North Star M165912I.3 manual

M165912I.3 Owner’s Manual Instructions for I nstallation/Set- up, Operation, Servicing, & S torage Portable, Out door Use-Only, Gas oline G enerator 2,400 Watt C ontinuous (2,7 00 Watt Sur ge) Capacit y Can be used to power individual appliances plugged dir ectly into the generator’s outlets, or as a back -up connection to a building’s po[...]

Hazard Signal Word Definitions 2[...]

Table of Contents 3 Hazard Signal Word Definitions ................................................................................................. 2 About Your Generator ................................................................................................................. 4 Specifications ...............................................[...]

About Your Generator 4 Thank you for p urchasin g your NorthS tar portable generator! About Your Gene rator This engine-driven, portable generator is designed to provide up to 2700 Watts of electrical power (2400 watts continuous, 2700 watts surge). I t can suppl y power: 1. As a portable power source . You can plug appliances directly into the ge [...]

About Your Generator (cont’d) 5 Proper preparation, operation, and maintenance will result in operator safety , as well as best performance and long life of the ge nerator. For detailed engine operation and maintenance information, always refer to the engine Owner’s Manual furnished with the generator. NorthStar is constantly improving its prod[...]

Specifications 6 SPECIFICATIONS Item Number #165912 Maximum Output 2700 Watts ( W ) Continuous Output 2400 Watts ( W ) Generator Type Brushless Voltage 120 Volt (V) Phase Single phase Frequency 56.5 - 63.3 Hertz (Hz) Power Factor 1.0 p.f. Engine 5 Hp Honda GC160 AVXA Engine Speed 3390 - 3798 RPM Fuel Type Unleaded gasoline Fuel Capacity 2.12 quarts[...]

Safety Label Locations 7 PN 39260 BURN HAZARD Do not touch hot muffler. ©2005 NT+E 1-800-270-0810 WARNING Fig02663 Always make sure saf ety labels are in place and in good co ndition . If a safet y label is missing or not legibl e, order new labels o r unsaf e operation could r esult. To order replacement safety labels , call NorthStar Product Sup[...]

Machine Component Id en tification – 165912I.3 8 Figure 1 (Ref . 1-7) Ref. Description Ref. Description 1 Circuit Breaker 7 Choke Lever 2 120V 20A Duplex Rece ptacle 8 Ignition Switch Lever 3 Generator Head 9 Recoil 4 Oil Drain Plug 10 Gas Tank 5 Vibration Isolation Mo unt 11 Air Cleaner 6 Muffler Figure 2 (Ref . 7- 11)[...]

Machine Component Identification – 165912I.3 (cont’d) 9 REFERENCE GUIDE Reference 1 – Circuit Breaker This portable single phase generator has 1, 20 amp (A) push to reset circuit breaker to protect against electrical overloads. Reference 2 – (2) 120V 20A Duplex Receptacles The generator has a control panel with two 12 0V duplex (two recepta[...]

Power Load Planning & Management 10 WARNING NEVER exceed the rated wattage capacity of y our generator. OVERLOADING may cause SERIOUS DAMAGE to the g enerator and attached electrical devices, and may re sult in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powerin[...]

Power Load Planning & Management (cont’d) 11 Device Running Watts Device Running Watts Electric range (1 element) 1500 Refrigerator 600 (b) Electric skillet 1250 Slow cooker 200 Furnace fan (1/3 HP ) 1200 (a) Submersible pum p (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pum p (1 HP) 2000 (a) Hair dryer 1200 Submersible pum p (1/2 HP) 1500[...]

Installation / Initial Set- Up 12 There are a number of important steps required to set up y our generator for initial u se. These steps are: Steps for Installation / Initial Set- Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s r ated capacity. 3. Setting up generator for the type of power gene[...]

Installation / Initial Set- Up (cont’d) 13 3. Set-up either as a BUILDING BA CK- UP or PORTABLE Po wer Source This generator is designed to provide up to 2700W 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 electricia n to conn[...]

Installation / Initial Set- Up (cont’d) 14 In addition to isolating your gene rator from the utilit y 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. The generator cannot power your entire home -- y ou must work with the installin[...]

Installation / Initial Set- Up (cont’d) 15  Extension cords may be used to power de vices 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 a[...]

Installation / Initial Set- Up (cont’d) 16 4. Select a Suitable Sit e Before using the generator, y ou 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 su itable site fo r operat ing your g enerator to avoid equ ipment d amage and/or inj[...]

Installation / Initial Set- Up (cont’d) 17 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 v entilation can result in fire, po sing a serious risk to nea rby perso ns and structures.  Situate so there is adequa[...]

Installation / Initial Set- Up (cont’d) 18 5. Grounding the gen erator Always ensure the generator is properly grounded to prevent electr ical shock. You must always ground the generator by the following method when using the generator a s a portable electrical source: 1) Drive a ¾” or 1” c opper pipe or rod into the ground close to the gene[...]

Operation 19 Once you have set up your generator for use, it is time to start your g enerator. The following are the procedures necessary for safe, succe ssful 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 Electrica[...]

Operation (cont’d) 20  Malfunction du ring operation. I mm ediately turn off the gene rator if any of the following conditions arise during operation: o Excessive chang e in engine speed, slow or fast o Overheating in load connecting devices o Sparking or a rcs from g enerator o Loss of electr ical output o Receptacle dam age o Engine m isfire[...]

Operation (cont’d) 21 Static electricity and filling the gasoline tank: Static electric ity can initiate from unground ed gasoline tanks or containers, from flo wi ng gasoline, and from persons carry ing a stat ic electric charge Static electrici ty can explosiv ely ignite gaso line vapors that ar e present dur ing the fueling process, result ing[...]

Operation (cont’d) 22 2. Preparing for Oper ation Position generator Position generator in accordance with the instructions given in “Installation & Initia l Set - up, Step 4: Select a Suita ble 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, t[...]

Operation (cont’d) 23 WARN ING : Gasoline fire/ explosion haz ard Gasoline is hig hly flamm able and explosiv e. Heat, sparks, and flames can ignite gaso line vapors, which can becom e widespr ead during fu eling. A flash fire and /or explosio n could result and ca use serious in jury or death. Use ext reme care when han dling g asoline. Carefull[...]

Operation (cont’d) 24  Keep nozzle in contact with portable conta iner while fil ling. Manua lly control the flow of g asoline ; do NOT use th e nozzle’s l ock -open device.  A portable conta iner made of m etal or conduc tive plast ic is preferred because it dissipa tes charge to ground m ore readily. 5) Clean up gasoline spills /splashe[...]

Operation (cont’d) 25 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) Adjust choke: a) To start a cold engine, pull the choke rod to the CLOSED position. b) To restart a warm engine: i) If the engine has run out[...]

Operation (cont’d) 26 4. Checking Generato r Output Although the speed of the engine was carefully adjusted at the fac tory 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 gener ator . WARNING : The generator m[...]

Operation (cont’d) 27 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the g enerator, 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 Connec[...]

Operation (cont’d) 28 7. Storage & Exercis e When you are finished using the generator, you must: o Disconnect all loads o Store the generator properly o Plan on exercising the engine regular ly unless the generator is prepared for long-term storage. Detailed instructions are provided below. Disconnect loads When you are finished using the ge[...]

Operation (cont’d) 29 Prepare engine for long term storage if needed If you will not be able to exercise t he generator regularly, you must prepare the engine for long term storage to pre vent gum deposits from forming and causing malfunction of the engine. Prepare engine for long term storage by: o Removing all gasoline from the tank and carbure[...]

Maintenance & Repair 30 Inspect and maintain your generator as specified below in order to keep it in saf e and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engi ne, disconnect th e spark plug (s) and discharg e the capacitor before cleaning, ad justing, or servicing the generator[...]

Maintenance & Repair (cont’d) 31 Check GFCI (if equipped) Once a month, test the Ground F ault Circuit Interrupter (GFCI) to protect against electrical shock due to failure of the GFCI. (Onl y f or those models equipped with GFCI – See the “Specifications” section.) To test the GFCI: 1. Depress the TEST button. The RESET button should e[...]

Troubleshooting 32 TROUBLESHOOTING Problem Possible Cau ses Possible Remed ies Engine will not start. a) Low oil level. b) Fouled spark plug. c) Out of fuel. d) Ignition switch lever in OFF position. a) F ill crankcase to proper oil level. b) Clea n or replace spark plug. c) Fill f uel tank. d) Place ignition s witch lever in ON position. Voltage t[...]

Summary of Important Safety Information for Operation 33 This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary ha ndy and refer to it to refresh your memory about how to safely use y our generator. WARNING Carefully read and make sure y ou understand the follo[...]

Summary of Important Safety Information for Operation (cont’d) 34 licensed electrician i nstalls the generator with a connection t o your building’s electrical cir cuit for use as a standby power syste m, grounding will be co mplete through the buildi ng’s grounding system.  Isolate connection t o building’s electrica l circuit . Never p[...]

Summary of Important Safety Information for Operation (cont’d) 35 Safety – Durin g Use  Safety equipment / contro ls . Always op erate the generator with all safety covers, guards, and barr iers in place and in good working order, and all co ntrols proper ly adjusted for safe operation.  Know how to stop . Be thoroughly familiar with prop[...]

Summary of Important Safety Information for Operation (cont’d) 36 Safety – After use  Cool engine before storing. Let e ngine cool for at least f ive minutes before storin g. A hot engine can be a fire hazard.  Prevent accidenta l starting. When generator is not in use, remove key fro m starter (key start engines) and secure in a safe loc[...]

Generator Exploded View 165912 - Rev I.3 37[...]

Generator Exploded View 165912 – Rev I.3 38 Diag # Part # Description Qty 1 305491 Honda 5 hp Engine 1 2 780422 Engine Adapter Plate 1 4 780423 Fan & bolts 1 5 31193 Drive End Bracket 1 7 780424 Enclosing Band 1 9 306426 120V, 20A, NEMA 5-20R Receptacle 2 10 30643 20A Circuit Breaker 1 11 31177 End Cover 1 14 30815 Hole Plug 1 15 38271 End Co[...]

Wiring Diagram 165912 - Rev I.3 39 Diag # Part # Description Qty 1 305555 Connector Wire Harness 1 2 306496 W ire Assembly ( W 43, G41, G42) 1 B46 306571 Black Terminated W ire 1 B52 305556 Black Terminated W ire 1 W 55 305557 W hite Terminated W ire 1[...]

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Limited Warranty 41 Dear Valued Customer: The NorthStar Product you j ust purchased is built with the finest material and crafts manship. Use this p roduct properly an d enjoy the benefits fro m its high p erformance. By p urchasing a NorthStar product, y o u show a desire f or quality and durability. Li ke all mechanical equip ment this unit requi[...]

42 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com[...]