North Star Portable Generator 8000 IPG User Manual

MODEL 8000 IPG, ITEM # 165920  
Industrial Portable Generator  
M165920F  
P r o v e n P e r f o r m a n c e  
OWNER’S MANUAL  
Any Questions, Comments, or Problems?  
Call Customer Service at 1-800-270-0810  
 
SPECIFICATIONS  
Item Number  
Maximum Output  
Continuous Output  
Voltage  
165920  
8000 Watts (W)  
6600 Watts (W)  
120 / 240 Volt (V)  
Phase  
Single phase (4-wire)  
Frequency  
56.5 - 63.3 Hertz (Hz)  
Power Factor  
Engine  
1.0 p.f.  
13 HP Honda GX390  
Engine Speed  
Fuel Type  
3390 - 3798 RPM  
Unleaded gasoline  
Fuel Capacity  
Oil Capacity  
Starting Method  
120 VReceptacle  
6.5 gallons (24.6 L)  
1.16 US quarts (1.1 L)  
Electric Start / Recoil  
(2) 20 Amp (A) duplex GFCI (NEMA 5-20R)  
(1) 30 Amp (A) twistlock (NEMA L5-30R)  
(1) 50 Amp (A) straight blade (NEMA 5-50R)  
30 Amp (A) twistlock (NEMA L14-30R)  
(2) 20 Amp (A) Thermal, push to reset  
(1) 30 Amp (A) Thermal, push to reset  
(1) 50 Amp (A) Thermal, push to reset  
(1) 30 Amp (A) Magnetic, 2 Pole  
Receives 10 Ga. wire or fork terminal  
Use a 12-volt battery with an amperage rating  
of at least 18Ah (Amp-Hour).  
120/240 VReceptacle  
Circuit Breaker  
Grounding Post  
Battery Requirements  
Dimensions  
Length  
Width  
Height  
Dry Weight  
Gross Weight  
31.75” (80.6 cm)  
23.63” (60.0 cm)  
22.25” (56.5 cm)  
225 lb (103 kg)  
280 lb (128 kg)  
MACHINE COMPONENT IDENTIFICATION  
2
 
Figure 1 (Ref. 1-7)  
Ref. Description  
00576  
Ref. Description  
1
2
3
4
5
6
7
Air Cleaner  
Starting/Stopping Instructions  
Oil Drain Plug  
Control Panel  
Gas Cap with Gauge  
6.5 Gallon Gas Tank  
Super Silent Muffler  
8
9
Generator Head  
Battery Box  
Vibration Isolation Mount  
Recoil  
Fuel Shut-Off Valve  
Choke Lever  
Electric Stop/Start Switch  
10  
11  
12  
13  
14  
Figure 2 (Ref. 8-14)  
fig. 01810  
3
 
Reference 14 - Electric Start/Stop Switch. The  
engine key is located on the engine. Always locate this  
switch and be familiar with its location before operating the  
generator.  
GENERATOR FEATURE  
Reference 1 - Air Cleaner. Refer to your Honda  
engine manual for air cleaner care.  
Reference 15 and 16 – Reserved for future use.  
Reference 2 - Starting/Stopping Instructions.  
Reference 3 - Oil Drain Plug. Refer to your Honda  
engine manual for oil change recommendations.  
Reference 4 - Control Panel. See Fig. 3 for details.  
Reference 5 - Gas Cap with Gauge. The gas cap is  
extra large, creating a large hole for refueling. You can  
monitor the fuel level without removing the cap by using  
the fuel level indicator built into the gas cap.  
Reference 6 - 6.5-Gallon Gas Tank. Large tank  
allows for extended run capabilities. ALWAYS allow room  
for gasoline expansion by not filling the gas tank  
completely full.  
CONTROL PANEL IDENTIFICATION  
Figure 3 (Ref. 17-30)  
Ref. Description  
01937  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
Full Power Switch  
Voltmeter  
Hour Meter  
120V/240V-30ATwist-lock Receptacle  
Grounding Post  
120V-30A Twist-lock Receptacle  
120V-50A Straight Blade Receptacle  
120V-20A Duplex Receptacle  
120V-20A GFCI Duplex Receptacles  
20A Circuit Breaker  
30A Circuit Breaker  
50A Circuit Breaker  
Reference 7 - Super Silent Muffler. 4 dB less than  
Honda’s standard muffler.  
Reference 8 - Generator Head.  
The electricity  
producing part of the generator.  
Reference 9 - Battery Box. Warning: Always wear  
safety glasses when working on or near the battery.  
The battery box provides protection for the battery and will  
accept a standard lawn tractor size battery (Group U1-7).  
The engine requires a 12-volts battery, with a minimum  
rating of 18Ah (Amp-Hour). When installing the battery,  
always connect the red colored (“positive” or “+”) cable  
first. When disconnecting the battery, always remove the  
black colored (“negative” or “-”) cable first.  
Main Line Circuit Breaker 30A  
Idle Control On/Off Switch  
Reference 17 - Full Power Switch. The switch  
reconnects the two generator windings from parallel (120V  
only) to series (120/240V).  
WARNINGSulfuric acid is a corrosive poison.  
Avoid contact with skin, eyes or clothing. Always wear  
safety gl asses.  
120V Only: Allows all 6600 watts (55A) to be used in  
any combination of 120 volt receptacles. The  
120/240V 30A twist-lock receptacle is 120V only at this  
time.  
120/240V : Allows all 6600 watts to be used for 240V.  
However, only half the power or 3300 watts (27.5A),  
can be used at any one 120V receptacle. 120V output  
can total 6600 watts.  
Reference 10 - Vibration Isolation Mounts. 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.  
Reference 11 - Recoil. Grasp firmly when starting  
engine.  
Reference 12 - Gas Line Valve. The engine is  
equipped with an ON-OFF valve located on the left side of  
the recoil. ALWAYS keep this valve closed when the  
generator is not in use.  
Reference 13 - Choke Lever. Used during cold  
starts. Refer to the starting/stopping instructions and the  
Honda engine manual for usage.  
Reference 18 - Voltmeter. Voltmeter needle should  
be in green area during all generator load conditions.  
Reference 19 - Hour Meter.  
Allows for better  
maintenance scheduling of generator.  
Reference 20 - 120/240V 30A Receptacle. This  
receptacle is a NEMA L14-30P twist-lock device, and is  
capable of drawing 30 amps. This receptacle accepts only  
NEMA L14-30P plugs. Use this receptacle if installing a  
transfer switch.  
Reference 21 - Grounding Post.  
Ground the  
generator via the grounding post, to a copper pipe or rod  
RE CEPTA CLES  
that is driven down until it reaching moist soil.  
IDLE CO NTR OL  
References 22-25 - 120V Receptacles.  
The  
generator has a control panel with:  
Reference 22  
receptacle, capable of drawing 30 amps. This  
-
One NEMA L5-30R twist-lock  
HO UR M ETE R  
receptacle accepts a NEMA L5-30P plug.  
G
H
@
H
?
4
 
engine operation and maintenance always refer to the  
Honda engine owner’s manual furnished with the  
generator (Honda refers to the 13 HP engine as a GX390).  
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 of any modification and/or  
alterations on this equipment from original design and  
manufacture.  
Reference 23 - One straight-blade 120V receptacle  
capable of drawing 50 amp, NEMA 5-50R. This  
accepts a NEMA 5-50P plug.  
Reference 24 - One duplex (two receptacles in a  
common housing) 120V straight-blade receptacle  
capable of drawing 20 amp, National Electrical  
Manufacturer’s Association (NEMA) part number 5-  
20R. This receptacle accepts a NEMA numbers 5-  
15P or 5-20P plugs. This receptacle is GFCI protected  
by reference 25. To reset this receptacle, press the  
reset button on item 25.  
Before using, the user shall determine the suitability of  
this product for its intended use and assumes liability  
therein.  
Reference 25 – One duplex (two receptacles in a  
common housing) 120V GFCI  
straight-blade  
receptacles capable of drawing 20 amps, National  
Electrical Manufacturer’s Association (NEMA) number  
5-20R. This receptacle accepts a NEMA number 5-  
15P or 5-20P plug. This receptacle has a test and  
reset button located on the receptacle face.  
ALWAYS use grounded male plugs. The neutral line  
of the generator is mechanically grounded to the  
frame. Matching NEMA male plugs must always be  
used.  
ANSI SAFETY DEFINITIONS  
DANGER indicates an imminently hazardous  
situation which, if not avoided, will result in death or  
serious injury. This signal word is to be limited to the most  
extreme situations.  
WARNING indicates  
a
potentially hazardous  
situation which, if not avoided, could result in a death or  
serious injury.  
WARNING Contact a licensed electrician to  
wire electrical plugs and/or cord-sets. Improper wiring  
could result in a fire or electrical shock.  
References 26-29 - Circuit Breakers. This portable  
generator has:  
CAUTION indicates  
a
potentially hazardous  
situation, which if not avoided, may result in minor or  
moderate injury. It may also be used to alert against  
unsafe practices.  
Reference 26 - 1 - 20 amp (A) push-to-reset circuit  
breaker  
Reference 27 - 1 - 30 amp (A) push-to-reset circuit  
breaker  
Reference 28 - 2 - 50 amp (A) push-to-reset circuit  
breaker  
Reference 29 - 1 - 30 amp (A) magnetic 2-pole main  
circuit breaker to protect against electrical overloads.  
RULES FOR SAFE OPERATIONS  
Safety precautions are essential when operating this  
generator. Respectful and cautious operation will  
considerably lessen the possibilities of a personal injury.  
This manual will warn of specific personal injury potential,  
and these will be designated by the symbol:  
Reference 30 - Idle Control On/Off Switch. This  
feature senses the load on the generator. With no load on  
the generator the engine speed drops to idle. This saves  
fuel and lengthens engine life. When a load is applied, the  
engine speed returns to 3600 - 3780 RPMs. Turning the  
switch off disables the sensing device and the generator will  
run at 3600 - 3750 RPM whether or not a load is applied.  
Note: When the engine is idling, it is normal for the  
voltmeter needle to be in the red range.  
Low Oil Shutdown. The Honda engine is protected  
against damage resulting from low oil level. As the oil falls  
below the safe level, the engine automatically shuts off (the  
engine stop switch remains in the on position). The engine  
will not start until the oil is refilled to above the safe level.  
WARNING This generator is equipped with a  
grounding post, located on the control panel for your  
protection. Always complete the grounding path from the  
generator to a copper pipe/rod that is driven into moist  
earth, to prevent electrical shock.  
ALWAYS use electrical cords that are in good  
condition. Worn, bare, frayed or otherwise damaged cords  
can cause electric shock.  
NEVER 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.  
ALWAYS use a ground fault circuit interrupter (GFCI)  
in damp or highly electrical conductive areas and on  
construction job-sites to prevent electric shock.  
INTRODUCTION  
Before starting your generator, thoroughly study the  
instructions and cautions in this manual to assure you are  
fully acquainted with the operation of all components of  
this generator. Proper preparation, operation and  
maintenance will result in operator safety, best  
performance and long life of the generator. For detailed  
5
 
ALWAYS remove the spark plug or spark plug wire  
before working on the engine or generator, to prevent  
accidental starting.  
NEVER install your generator inside confined areas.  
Inside installation can cause health hazards or death.  
ALWAYS provide adequate ventilation. Do not operate  
generator in any enclosed or narrow space. Engines  
consume oxygen and give off deadly carbon monoxide  
poisonous gas. Improper ventilation will cause damage to  
generator and possible injury to people.  
NEVER touch hot muffler, hot exhaust manifold or  
engine cooling fins.  
DANGER Remember, exhaust fumes are  
deadly carbon monoxide gas, and must be vented to the  
outside where there are no people.  
Cooling air of  
sufficient amounts must be allowed to flow in and  
exhausted out to ensure proper cooling of the engine and  
generator head.  
ALWAYS remove all oil or gasoline deposits and  
accumulated dirt from generator and immediate area.  
Keep generator head and engine clean.  
NEVER operate the generator under the following  
conditions:  
LOAD APPLICATION  
It is important to determine the total electrical load  
before it is connected to the generator. The two major  
factors in determining the life of a generator head are heat  
build-up, caused by overloading the generator and  
corrosive contaminants that can attack the wiring  
insulation. If the generator is overloaded, the wires  
become excessively hot and cause the insulation to break  
down, reducing its ability to resist corrosive contaminants.  
Over time the effectiveness of the insulation is eliminated  
and a dead short can result.  
A. Excessive change in engine speed, slow or  
fast.  
B. Overheating in load connecting devices.  
C. Sparking or arcs from generator.  
D. Loss of electrical output.  
E. Damaged receptacles.  
F. Engine misfire.  
G. Excessive vibration.  
H. Enclosed compartments, or confined areas.  
I. Flame or smoke.  
J. Rain, snow or wet conditions.  
K. Operator non-attendance.  
L. Excessive overload of generator.  
M. Wire with too small a gauge for the load.  
Always compare the generator nameplate data with  
that of the equipment to be used to ensure that watts,  
volts, amperage, and frequency requirements are suitable  
for operating equipment. The wattage listed on the  
equipment nameplate is its rated output. However, some  
equipment may require three to ten times more wattage  
than its rating on the nameplate, as the wattage is  
influenced by the equipment efficiency, power factor and  
starting system. NOTE: If wattage is not given on  
equipment nameplate, approximate wattage may be  
determined by multiplying nameplate voltage by nameplate  
amperage.  
WARNING 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.  
Correct any defects before operation.  
VOLTS X AMPS = WATTS  
Example: 120V X 5A = 600W  
WARNING Keep the fire extinguisher close  
by your generator and be familiar on how to use it.  
Consult your local fire department for correct extinguisher  
type.  
When connecting  
a
resistive load such as  
incandescent lights, heaters or common electric power  
tools, a capacity of up to the generator full rated wattage  
output can be used.  
When connecting a resistive-inductive load such as a  
fluorescent or mercury light, transformers or inductive  
coils, a capacity of up to 0.6 times the generators full rated  
output can be used.  
Always allow the generator to reach operating speed  
before a load is applied.  
INSTALLATION  
OUTDOORS: Choose locations where the generator  
will not be exposed to rain, snow or direct sunlight.  
Position the generator on secure, level ground so it will not  
tip or slide down a hill. Place the generator so that the  
exhaust fumes will not be directed towards people.  
The installation site must be free from water, moisture,  
or dust. All electrical components should be protected  
from excessive moisture or the insulation system will  
deteriorate and result in grounding or shorting out the  
generating system.  
STARTING ELECTRIC MOTORS  
Electric motors require much more current (amps) to  
start than to run. Some motors, particularly low cost split-  
phase motors, are very hard to start and require 5 to 7  
times more current to start than to run. Capacitor motors  
are easier to start and usually require 2 to 4 times more  
current to start than to run. Repulsion-Induction motors  
Foreign matters, such as dust, dirt, sand, lint, or  
abrasive materials can cause damage to the generator  
head and engine if allowed into its cooling system.  
6
 
are the easiest to start and require 1.5 to 2.5 times more to  
start than to run.  
20  
30  
40  
50  
4800  
7200  
9600  
12000  
125’  
60’  
30’  
75’  
35’  
15’  
*
50’  
25’  
10’  
*
25’  
10’  
*
Most fractional motors take about the same amount of  
current to run them whether they are of Repulsion-  
Induction (RI), Capacitor (Cap), or Split-Phase (SP) type.  
The following chart shows the approximate current  
required to start and run various types and sizes of 120  
volt 60 cycle electric motors under various conditions.  
15’  
*
*Not recommended  
CAUTION: Equipment damage can result from the low  
voltage caused by using an extension cord with a small  
wire size.  
Use this chart to estimate the total load on your  
generator.  
Starting Amps  
RI type Cap type SP type  
120V, 60 Hz Motors  
Hp motor Running  
Watts  
For Determining Generator Load Requirements  
1/6  
1/4  
1/3  
1/2  
1
1 1/2  
2
525  
700  
875  
1175  
1925  
2400  
2900  
4075  
6750  
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-224  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
Device  
Running Watts  
1700 (a)  
500  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
Chain Saw  
Circular Saw (6-1/2”)  
Coffee Maker  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling Iron  
Dishwasher  
Edge Trimmer  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
1000  
1200  
900  
1000  
2000 (a)  
1800 (a)  
1400 (a)  
700  
1200  
500  
1200  
1500  
1250  
800 (b)  
1200 (a)  
1200  
1100  
875  
3
5
The figures given above are for an average load such  
as a blower or fan. If the electric motor is connected to a  
hard starting load such as an air compressor, it will require  
more starting current. If it is connected to a light load or no  
load such as a power saw, it will require less starting  
current. The exact requirement will also vary with the  
brand or design of the motor.  
Generators respond to severe overloading differently  
than the power line. When overloaded, the engine is not  
able to supply enough power to bring the electric motor up  
to operating speed. The generator responds to the high  
initial starting current, but the engine speed drops sharply.  
The overload may stall the engine. If allowed to operate at  
very low speeds, the electric motor starting winding will  
burn out in a short time. The generator head winding  
might also be damaged.  
Freezer  
Furnace Fan (1/3HP)  
Hair Dryer  
Hand Drill (1”)  
Hand Drill (1/2”)  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
500  
250  
450  
150  
500  
Running the generator under these conditions may  
result in damage to the generator stator as well as the  
motor windings. Because the heavy surge of current is  
required for only an instant, the generator will not be  
damaged if it can bring the motor up to speed in a few  
seconds. If difficulties in starting a motor are experienced,  
turn off all other electrical loads and if possible reduce the  
load on the electric motor.  
Load Requirements, continued  
Jet Pump  
800 (a)  
Lawn Mower  
1200  
100  
700  
Light Bulb  
Microwave Oven  
Milk Cooler  
1100 (a)  
Oil Burner on Furnace  
Oil Fired Space Htr (140,000 Btu)  
Oil Fired Space Htr (85,000 Btu)  
Oil Fired Space Htr (30,000 Btu)  
Oven  
300  
400  
225  
150  
EXTENSION CORDS  
4500  
When electric power is to be provided to various loads  
at some distance from the generator, extension cords can  
be used. These cords should be sized to allow for  
distance in length and amperage so that the voltage drop  
between the set and point of use is held to a minimum.  
Paint Sprayer, Airless (1/3 HP)  
Paint Sprayer, Airless (handheld)  
Radio  
Refrigerator  
Slow Cooker  
600 (a)  
150  
200  
600 (b)  
200  
Submersible Pump (1-1/2 HP)  
Submersible Pump (1 HP)  
Submersible Pump (1/2 HP)  
Sump Pump  
Table Saw (10”)  
Television  
2800 (a)  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
Current/Power Maximum Extension Cord Length  
Amps  
at  
Load  
(watts)  
#10  
Ga.  
#12  
Ga.  
#14  
Ga.  
#16  
Ga.  
240V  
Cord  
Cord  
Cord  
Cord  
10  
2400  
250’  
150’  
100’  
75’  
7
 
Toaster  
Vacuum cleaner  
VCR  
Water Heater  
Weed Trimmer  
1000  
250  
70  
3000  
500  
Load  
Output  
Frequency  
Percent of  
Generator  
Output  
0 %  
50 %  
100 %  
Speed  
(RPM)  
Generator  
Voltage at 120V  
Receptacle  
(Hz)  
3780  
3600  
3480  
63.0  
60.0  
58.0  
129V  
120V  
112V  
(a) Hard-starting motors require 3 to 5 times the rated  
running watts.  
(b) These loads may require up to 15 minutes to  
restart due to its normal build up of compressor head  
pressure.  
NOTE: For extremely hard to start loads such as air  
conditioners and air compressors, consult the equipment  
dealer to determine the maximum wattage.  
Output voltage should periodically be checked to  
ensure continued proper operation of the generating plant  
and appliances, it can be checked with a portable meter.  
Frequency can be checked using an electric clock with a  
sweep second hand. Timed against a wristwatch or a  
stopwatch the clock should be correct within +/- 2 seconds  
per minute. A qualified technician should do all speed  
setti ng adjustm ents.  
PRE-START PREPARATIONS  
BEFORE STARTING  
Your generator has been thoroughly tested prior to  
shipment from the factory. However, damage can occur  
during shipping, so be sure to check for damaged parts or  
loose or missing nuts and bolts. If problems occur, call  
Customer Service at 1-800-270-0810.  
1. Make sure the generator is positioned on firm level  
surface.  
2. Check the crankcase for oil and maintain at a proper  
level.  
3. Check fuel level and fill tank with fresh unleaded  
gasoline. Never fill fuel tank completely to the top. Always  
wipe up and remove any spilled gasoline.  
4. Make sure that the exhaust fumes are directed  
away from people.  
GROUNDING - All units must be grounded. Drive a  
3/4” or 1” copper pipe or rod into the ground close to the  
generator. The pipe/rod must penetrate moist earth.  
Connect an approved ground clamp to the pipe. Run a no.  
12 Ga. wire from the clamp to the generator grounding  
post located on the control panel. Do not connect to a  
water pipe or a ground used by a radio system.  
CAUTION: The engine has been shipped without oil.  
Fill the crankcase with oil before trying to start. Low oil  
shutdown prevents your generator from starting without  
sufficient oil.  
STARTING - MANUAL  
1. Disconnect all loads to generator.  
2. Turn gas line valve to ON position.  
3. Turn key to the ON position.  
OPERATING SPEED  
The generator must be run at the correct speed in  
order to produce the proper electrical voltage and  
frequency. The speed of the engine was carefully adjusted  
at the factory so that the generator produces the proper  
voltage and frequency.  
The output voltage should be checked to ensure the  
generator is working properly before connecting a load to  
the generator. Failure to do so could result in damage to  
equipment plugged into the unit and possible injury to the  
individual.  
4. For cold engine, move choke lever to full choke  
position, for warm engine, move choke lever to half choke  
or to RUN position.  
5. Firmly grasp recoil handle and pull.  
6. When engine starts, move choke lever to RUN  
position.  
7. Loads may now be connected to generator.  
All engines have a tendency to slow down when a load  
is applied. When the electrical load is 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. The slight variation has no appreciable effect in the  
operation of motors, lights and most appliances. Electronic  
equipment and clocks will be affected if correct RPM is not  
maintained. See Load vs. Output chart.  
STARTING - ELECTRIC  
1. Disconnect all loads to generator.  
2. Turn gas line valve to ON position.  
3. For cold engine, move choke lever to full choke  
position, for warm engine, move choke lever to half choke  
or to RUN position.  
4. Turn key to start position.  
8
 
5. When engine starts, move choke lever to RUN  
position.  
without an isolating, UL approved transfer switch, installed  
by a licensed electrician.  
6. Loads may now be connected to generator.  
STOPPING  
1. Disconnect all loads to generator.  
2. Place key to the OFF position.  
3. Turn gas line valve to OFF position.  
ENGINE CARE  
Refer to your Honda Owner’s Manual for proper care  
and maintenance.  
NOTE: When changing the oil on a hot engine, the oil  
might overshoot the oil drain hole on the generator base.  
GENERATOR CARE  
The generator head is a 2-pole, 3600-RPM, 60-Hz,  
brushless, revolving field and synchronous type with one  
sealed ball bearing. The rotor of the generator head is  
directly connected to the engine crankshaft and the stator  
is rigidly coupled to the engine casting via the generator  
head casting.  
Exercising the Generator - The generator should  
be operated every four weeks. This is accomplished by  
starting the engine and applying a load for 10 to 15  
minutes.  
This will dry out any moisture that has  
accumulated in the windings. If left, this moisture can  
cause corrosion in the winding. Frequent operation of the  
engine generator will also ensure that the set is operating  
properly should it be needed in an emergency.  
Generator Maintenance - The generator head is  
brushless and maintenance free. Major generator service,  
including installation or replacement of parts should be  
performed only by a qualified electrical service technician.  
USE ONLY NORTHSTAR APPROVED REPAIR PARTS  
AVAILABLE AT 1-800-270-0810.  
A. Bearing - The bearing used in these generators is a  
heavy duty sealed ball bearing. They require no  
maintenance or lubrication.  
B. Receptacles - Quality receptacles have been  
utilized. If a receptacle should become cracked or  
otherwise damaged, replace it.  
Using cracked or  
damaged receptacles can be both dangerous to the  
operator and destructive to the equipment.  
WARNING, Stand-by Operation  
If your generator is to be used as a standby electric  
power source in case of utility failure, it must be installed  
by a registered and licensed electrician and in compliance  
with all applicable state and local electrical codes. Also,  
local Fire Departments must be consulted concerning  
proper and safe handling procedures for gasoline. NEVER  
connect any generator to any existing electrical system  
9
 
TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Engine will not start.  
a) Low oil level.  
b) Fouled spark plug.  
c) Out of fuel.  
a) Fill crankcase to proper oil level.  
b) Clean or replace spark plug.  
c) Fill fuel tank.  
d) Stop switch in OFF position.  
e) Battery has lost its charge.  
d) Place switch in ON position.  
e) Battery has low electrolyte and/or  
needs to be charged or replaced.  
a) Bring generator to a qualified  
technician for adjustment.  
b) Reduce the load. (See Load  
Application section of this manual.)  
c) Bring generator to a qualified  
technician for inspection.  
Voltage too low.  
a) Engine speed too slow.  
b) Generator is overloaded.  
c) Idle control is malfunctioning.  
Circuit breaker trips.  
Voltage too high.  
a) Defective load connected to generator.  
b) Defective receptacle.  
c) Generator overloaded.  
a) Disconnect load.  
b) Replace receptacle.  
c) Reduce the load. (See Load  
Application section of this manual.)  
a) Bring generator to a qualified  
technician for adjustment.  
a) Engine speed too high.  
Generator overheating. a) Generator is overloaded.  
b) Insufficient ventilation.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Make sure there is at least 3 feet of  
clearance on all sides of generator.  
a) Disconnect load.  
No output voltage.  
a) Defective load connected to generator.  
b) Broken or loose wire.  
b) Bring generator to a qualified  
technician for repair.  
c) Defective receptacle.  
d) Defective stator.  
c) Replace receptacle.  
d) Bring generator to a qualified  
technician for repair.  
e) Bring generator to a qualified  
technician for repair.  
e) Defective rotor.  
f) Defective capacitor.  
a) Generator is overloaded.  
f) Bring generator to a qualified  
technician for repair.  
Engine lacks power.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Clean or replace air filter.  
a) Place switch in ON position.  
b) Check for 12 VDC at solenoid. Check  
coil resistance, it should be 18.5Ω ±5%.  
Check for sticking in mechanism and  
solenoid. Replace idle assembly if  
necessary.  
b) Dirty air filter.  
a) Switch is in OFF position.  
b) Solenoid failure.  
Idle control doesn’t  
work.  
c) Defective circuit board.  
d) Defective capacitor.  
c) Bring generator to a qualified  
technician for repair.  
d) Bring generator to a qualified  
technician for repair.  
e) Circuit breaker tripped  
e) Reset circuit breaker.  
f) Engine idle speed to low-engine will not  
jump back to normal operating speed  
unless idle on/off switch is placed in off  
position.  
f) Raise engine idle speed by turning  
engine throttle stop screw. See  
carburetor adjustment section of the  
Honda Owner’s Manual. Turn stop  
screw ½ turn clockwise.  
Engine shuts off during a) Out of fuel.  
operation. b) Low oil level.  
a) Fill fuel tank.  
Fill crankcase to proper oil level.  
10  
 

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