Description Qty 1 306438 15 Amp, 120 Volt Receptacle (NEMA 5-15R) 1 2 31736 20 Amp, 120 Volt Receptacle (NEMA 5-20R) 1 3 306422 30 Amp, 120/240 Volt Locking Receptacl e (NEMA L14-30R) 1 4 306429 Grounding Post 1 5 306433 Thermal Circuit Breaker, 15 Amp 1 6 38191 Wiring Harness (Connects generato r to Control ...
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North Star M165957K - page 41
Generator Head Exploded View Rev - K 41 Item # Part # Description Qty 1 38266 Mount Plate (J609B) 1 2 38267 Fan Bolts 2 3 38268 Fan 1 4 38269 Drive End Bracket 1 5 38270 Enclosing Band 1 6 777304 End Cover 1 7 38271 End Cover Plug 1 8 38272 Stator 1 9 38273 Rotor 1 10 307479 Diode 2 11 38275 Securing Stud 1 12 38276 Bearing 1 13 38277 Nut 1 14 3827 ...
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