NORTH STAR M165601AI Portable Generators

About Your Generator

The M165601AI is a portable, outdoor use-only, gasoline generator. It is designed to provide power for individual appliances or as a backup connection to a building’s power supply. The generator comes in different models with item numbers 165601, 165603, 165604, 165605, 165606, and 165607.

Specifications

• Item Number: 165601, 165603, 165604, 165605, 165606, 165607
• Serial Number: _____
• Use: Portable, outdoor use-only
• Fuel Type: Gasoline

Safety Label Locations
The generator has safety labels placed in various locations to provide important safety information. Please refer to the user manual for the exact locations of these labels.

Machine Component Identification

The user manual provides detailed information on the identification of various machine components. It is important to bef amiliar with these components for proper installation, operation, and maintenance of the generator.

Power Load Planning & Management
Before using the generator, it is crucial to determine your power load requirements and compare them to the generator’s rated capacity. The user manual provides a section on Power Load Planning & Management that will guide you through this process.

Maintenance & Repair

Proper maintenance and repair are essential for the safe and efficient operation of the generator. The user manual provides detailed instructions on how to maintain and repair the generator. It is important to follow these instructions to ensure optimal performance and longevity of the product.

Troubleshooting

If you encounter any issues or problems with the generator, the user manual includes a troubleshooting section. This section provides step-by-step instructions to help you identify and resolve common problems.

Summary of Important Safety Information for Operation
For safe operation, it is crucial to read and understand the user manual completely. Failure to set up, operate, and maintain the generator properly can result in serious injury or even death. The user manual contains important safety information that should be followed at all times.

Generator Exploded View

The user manual includes an exploded view of the generator, which provides a detailed visual representation of its components and their arrangement. This view can be used as a reference for understanding the generator’s internal structure.

If you have any questions, comments, problems, or need to order parts, please contact NorthStar Product Support at 1-800-270-0810.

Hazard Signal Word Definitions
The user manual includes definitions of hazard signal words that indicate specific risks associated with using the generator. It is important to familiarize yourself with these definitions to ensure your safety.

M165601AI
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).
WARNING
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. · ONLY run generator OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to
allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. 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 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.
Fire / Explosion · 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.
STOP!
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 Call NorthStar Product Support 1-800-270-0810

Hazard Signal Word Definitions

About Your Generator

Thank you for purchasing your NorthStar portable generator!
About Your Generator
This engine-driven, portable generator is designed to provide up to its rated amount of electrical power. (See specifications section of this manual for model specific ratings) It can supply power:
1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets.
2. As a back-up, standby power source for a building. A licensed electrician can connect the generator to your building’s electrical system via the installation of an UL-approved transfer switch. (See the “Installation & 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 & 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 information can be found in the “Installation & Initial Set-up, Steps 5 & 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
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 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.
5

Specifications

Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type
Fuel Capacity Oil Capacity Starting Method Spark Arrester Dimensions
Length Width Height Dry Weight

165601 5500 Watts (W) 4500 Watts (W) 120 / 240 Volt (V) Single phase (4-wire)

56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX270 3390 – 3798 RPM Non-leaded automobile
gasoline 6.5 gallons 1.16 US quarts
Recoil Included on muffler
27″ 21.25″ 22.63″ 174 lb.

165603 8000 Watts (W) 6600 Watts (W) 120 / 240 Volt (V) Single phase (4-wire)

56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX390 3390 – 3798 RPM Non-leaded automobile
gasoline 6.5 gallons 1.16 US quarts
Recoil Included on muffler
27″ 21.25″ 22.63″ 200 lb.

Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type
Fuel Capacity Oil Capacity Starting Method Battery (not included) Battery Dimensions Spark Arrester Dimensions
Length Width Height Dry Weight

165604 8000 Watts (W) 6600 Watts (W) 120 / 240 Volt (V) Single phase (4-wire)

56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX390 3390 – 3798 RPM Non-leaded automobile
gasoline 6.5 gallons 1.16 US quarts
Electric 12VDC. 18AH (L x W x H) 7.13″ x 3″ x 6.57″ Included on muffler
27″ 21.25″ 22.63″ 206 lb.

165605 10000 Watts (W) 8500 Watts (W) 120 / 240 Volt (V) Single phase

(4-wire) 56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX630 3390 – 3798 RPM Non-leaded automobile
gasoline 11 gallons see Honda Manual
Electric 12VDC. 35AH (L x W x H) 7.69″ x 5.13″ x 7″ Included in manual bag
32.38″ 24.38″ 26.90″ 209 lb.

6

Specifications

Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type
Fuel Capacity Oil Capacity Starting Method Battery (not included) Battery Dimensions Spark Arrester Dimensions
Length Width Height Dry Weight

165606 13000 Watts (W) 10500 Watts (W) 120 / 240 Volt (V) Single phase

(4-wire) 56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX630 3390 – 3798 RPM Non-leaded automobile
gasoline 11 gallons see Honda Manual
Electric 12VDC. 35AH (L x W x H) 7.69″ x 5.13″ x 7″ Included in manual bag
32.38″ 24.38″ 26.90″ 313 lb.

165607 15000 Watts (W) 13500 Watts (W) 120 / 240 Volt (V) Single phase

(4-wire) 56.5-63.3 Hertz (Hz)
1.0 p.f. Honda GX690 3390 – 3798 RPM Non-leaded automobile
gasoline 11 gallons see Honda Manual
Electric 12VDC. 35AH (L x W x H) 7.69″ x 5.13″ x 7″ Included in manual bag
32.38″ 24.38″ 26.90″ 325 lb.

Any Questions, Comments, Problems, or Parts Orders Call NorthStar Product Support 1-800-270-0810
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Safety Label Locations

Models: 165601, 165603, 165604

Models: 165605, 165606, 165607

WARNING – BATTERY HAZARDS
BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock
ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns. NO smoking, sparks, or flames. NEVER touch both battery terminals at the same time with your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing. CONNECT cables in 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.
782397

Part # 786635 785265 786837 782397

Description

Qty

Burn Hazard

1

Danger Warning

1

Over Fill Warning 1

Battery Hazard

1

Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. To order replacement safety labels, call NorthStar Product Support at 1-800-2700810.
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Machine Component Identification
Items: 165601, 165603, 165604

Ref.
1 2 3 4 5 6 7 8

Description
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

Ref.
9 10 11 12 13 14 15

Description
Generator Head 6.5 Gallon Gas Tank Muffler Gasoline Tank Cap Carbon Canister Air Cleaner Choke Lever

9

Machine Component Identification
Items: 165601, 165603, 165604

REFERENCE GUIDE

Reference 1 ­ Recoil Reference 2 ­ Fuel Valve Lever
Reference 3 ­ Engine Key Switch
Reference 4 ­ Vibration Isolation Mount
Reference 5 ­ Oil Drain Plug Reference 6 ­ Oil Fill Port Reference 7 ­ Battery (not included) Reference 8 ­ Control Panel Reference 9 ­ Generator Head Reference 10 ­ 6.5 Gallon Gas Tank
Reference 11 ­ Muffler Reference 12 ­ Gasoline Tank Cap Reference 13 ­ Carbon Canister Reference 14 ­ Air Cleaner Reference 15 ­ Choke Lever

Grasp firmly when starting engine. 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. The engine key switch is located on the control panel. Always locate this switch and be familiar with its location before operating the generator. 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. Refer to your Honda engine manual for oil change recommendations. Refer to your Honda engine manual for oil change recommendations. Type required: 12VDC. 18AH An electrical device that contains outlets and meters for controlling other electrical devices The electricity producing part of the generator. Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full. An acoustic device installed onto the exhaust system that is designed to reduce noise. The gasoline tank cap is extra-large, creating a large hole for refilling and a comfortable grip. Prevents gasoline vapors from exiting the fuel system. Refer to your Honda engine manual for air cleaner care. Used during cold starts. Refer to the Honda engine manual for usage.

Machine Component Identification
Items: 165605, 165606, 165607

Ref.
1 2 3 4 5 6 7

Description
Air Cleaner 11 Gallon Gas Tank Gasoline Tank Cap Choke Engine Key Switch Oil Drain Plug Oil Fill Port

Ref.
8 9 10 11 12 13 14

Description
Battery (not included) Control Panel Vibration Isolation Mount Generator Head Carbon Canister Fuel Valve Lever Muffler

11

Machine Component Identification
Items: 165605, 165606, 165607

REFERENCE GUIDE

Reference 1 ­ Air Cleaner Reference 2 ­ 11 Gallon Gas Tank
Reference 3 ­ Gasoline Tank Cap Reference 4 ­ Choke Reference 5 ­ Engine Key Switch
Reference 6 ­ Oil Drain Plug Reference 7 ­ Oil Fill Port Reference 8 ­ Battery (not included) Reference 9 ­ Control Panel Reference 10 ­ Vibration Isolation
Mount
Reference 11 ­ Generator Head Reference 12 ­ Carbon Canister Reference 13 ­ Fuel Valve Lever
Reference 14 ­ Muffler

Refer to your Honda engine manual for air cleaner care. Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full. The gasoline tank cap is extra-large, creating a large hole for refilling and a comfortable grip. Used during cold starts. Refer to the Honda engine manual for usage. The engine key switch is located on the engine. Always locate this switch and be familiar with its location before operating the generator. Refer to your Honda engine manual for oil change recommendations. Refer to your Honda engine manual for oil change recommendations. Type required: 12VDC. 35AH An electrical device that contains outlets and meters for controlling other electrical devices 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. The electricity producing part of the generator. Prevents gasoline vapors from exiting the fuel system 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. An acoustic device installed onto the exhaust system that is designed to reduce noise.

Initial Unpacking & Set-Up

WARNING
NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire.

Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously. 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:
· Devices without electric motors such as light bulbs, radios, and televisions have the same running and starting wattage.
· 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
10in. Table Saw 7-1/4in. Circular Saw 8in. Bench Grinder Air Conditioner – Central (24,000 BTU) Air Conditioner – RV (13,500 BTU) Air Conditioner – Window (10,000 BTU) Battery Charger: 100 Amp with 300 Amp Boost Battery Charger: 15 Amp Battery Charger: 60 Amp with 250 Amp Boost Belt Sander Ceiling Fan Clock Radio Clothes Dryer (electric) Clothes Dryer (gas)

Running Watts (Continuous)
1800 1400 1400 3800 1500 1200 2400 380 1500 1200 800 100 1800 700

Starting Watts (Surge) 4500 2300 2500 4950 3000 2200 7800 5750 2400 1200 5750 1200

13

Power Load Planning & Management (cont’d)

Device
Clothes Washer Coffee Maker Deep Freezer Desktop Computer w/ 17″ monitor Dishwasher (Hot Dry) Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles Electric Fry Pan Electric Range: 8in. Element Furnace Fan (Gas or fuel oil): 1/2 HP Furnace Fan (Gas or fuel oil): 1/4 HP Furnace Fan (Gas or fuel oil): 1/8 HP Garage Door Opener Hair Dryer Hot Plate Inkjet Printer Iron Laser Printer Lights (Ten 75 Watt light bulbs) Microwave Oven 1000W Milk Cooler Milker (Vacuum Pump): 2 HP Miter Saw – 10″ Oscillating Fan Portable Heater (Kerosene, Diesel: 150,000 BTU Pressure Washer: 1 HP Quartz Halogen Work light Reciprocating Saw Refrigerator Freezer Security System Space Heater Stereo Receiver Sump Pump: 1/2 HP Sump Pump: 1/3 HP Television 27″ VCR Water Heater (Electric 40gal) Water Well Pump (1/3hp 220v)

Running Watts (Continuous)
1150 1750 700 800 1500 600 440 100 2500 1300 2100 875 600 300 750 1250 2100 80 1200 950 750 1000 1100 1000 1650 200 625 1200 1000 1200 700 500 1800 450 1050 800 500 100 4000 1000

Starting Watts (Surge) 2300 1000 1500 900 600 2350 1000 500 1200 1800 2300 2400 400 1000 3600 2000 1500 2150 1300 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 & 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:
Device to be Powered Light Bulbs (10 ­ 75 watt) Refrigerator Freezer Microwave Oven 1000W Air Conditioner, Window (10,000 BTU) Sump pump (1/3 hp) Total

Greater of Starting/Running Wattage
750 W 1500 W 1000 W 2200 W 1300 W 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 & 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. 5. Grounding. 6. Battery installation (electric start models only).
Each of these steps is discussed in detail below:
1. Unpacking & 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. · If you have missing or damaged components, contact Product Support at 1-800-270-0810.
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 & 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. 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. The transfer switch must be installed in accordance with building electrical code and guidelines supplied by your power company.
2. As a 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 Back-up Power Source for a Building

Contact a licensed electrician to install an UL-approved transfer switch if you want to use your generator as a back-up power source for a building.
What does a transfer switch do? It:
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.

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 addition to isolating your generator from the utility system, the transfer switch connects your generator to a limited set of circuits in your building that have been chosen as critical to operate during a power outage.

17

Using as a Portable Power Source

Installation / Initial Set-Up
The generator may not power your entire home — you must work with the installing electrician to determine which devices/appliances you wish to power during an outage. The electrician can help you determine which circuits and devices can be powered simultaneously without overloading the generator.
(See the previous section of this manual entitled “Power Load Planning & 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).
3. 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle compatible with NEMA L5-30P mating plug)
4. 120 Volt, 20 Amp, duplex GFCI-protected straight-blade receptacles (NEMA 5-20R duplex receptacles compatible with NEMA 5-20P or 5-15P mating plugs) (ONLY APPLIES TO ITEM #165604)
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

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Item # 165604

Installation / Initial Set-Up

Item # 165605 &
165606
Item # 165607

1. Make sure you plug each electrical device/appliance into the correct generator outlet based on the device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet.
2. Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoorrated, grounded extension cords of the proper size. 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

Amps at Load 240V (watts)

10

2400

20

4800

30

7200

40

9600

50 12000

Maximum Extension Cord Length

10 Ga. #12 Ga. #14 Ga. #16 Ga. Cord Cord Cord Cord

250′ 150′ 100′

75′

125′

75′

50′

25′

60′

35′

25′

10′

30′

15′

10′

15′

WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.
3. All extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise damaged.
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.
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 surface.
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

WARNING: 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 at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY:

· 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.
· Never place the generator immediately adjacent to a building or other structure ­ allow at least 20 feet clearance.
· Place the generator so that the exhaust fumes will not be directed towards people or building air intakes.
· 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.
· Note that this generator is NOT designed 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.

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 ventilation

The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head.
WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures.
· Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.
· Never place the generator immediately adjacent to large objects or structures ­ allow at least a 7′ clearance.
· Do not run 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.
· Do not allow debris to accumulate and block airflow. · Do not operate with a tarp, blanket, or cover surrounding the generator.

No wet conditions
Hot exhaust clearance

Choose a location where the generator will NOT be exposed to rain, snow, or direct sunlight. Exposure to water can cause electric 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. The exhaust gas from your generator is extremely hot and can cause combustible materials to catch on fire.

· Make sure your generator’s exhaust system is at least 7 feet from all combustible materials and structures.

· Equip the engine with a spark arrester 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.

Away from dust/dirt

· Insert steel mesh of spark arrester inside exhaust pipe, and slide spark arrester over exhaust pipe. Secure with supplied screw.
· Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged and be familiar with its use.
Do not use the generator in extremely dusty or dirty conditions. Excessive dust and dirt can cause premature failure of the machine.

22

Hearing protection

Installation / Initial Set-Up
Generators can produce noise levels of up to 95 dB in close proximity, which can be dangerous to human hearing with prolonged exposure.
Hearing protection may be required for persons working within 15-20 feet of the running generator for an extended period of time.
WARNING: Never attempt to attach ductwork to the muffler system to lower noise levels. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator.

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

Item # 165601 Control panel
Ground

Grounding

If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a back-up power system, grounding may alternatively be completed through the building’s grounding system. Ask your electrician. If the generator is not grounded through your building’s electrical system, follow the procedure above.
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.

WARNING: 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.

Positive battery terminal

Negative battery terminal

Tie plate

1/4″-20 wing nut 1/4″-20 x 7″ bolt

Battery

Base

General Battery Safety Rules

· ALWAYS use eye protection when handling batteries. · NEVER smoke or work near sparks or other sources of ignition. · NEVER touch both battery terminals at the same time with your hand or
any non-insulated tools. · 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.

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. Starting the Engine 4. Checking Generator Output 5. Connecting Electrical Loads (Portable Power Generation) 6. Stopping 7. Storage & Exercise of Generator
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 follow safety rules may result in serious injury or death to the operator or bystanders.
· 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”).
· 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.
· 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.
· Under the influence. Never operate, or let anyone else operate, the generator while under the influence of alcohol, drugs, or medication.
· 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.
· Damaged. Do not operate the generator with damaged, missing, or broken parts. · Modifications. Do not modify the generator in any way. Modifications can create serious safety hazards
and will also void the warranty. · 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 factoryauthorized personnel. · 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

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 o Excessive vibration o Flame or smoke o Abnormal noise
· 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. (See Maintenance & Repair section of this manual for instructions on how to do this.)
· 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 poisoning.
· 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.
· 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.
· 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.
· Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running. · 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. · Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or flames. · 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.
· 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.
26

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. 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:
· 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.
· 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.
· 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.
· Keep nozzle in contact with container. Keep nozzle in contact with the portable container at all times while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device.
· 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) 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

Operation

Position generator
Ground generator

2. Preparing for Operation Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation.
WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. NEVER run generator inside any enclosed or semi- enclosed spaces, including homes, 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. Make sure the generator is grounded in accordance with instruction given in
“Installation & Initial Set-up, Step 5: Grounding the Generator” of this manual.

Perform scheduled maintenance as needed Check/add oil

WARNING: Electric shock hazard Always ensure generator is properly grounded to prevent electrical shock. Make sure that any regular maintenance has been performed as prescribed in this manual in the “Maintenance & Repair” section.
Refer to the engine owner’s manual for engine maintenance instructions
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.)
WARNING: 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.

Check/fill gasoline tank

IMPORTANT: Under long, continuous-run operating conditions, be prepared to:
· Check engine oil level every time you refuel the engine. · Change oil after the first 20 operating hours, and at least every 100
operating hours thereafter, or as directed in engine owner’s manual. Check the gasoline level in the generator’s tank. If needed, fill tank with fresh unleaded gasoline from a portable container, after first reading the warnings and instructions below.
28

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: · 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 OUTDOORS ­ 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.
   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: · 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

Operation

· Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed. ALWAYS place container on the ground to be filled.
· Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device.
· A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily.

5. Clean up gasoline spills /splashes immediately.
   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.

Inspect Fuel System / Check for Leaks

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 system & check for leaks BEFORE starting generator. Do not start generator until all needed repairs have been completed.
WARNING: Fuel leak hazard Gasoline is highly explosive and fuel leaks can result in fire or explosions. You can 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.

Personal Protection

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, · a damaged gasoline tank, or · a defective gasoline shut-off valve.

1. Hearing can be damaged from prolonged, close-range exposure to the type of 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

Operation
3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position. To restart a warm engine, move choke
lever to half choke or to RUN position. 4) Start the engine:
a. Recoil: – Move the engine on/off switch to the ON position. – Pull the starter grip lightly until you feel resistance, then pull the starter cord out briskly and rapidly. Allow starter cord to return slowly.
b. Electric: – Turn the engine key switch to the START position and hold it there until the engine starts. NOTE: If the 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 minutes. b. Check engine oil level each time you refuel. 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

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. 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. Start engine 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: Slight variation in voltage/speed with changing electrical loads

All engines have a tendency to slow down when a load is applied. When electrical loads are connected to the generator, the engine is more heavily loaded and as a result the speed drops slightly.
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 voltage 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

Operation

5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load.
Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source

WARNING: Do not overload generator. Make sure that combined starting and running loads do not exceed rated capacity of generator. Overloading the generator can cause damage to the generator and attached electrical devices, and may result in fire.

Using as a Portable Power Source
Using as a Back-up Power Source for a Building

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 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.
Each transfer switch installation will be unique.
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. 2. Turn engine on/off switch to OFF position. 3. Turn gasoline line shut-off valve to OFF position. 4. Remove spark plug to prevent accidental starting of engine.

33

Operation

7. 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. Detailed instructions are provided below.
Disconnect loads & When you are finished using the generator, disconnect all loads and turn off fuel supply turn off fuel supply:
1. Make sure all devices that were connected to the generator’s outlets have been disconnected.
2. Check to 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 location

Store the generator in a location that is: 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 starting

Remove key from starter (for electric start engines) and secure key in a 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 every 4 weeks

The generator should be exercised regularly. 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 maintenance

Perform periodic maintenance as directed in this manual to keep the generator in safe working condition.

34

Operation

Prepare engine for If you will not be able to exercise the generator regularly, you must

long term storage if prepare the engine for long term storage to prevent gum deposits from

needed

forming and causing malfunction of the engine.

Prepare engine for long term storage by:
o Removing all gasoline from the tank and carburetor
OR
o Adding fuel stabilizer to the gasoline (following manufacturer’s instructions)
Fuel stabilizer steps: 1. Ensure gasoline tank is full. 2. Add fuel stabilizer to fuel tank. 3. Run engine at least 10 minutes after adding stabilizer to allow it to
enter the fuel system. 4. Shut off engine 5. Disconnect spark plug wire and remove spark plug 6. Add one teaspoon oil through spark plug hole 7. Place rag over spark plug hole and turn starter (or pull the recoil) a
few times to lubricate the combustion chamber. 8. Replace spark plug, but do not reconnect the spark plug wire.

35

Maintenance & Repair
Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps.
WARNING ALWAYS shut off the engine and disconnect the spark plug(s) before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using.

Note: The generator head is a brush style head and requires maintenance. The bearing is a heavy-duty sealed ball bearing, which requires no maintenance or lubrication.

Follow safety rules

Maintenance & Repair
Read and follow these safety rules whenever you will be servicing the generator: · 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. · Replace guards. Make sure all guards and shields are replaced after servicing the generator. · 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. 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

Perform engine maintenance as specified in the engine owner’s manual. Engine maintenance items include:
1. Changing oil and oil filter 2. Air filter check/replacement 3. Spark plug cleaning and replacement 4. Fuel filter check/replacement 5. Fuel tank cleaning.

Check receptacles

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 fuel system / check for leaks

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.

Check GFCI (if equipped)

Once a month, test the Ground Fault Circuit Interrupter (GFCI) to protect against electrical shock due to failure of the GFCI. (Only for those models equipped with GFCI.)

36

Maintenance & Repair (cont’d)

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 & inspect spark arrester (if equipped)

Clean and inspect the spark arrester on muffler If the engine has been running, the muffler and spark arrester will be hot. Allow those to cool before servicing the spark arrester. Tools needed: Wire brush and Philip’s head screwdriver 1. Remove the securing screw from the top of the spark arrester. 2. Slide the spark arrester off the exhaust pipe. 3. Inspect the spark arrester mesh (screen). Replace spark arrester if mesh
(screen) is damaged. 4. Use a wire brush to lightly remove the carbon deposits from the spark
arrester mesh (screen). Be careful to avoid damaging the mesh (screen). 5. Slide the spark arrester over the exhaust pipe and align the hole to the 12
o’clock position. 6. Secure the spark arrester using the supplied screw.

Keep generator clean

Keep generator 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 maintain battery (if electric start)
Brush Assembly Maintenance

Inspect, recharge, and maintain your battery according to your battery manufacturer’s instructions. (Only for those models equipped with electric start.)
Do not store with battery charger always connected. Batteries that are overcharged can boil themselves dry and produce excessive amounts of hydrogen, an explosive gas. Inspect brushes every 12 months, or 200 hours. Replace brush assembly after 1000 hours of operation. Hours of operation and environmental conditions influence brush life. Look for excessive or uneven wear, if either condition is present, take the unit to a qualified repair technician.

IMPORTANT: 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.

Contact NorthStar Product Support at 1-800-270-0810 for any questions, problems, or parts orders.

37

Problem
Engine will not start. Voltage too low.
Circuit breaker trips.
Voltage too high.
Generator overheating. No output voltage.

Troubleshooting

Possible Causes

Possible Remedies

a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Stop switch in OFF position. a) Engine speed too slow.
b) Generator is overloaded.
c) Defective AVR (165601, 165603, 165604 only) a) Defective load connected to
generator. b) Defective receptacle. c) Generator overloaded.
a) Engine speed too high.
b) Defective AVR (165601, 165603, 165604 only) 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) Circuit breaker tripped.
g) Defective AVR (165601, 165603, 165604 only)

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 &
Mgt. section of this manual.) c) Bring generator to a qualified technician for
repair. a) Disconnect load.
b) Replace receptacle. c) Reduce the load. (See Power Load Planning &
Mgt. section of this manual.) a) Bring generator to a qualified technician for
adjustment. c) Bring generator to a qualified technician for
repair. a) Reduce the load. (See Power Load Planning &
Mgt. 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 circuit breaker and reduce loads
connected to the generator.

h) Defective Brush Assembly (165601, 165603, 165604 only)

h) Bring generator to a qualified technician for repair

Engine lacks power.
Engine shuts down during operation.

a) Generator is overloaded.
b) Dirty air filter. a) Out of fuel. b) Low oil level.

a) Reduce the load. (See Power Load Planning & Mgt. section of this manual.)
b) Clean or replace air filter. a) Fill fuel tank. b) Fill crankcase to proper oil level.

38

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. 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
· 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.
· 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.
· Adults only. Only trained adults should set up and operate the generator. Do not let children operate. · Under the influence. Never operate, or let anyone else operate, the generator while under the influence of
alcohol, drugs, or medication. · 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. · 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 factoryauthorized personnel. · Fuel/exhaust system. Never modify the exhaust system, fuel tanks, or fuel lines. Carbon monoxide poisoning, fire, or explosion could result. · 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 & 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: · Eye/skin protection. Always wear eye protection and protective clothing when connecting or disconnecting
battery. · Sparks/Smoking. Never smoke or work near sparks or other sources of ignition. · Electric shock. Never touch both battery terminals at the same time with your hand or any non-insulated tools. · 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 · 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
· Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable.
· Operate OUTSIDE only ­ dangerous carbon monoxide exhaust! Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the generator, shut off the engine and get to fresh air RIGHT AWAY. 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.
· No vehicle/marine use. This generator is NOT designed 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.
· 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.
· 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 building’s grounding system.
· 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 utility 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.
· Wet conditions. Water conducts electricity. Do not operate generator where it is wet. Operate on a dry surface under an open, canopy-like structure.
· 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.
· Hot exhaust – fires. Exhaust from engine can be extremely hot and cause fire. Position muffler at least 7′ from combustible objects during operation.
· Spark arrester. Equip engine with a spark arrester 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.
· 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
· 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.
· 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 needed.
Personal protective equipment
· 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.
· 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:
40

Summary of Important Safety Information for Operation (cont’d)
· Fuel outdoors. Fill fuel tank outdoors ­ never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result.
· Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel. Use an UL approved fuel container to transfer gas to the engine.
· Running / hot engine. A running engine is hot enough to ignite fuel. 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.
· 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.
· Replace cap. Replace gas cap securely before starting engine. · Spills. Clean up fuel spills immediately. 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. · On skin / clothes. If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately. · 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. · Gasoline storage. Store gasoline in a cool, dry place in an UL-approved, tightly sealed container.
Safety ­ During Use
· Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation.
· Know how to stop. Be thoroughly familiar with proper use of the equipment and all generator controls, output receptacles, and connections. Know how to stop the generator quickly if needed.
· Damaged. Do not operate the generator with damaged, missing, or broken parts. · 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 carbon monoxide poisoning. · 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. · Smoking/sparks. Never smoke near the running generator, and never operate near sources of sparks or flames. · 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. · Stabilize before connecting loads. Start generator and let engine stabilize before connecting electrical loads. · 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. · 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. · 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. · 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. · 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. · Avoid contact. Avoid contact with bare wires, terminals, connections, etc. while the unit is running. · 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.
41

Summary of Important Safety Information for Operation (cont’d)
· 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.
· Moving parts. Keep hands, feet, and apparel away from drive belts, fans, and other moving parts. Never remove any drive belt or fan guard while the unit is operating.
· Refueling. DO NOT refuel the engine until it has cooled at least two minutes. · Malfunction during operation. Immediately turn off the generator if any of the following conditions arise
during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire o Excessive vibration o Flame or smoke o Abnormal noise
· Adjusting / repairing. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the generator to prevent accidental starting.
Safety ­ After use
· Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine can be a fire hazard.
· Shut off fuel supply. Make sure gasoline shut-off valve is in the OFF position. · Prevent accidental starting. When generator is not in use, remove key from starter (key start engines) and
secure in a safe location, or remove spark plug(s) in order to ensure that generator cannot be started in a storage location or by untrained persons. · Storage location. 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. · Exercise regularly. Exercise generator every four weeks to dry out moisture that accumulates in the windings. If generator cannot be exercised on a regular basis, prepare generator for long term storage. · 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: · 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. · Replace guards / shields. Make sure all guards and shields are replaced after servicing the generator. · 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

Generator Exploded View Rev ­ AI
Item #s 165601, 165603, & 165604
43

Ref #
1 2A
2B
3 4
5
6 7 8 9 10
11
16
17
19
20
21 22 23 24 25 26 27 28 29 30 31 32 33 34
35
36
37
38
39
40 43 44 45

Generator Exploded View Rev ­ AI
Item #s 165601, 165603, & 165604

Part #

Description

Qty

Used on

791171 803568
803568
784959 795069 803315 803316 780061 793322 794658 796135 792933 794780 794617 786712 794606 803774 306459 794614 794615 785291 Northern # 349920 787698 785292 82377 82083 787619 30825 32848 804203 32844 785768 801491 801165 794462 784820 784821 795890 795891 802232 794754
801490
784707 782524 794699 803569 777834 30746

6 gallon fuel tank assembly w/cap 3/16″ fuel line, Hose
3/16″ fuel line, Hose
Fuel valve Roll cage
Muffler
Heat Shield, Outer-Muffler Bracket, Upper Heat Shield Heat Shield, Inner- Muffler Bracket, Lower Heat Shield Spacer, Heat Shield
Bracket, Support Heat Shield
Fuel cap with strainer
Generator head
Engine ground wire
Base
Positive battery cable Battery (not included) 12VDC. 18AH Battery stop Negative battery cable 1/4″-20 x 7″ HHSC, gr g zinc 1/4″-20 wing nut Battery tie plate 1″ iso mount Upper iso bracket Bracket, Mounting Carb Canister Lower iso bracket 3/8″ x 1/4″ hose mender Hose, 3/8″ fuel line Carbon canister (700CC) GX270 Honda engine, red GX390 Honda engine, red GX390 Honda engine, electric start
Control Panel
Tank bolt bar
Hose, 1/4″ fuel line
NorthStar decal
Heat shield 7/16″ Spring action hose clamp 1/4″ hose clamp 3/8″ Hose clamp

1 7 in 22 in 5 in
1 1
1
1 1 1 2 2
1
1
1
1
1
1 n/a 1 1 2 2 1 4 4 1 4 1 2 in 1
1
1
1 3.791 ft. 2.958 ft.
2
1 4 2 2

All 165601 165601 165603, 165604
All All 165601 165603, 165604 All All All All All 165601 165603, 165604 All 165601 165603, 165604 All 165601 165603, 165604 165604 165604 165604 165604 165604 165604 165604 All All 165601,165603,165604 All All All All 165601 165603 165604 165601 165603 165604 All 165601 165603, 165604 165601 165603, 165604
All
All
All
All

44

Generator Exploded View Rev ­ AI
Item #s 165605, 165606, & 165607
45

Ref # 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
39
40
41 42
43
44 45 46 48 49 50 51 52 53 54

Generator Exploded View Rev ­ AI
Item #s 165605, 165606, & 165607

Part # 791699 795073 803568 787525 795183 804630 783214 801490 783250 783260 783333 783410 802314 780061 783264 784957 795152 795130 803775 803776 803777 786712 795215 306459 801019 82377 777164 787453 Northern # 48737 777108 82083 787620 794783 795202 30825 795203 798109 785768 801491 783226 785264 795893 795895 795898 777834 31881 783277 783278 783279 795139 795132 795214 795204 787259 795181 30501 799297 30746 803569

Description 11 gallon fuel tank assembly w/cap Channel, roll cage 3/16″ fuel line, Hose Fuel valve Roll cage Carbon canister (1280CC) Ring, carbon canister Hose, 1/4″ fuel line Header assembly, muffler Upper mounting bracket, muffler Gasket, muffler Canister, muffler Spark arrester Heat shield, muffler Lower mounting bracket, muffler Shim, muffler AVR Mount Box AVR Support Bracket
Generator head
Fuel cap with strainer Lower iso mount bracket, gen head Engine ground wire Base 1/4″-20 x 7″ HHSC, gr g zinc Battery cable, positive Battery stop Battery (not included) 12VDC. 35AH Battery cable, negative 1/4″-20 wing nut Battery tie plate Deflector 1 Lower iso bracket 1″ iso mount Upper iso bracket Deflector 2 3/8″ x 1/4″ hose mender Hose, 3/8″ fuel line GX630 Honda engine GX690 Honda engine
Control panel
1/4″ hose clamp 3/4″ heat reflective sleeving
NorthStar decal
Tank heat shield Heat shield mount Upper iso mount bracket, gen head Adjustable bumper tab Grommet bumper Short adjustable bumper tab 1/4″ Split Loom AVR Excitation wire harness 3/8″ Hose clamp 7/16″ Spring action hose clamp

Qty 1 1
3.16ft 1 1 1 1
6.66ft 1 1 1 1 1 1 1 1 1 1
1
1 1 1 2 1 1 n/a 1 2 1 1 1 4 1 1 1 2 in
1
1
4 1.5 ft.
2
1 1 1 3 7 1 2.42 ft. 1 2 2

46

Used on All All
All All All All All All All All All All All All All All All All 165605 165606 165607 All All All All All All All All All All All All All All All All All All 165605, 165606 165607 165605 165606 165607 All All 165605 165606 165607 All All All All All All All All All All

Control Panel Parts List Rev ­ AI
Item # 165601
Item # 165603
Item # 165604
47

Control Panel Parts List Rev ­ AI
Item # 165605
Item # 165606
Item # 165607
48

Control Panel Parts List Rev ­ AI

Ref # 1 2 3 4
5
6 7
8
9
10 11 12 13 14 15 16 17 18 19
20

Part # 790409 783060 783058 783059
783061
783050 783053
783091
783085
783094 802231 783964 31953 783965 783966 305619 783133 786128 781830 783275
783134

Description Switch ­ 2 pole, red 8 AMP Circuit Breaker 300V Volt Meter 12VDC Outlet
20 AMP Circuit Breaker
NEMA L14-30 Receptacle NEMA 5-20 Receptacle

Qty 1 1 1 1
2
4
1
(4) duplexes

30 AMP Circuit Breaker

2

NEMA L5-30 Receptacle
Engine Switch w/ key, Electric Start GFCI 5-20R Receptacle 37 AMP Circuit Breaker 14-50 Receptacle 45 AMP Circuit Breaker 58 AMP Circuit Breaker 14-60R Outlet Grounding Post Panel Bolts Back Cover, Small (not shown) Back Cover, Large (not shown) Throttle Control Module for Idle Control (not shown, behind panel)

1
1
(4) duplexes 2 1 2 1 1 1 4
1
1

Used on 165601, 165603, 165604 165601, 165603, 165604
All 165601, 165603, 165604
165601
165603, 165604, 165605, 165606, 165607 All
165601, 165603, 165605, 165606, 165607
165603, 165604, 165605, 165606, 165607
165603, 165604, 165605, 165606, 165607
165604
165604 165605 165605, 165606 165606 165607 165607
All All 165601, 165603, 165604 165605, 165606, 165607
165604

49

Generator Head Exploded Views Rev ­ AI
Item #s 165601
50

Generator Head Exploded Views Rev ­ AH
Item #s 165601

Ref # 1
2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part # 796591
796580
796551 796586 796567 796576 796557 796553 795996 796564 796583 796563 795999 796581 796573 796558 796556 796588 796594 796574 796593

Description

Qty

Engine Adapter

1

Cover Band

1

Stator Assembly

1

Bearing Support

1

Hexagon Flange Bolt M6 x 140

5

Bridge Rectifier

1

Outer Hexagon Bolt M5 x 20

1

Terminal Block

1

AVR

1

Hexagon Flange Bolt M5 x 10

6

End Cover

1

Hexagon Flange Bolt M5 x 12

2

Carbon Brush

1

Rubber Boot

1

Flat Washer

1

Hexagon Flange Bolt 5/16-24 x 7.28″ 1

Rotor Assembly

1

Fan

1

Spring Washer

3

Flat Washer

3

Fan Bolts

3

Used On 165601
165601
165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601 165601

51

Generator Head Exploded Views Rev ­ AI
Item #s 165603, 165604
52

Generator Head Exploded Views Rev ­ AI
Item #s 165603, 165604

Ref # 1
2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part # 803811
803813
803814 803815 803816 803817 803818 803942 803943 803944 803945 803946 803803 803804 803819 803947 803821 803822 803823 803941 803937

Description Stator Assembly
Rotor Assembly
Engine Adapter Bearing Support End Cover Carbon Brush Terminal Block Assembly Bolt, Hex Flange M6x180 Bolt, Hex Flange ø8×230 Bolt, Hex Flange M5x16 Bolt, Hex Flange M5x20 Washer, Flat ø25xø8×2 Harness, Wire 10ga x 160 Harness, Wire 10ga x 160 Rubber Boot Bolt, M5x215 Nut, M5x5 Washer, Spring ø5 Rectifier AVR Cover Band

Qty

Used On

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

4

165603, 165604

1

165603, 165604

6

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

2

165603, 165604

2

165603, 165604

2

165603, 165604

1

165603, 165604

1

165603, 165604

1

165603, 165604

53

Generator Head Exploded Views Rev ­ AI
Item #s 165605
54

Ref # 1 2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Generator Head Exploded Views Rev ­ AI
Item #s 165605

Part # Description

Qty

803790 Stator Assembly

1

803793 Rotor Assembly

1

803796 Engine Adapter

1

803799 Bearing Support

1

803800 End Cover

1

803801 Carbon Brush

1

803802 Terminal Block Assembly

1

803948 Bolt, Hex Flange M8x165

4

803949 Bolt, Hex Flange M10x250

1

803944 Bolt, Hex Flange M5x16

6

803803 Harness, Wire 10ga x 160

1

803804 Harness, Wire 10ga x 160

1

803805 Harness, Wire 18ga x 620

1

803950 Washer, Flat ø34xø10.5×3.5

1

803806 AVR

1

803807 Rubber Boot

1

803808 Socket Jacket

1

803809 Conduit, ø20x.3, Black

1

803939 Cover Band

1

Used On 165605 165605
165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605 165605

55

Generator Head Exploded Views Rev ­ AI
Item #s 165606

Ref #

Part # Description

Qty

1

803791 Stator Assembly

1

2

803794 Rotor Assembly

1

3

803798 Engine Adapter

1

4

803799 Bearing Support

1

5

803800 End Cover

1

6

803801 Carbon Brush

1

7

803802 Terminal Block Assembly

1

8

803953 Bolt, Hex Flange M8x185

4

9

803954 Bolt, Hex Flange ø10×270

1

10

803944 Bolt, Hex Flange M5x16

6

11

803803 Harness, Wire 10ga x 160

1

12

803804 Harness, Wire 10ga x 160

1

13

803805 Harness, Wire 18ga x 620

1

14

803950 Washer, Flat ø34xø10.5×3.5

1

15

803806 AVR

1

16

803807 Rubber Boot

1

17

803808 Socket Jacket

1

18

803809 Conduit, ø20x.3, Black

1

19

803938 Cover Band

1

56

Used On 165606
165606
165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606 165606

Generator Head Exploded Views Rev ­ AI
Item #s 165607

Ref #

Part # Description

Qty

1

803792 Stator Assembly

1

2

803795 Rotor Assembly

1

3

803798 Engine Adapter

1

4

803799 Bearing Support

1

5

803800 End Cover

1

6

803801 Carbon Brush

1

7

803802 Terminal Block Assembly

1

8

803951 Bolt, Hex Flange M8x195

4

9

803952 Bolt, Hex Flange ø10×280

1

10

803944 Bolt, Hex Flange M5x16

6

11

803803 Harness, Wire 10ga x 160

1

12

803804 Harness, Wire 10ga x 160

1

13

803805 Harness, Wire 18ga x 620

1

14

803950 Washer, Flat ø34xø10.5×3.5

1

15

803806 AVR

1

16

803807 Rubber Boot

1

17

803808 Socket Jacket

1

18

803809 Conduit, ø20x.3, Black

1

19

803940 Cover Band

1

57

Used On 165607 165607
165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607 165607

This page has intentionally been left blank. 58

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 liability 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 # 165601, 165603, 165604,165605, 165606, 165607

Consumer Warranty Period 4 years from date of purchase by user

Commercial Warranty Period 2 years from date of purchase by user

Engine Warranty Item # 165601, 165603, 165604,165605, 165606, 165607

Consumer Warranty Period 3 years from date of purchase by user

Commercial Warranty Period 3 years from date of purchase by user

“Consumer use” means personal residential household and/or recreational use by a consumer. “Commercial use” means all other uses, including use for commercial, income producing, primary power, off grid power, 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 decision 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 and electrical brushes.

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 surrounding 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:

59

WARNING: This product can expose you to chemicals including
gasoline engine exhaust, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
Assembled by Northern Tool & Equipment Company, Inc.
Burnsville, MN 55306 NorthernTool.com
60

References

• P65Warnings.ca.gov
• p65warnings.ca.gov/

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