NorthStar 165601 Owner'S Manual Download Page 44

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Generator Exploded View Rev – O.3

Item #s 165601, 165603, & 165604

Ref #

Part #

Description

Qty

Used on

786710

6.5 gallon fuel tank assembly w/cap

All

785337

4.5mm fuel line

6 in

165601

785337

4.5mm fuel line

7 in

165601

5 in

165603, 165604

784959

Fuel valve

All

787295

Roll cage

All

784974

Exhaust pipe

165601

784975

165603, 165604

785352

Muffler gasket

All

784699

Muffler

All

784792

Heat shield, out - muffler

All

785269

Heat shield, side - muffler

All

784795

Iso mount – heat shield

All

784709

Muffler hanger

All

784791

Heat shield, in - muffler

All

784710

Mount, muffler

All

782487

Strap, muffler

All

777110

1/2” hose clip

165601

786712

Fuel cap with strainer

All

784971

Generator head

165601

784972

165603, 165604

777302

Base bracket

165601

782435

165603, 165604

306459

Engine ground wire

All

784706

Base

165601

782306

165603, 165604

785291

Positive battery cable

165604

Northern # 349920

Battery (not included) 12VDC. 18AH

n/a

165604

785607

Battery stop

165604

785292

Negative battery cable

165604

82377

1/4”-20 x 7” HHSC, gr g zinc

165604

82083

1/4”-20 wing nut

165604

787619

Battery tie plate

165604

30825

1” iso mount

All

32848

Upper iso bracket

All

783217

Carbon canister strap

All

32844

Lower iso bracket

All

785768

3/8” x 1/4” hose mender

All

785755

3/8” fuel line

1.5 in

All

782126

Carbon canister

All

784819

GX270 Honda engine, red

165601

784820

GX390 Honda engine, red

165603

784821

GX390 Honda engine, electric start

165604

783072

Control Panel

165601

783075

165603

787668

165604

787300

Tank bolt bar

All

777345

1/4” fuel line hose

3 ft

All

784707

NorthStar decal

165601

782524

165603, 165604

787306

Heat shield

All

787307

Adjustable bumper tab

All

787259

Grommet bumper

All

786123

3/8” Spring action hose clamp

165601

165603, 165604

Summary of Contents for 165601

Page 1: ...tor 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 ventila...

Page 2: ...Hazard Signal Word Definitions 2 ...

Page 3: ... PORTABLE Power Source 17 4 Selecting a Suitable Site 21 5 Grounding the Generator 23 6 Battery Installation 24 Operation 1 General Safety Rules for Operation 25 2 Preparing for Operation 28 3 Starting the Engine 31 4 Checking Generator Output 32 5 Connecting Loads 33 6 Stopping the Engine 33 7 Storage Exercise 34 Maintenance Repair 36 Troubleshooting 38 Summary of Important Safety Information for...

Page 4: ...erator 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 recom...

Page 5: ...ny 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 t...

Page 6: ...21 25 Height 22 25 22 25 Dry Weight 174 lb 200 lb Item Number 165604 165605 Maximum Output 8000 Watts W 10000 Watts W Continuous Output 6600 Watts W 8500 Watts W Voltage 120 240 Volt V 120 240 Volt V Phase Single phase 4 wire Single phase 4 wire Frequency 56 5 63 3 Hertz Hz 56 5 63 3 Hertz Hz Power Factor 1 0 p f 1 0 p f Engine Honda GX390 Honda GX630 Engine Speed 3390 3798 RPM 3390 3798 RPM Fuel ...

Page 7: ...gine Speed 3390 3798 RPM 3390 3798 RPM Fuel Type Non leaded automobile gasoline Non leaded automobile gasoline Fuel Capacity 11 gallons 11 gallons Oil Capacity see Honda Manual see Honda Manual Starting Method Electric Electric Battery not included 12VDC 35AH 12VDC 35AH Battery Dimensions L x W x H 7 69 x 5 13 x 7 L x W x H 7 69 x 5 13 x 7 Dimensions Length 32 38 32 38 Width 24 38 24 38 Height 26 ...

Page 8: ...S 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 disconnec...

Page 9: ...n 1 Recoil 9 Generator Head 2 Fuel Valve Lever 10 6 5 Gallon Gas Tank 3 Engine Key Switch 165604 only 11 Muffler 4 Vibration Isolation Mount 12 Gasoline Tank Cap 5 Oil Drain Plug 13 Carbon Canister 6 Oil Fill Port 14 Air Cleaner 7 Battery not included 165604 only 15 Choke Lever 8 Control Panel ...

Page 10: ... recommendations Reference 6 Oil Fill Port Refer to your Honda engine manual for oil change recommendations Reference 7 Battery not included Type required 12VDC 18AH Reference 8 Control Panel An electrical device that contains outlets and meters for controlling other electrical devices Reference 9 Generator Head The electricity producing part of the generator Reference 10 6 5 Gallon Gas Tank Large...

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

Page 12: ...ommendations Reference 7 Oil Fill Port Refer to your Honda engine manual for oil change recommendations Reference 8 Battery not included Type required 12VDC 35AH Reference 9 Control Panel An electrical device that contains outlets and meters for controlling other electrical devices Reference 10 Vibration Isolation Mount The engine and generator are mounted on rubber cylinders that absorb most of t...

Page 13: ...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 ...

Page 14: ...0 Inkjet Printer 80 Iron 1200 Laser Printer 950 Lights Ten 75 Watt light bulbs 750 Microwave Oven 1000W 1000 Milk Cooler 1100 1800 Milker Vacuum Pump 2 HP 1000 2300 Miter Saw 10 1650 2400 Oscillating Fan 200 400 Portable Heater Kerosene Diesel 150 000 BTU 625 1000 Pressure Washer 1 HP 1200 3600 Quartz Halogen Work light 1000 Reciprocating Saw 1200 2000 Refrigerator Freezer 700 1500 Security System...

Page 15: ...es on your list This total must be lower than the continuous output rating of your generator Example Device to be Powered Greater of Starting Running Wattage Light Bulbs 10 75 watt 750 W Refrigerator Freezer 1500 W Microwave Oven 1000W 1000 W Air Conditioner Window 10 000 BTU 2200 W Sump pump 1 3 hp 1300 W Total 6750W In this example the generator must have a continuous output of at least 6750 wat...

Page 16: ...on 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 components contact Product Support at 1 800 270 0810 If you have damaged components...

Page 17: ... 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 ...

Page 18: ... 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 wi...

Page 19: ...d 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 outdoor rated grounded extension cords of the proper size Use Table 2 below to choose an adequately sized extension cord according to the amperage of the device being used and the length of the cord Item 165604 Item 165605 165606 Item 165607...

Page 20: ...ed 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 dama...

Page 21: ...ow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning The location you choose to operate the generator must be OUTDOORS and away from all air intakes 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 ...

Page 22: ... at least 7 from exhaust and allow for adequate clearance above generator so that heat does not build up Hot exhaust clearance 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 buildings structures Equip the engine with a spark arrestor if the gene...

Page 23: ...4 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 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 comple...

Page 24: ... below 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 ...

Page 25: ... 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...

Page 26: ...e 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 co...

Page 27: ...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 sp...

Page 28: ...l shock Perform scheduled maintenance as needed 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 add oil Check the oil level using the dipstick and add oil as needed Using a funnel add oil up to the FULL mark on the dip stick with the recommended oil ...

Page 29: ...o 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 avo...

Page 30: ... 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 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 b...

Page 31: ...econds 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...

Page 32: ...easured 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 ...

Page 33: ...ecommended 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 ...

Page 34: ...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 ...

Page 35: ...ng 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 h...

Page 36: ...rging the capacitor 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 appro...

Page 37: ...r 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 Inspect recharge and maintain your batte...

Page 38: ...heating a Generator is overloaded b Insufficient ventilation 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 No output voltage a Defective load connected to generator b Broken or loose wire c Defective receptacle d Defective stator e Defective rotor f Defective capacitor g Circuit breaker tripped a Dis...

Page 39: ... 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 factory authorized 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...

Page 40: ...cal 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 o...

Page 41: ...ion 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 ...

Page 42: ... 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...

Page 43: ...Generator Exploded View Rev O 3 Item s 165601 165603 165604 43 ...

Page 44: ...e 1 All 20 784706 Base 1 165601 782306 165603 165604 21 785291 Positive battery cable 1 165604 22 Northern 349920 Battery not included 12VDC 18AH n a 165604 23 785607 Battery stop 1 165604 24 785292 Negative battery cable 1 165604 25 82377 1 4 20 x 7 HHSC gr g zinc 2 165604 26 82083 1 4 20 wing nut 2 165604 27 787619 Battery tie plate 1 165604 28 30825 1 iso mount 5 All 29 32848 Upper iso bracket ...

Page 45: ...Generator Exploded View Rev O 3 Item s 165605 165606 165607 45 ...

Page 46: ... head 1 All 23 306459 Engine ground wire 1 All 24 787370 Base 1 All 25 82377 1 4 20 x 7 HHSC gr g zinc 2 All 26 777164 Battery cable positive 1 All 27 785609 Battery stop 1 All 28 Northern 349900 Battery not included 12VDC 35AH n a All 29 777108 Battery cable negative 1 All 30 82083 1 4 20 wing nut 2 All 31 787620 Battery tie plate 1 All 32 785299 Deflector 1 1 All 33 787375 Lower iso bracket 1 Al...

Page 47: ...Control Panel Parts List Rev O 3 47 Item 165601 Item 165603 Item 165604 ...

Page 48: ...Control Panel Parts List Rev O 3 48 Item 165605 Item 165606 Item 165607 ...

Page 49: ...ker 2 165603 165604 165605 165606 165607 9 783085 NEMA L5 30 Receptacle 1 165603 165604 165605 165606 165607 10 783094 Engine Switch w key Electric Start 1 165604 11 783132 GFCI 5 20R Receptacle 4 duplexes 165604 12 783964 37 AMP Circuit Breaker 2 165605 13 31953 14 50 Receptacle 1 165605 165606 14 783965 45 AMP Circuit Breaker 2 165606 15 783966 58 AMP Circuit Breaker 1 165607 16 305619 14 60R Ou...

Page 50: ...Generator Head Exploded Views Rev O 3 Item s 165601 165603 165604 165605 50 ...

Page 51: ...5604 165605 7 MA306408 End Cover Plug 1 165601 38271 165603 165604 165605 8 786124 Stator 1 165601 786125 165603 165604 779787 165605 9 778956 Rotor w Diode and Varistor 1 165601 779788 165603 165604 779560 165605 10 MA307479 Diode 2 All 11 778957 Securing Stud 1 165601 779790 165603 165604 779561 165605 12 MA307485 Bearing 1 165601 MA38276 165603 165604 165605 14 MA306417 Non Drive End Bracket 1 ...

Page 52: ...Generator Head Exploded Views Rev O 3 Item s 165606 165607 52 ...

Page 53: ...ll 9 MA31015 M5 X 8 10mm Long 4 All 10 N A Rubber Cup 2 All 11 MA306403 Rear Bearing 1 All 12 MA306416 Nyloc Nut and Star Washer 1 All 13 MA30997 Grill 1 All 14 MA31065 Securing Stud Cap 1 All 15 MA30999 Fixing Ring 1 All 16 MA30992 Rotor Assembly 1 All 17 MA307479 Diode 2 All 18 MA307481 Varistor 2 All 19 MA31021 Capacitor 31 5 uF 2 165606 MA9910303129 Capacitor 35 uF 165607 20 N A Frame and Stat...

Page 54: ...54 This page has intentionally been left blank ...

Page 55: ... 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 ce...

Page 56: ...56 Assembled by Northern Tool Equipment Company Inc Burnsville MN 55306 NorthernTool com ...

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