North Star M165967M User manual

M165967M
Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
8,500 Watt Continuous (10,000 Watt Surge) Capacity
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 AWAY from building air intakes. 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’ 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
ITEM NUMBER: 165967
SERIAL NUMBER: _____________
®

Hazard Signal Word Definitions
2

Table of Contents
3
Hazard Signal Word Definitions ..................................................................................................2
About Your Generator ..................................................................................................................4
Specifications ..................................................................................................................................6
Safety Label Locations...................................................................................................................7
Machine Component Identification..............................................................................................8
Power Load Planning & Management.......................................................................................10
Installation / Initial Set-Up:
1. Unpacking & Delivery Inspection..........................................................................................12
2. Planning the Power Load........................................................................................................12
3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ......................................13
4. Selecting a Suitable Site.........................................................................................................16
5. Grounding the Generator........................................................................................................18
6. Battery Installation .................................................................................................................19
7. Spark Arrester Installation......................................................................................................19
Operation:
1. General Safety Rules for Operation .......................................................................................20
2. Preparing for Operation..........................................................................................................23
3. Starting the Engine.................................................................................................................26
4. Checking Generator Output....................................................................................................27
5. Connecting Loads...................................................................................................................28
6. Stopping the Engine ...............................................................................................................28
7. Storage & Exercise.................................................................................................................29
Maintenance & Repair..................................................................................................................31
Troubleshooting.............................................................................................................................33
Summary of Important Safety Information for Operation.......................................................34
Generator Exploded View............................................................................................................38
Wiring Diagram.............................................................................................................................40
Generator Head Exploded View..................................................................................................42
Limited Warranty.........................................................................................................................43

About Your Generator
4
Thank you for purchasing your NorthStar portable generator!
About Your Generator
This engine-driven, portable generator is designed to provide up to 10,000 Watts of
electrical power (8500 watts continuous, 10,000 watts surge).
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 vinyl
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.

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 generator. For detailed engine operation and maintenance
information, always refer to the engine Owner’s Manual furnished with the 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 out and submit the warranty registration card so that we have your contact
information for any future product literature or replacement parts you may need.
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.

Specifications
6
SPECIFICATIONS
Item Number #165967
Maximum Output 10000 Watts (W)
Continuous Output 8500 Watts (W)
Voltage 120/240 Volt (V)
Phase Single phase (4-wire)
Frequency 56.5 - 63.3 Hertz (Hz)
Power Factor 1.0 p.f.
Total Harmonic Distortion less than 5%
Engine 18 HP Honda
Engine Speed 3390 - 3798 RPM
Fuel Type Unleaded gasoline
Fuel Capacity 10 gallons (38.0 L)
Oil Capacity 1.6 US quarts
Starting Method Electric start/Recoil
120 V Receptacles 2 - 20 Amp (A) duplex (NEMA 5-20R)
30 Amp (A) locking receptacle (NEMA L5-30R)
120/240 V Receptacle 30 Amp (A) locking receptacle (NEMA L14-30R)
50 Amp (A) straight blade (NEMA 14-50R)
Circuit Breakers 40 Amp (A) thermal magnetic
30 Amp (A) thermal magnetic
30 Amp (A) thermal, push to reset
2 - 20 Amp (A) thermal, push to reset
Battery (not included) 12 Volt, 400 CCA minimum, Group size U1
Dimensions
Length 35.75” (90.8 cm)
Width 24.25” (61.6 cm)
Height 26.25” (66.7 cm)
Dry Weight 320 lb. (136 kg)

Safety Label Locations
7
WARNING - BATTERY HAZARDS
ATTENTION
IF GENERATOR IS TO BE STORED LONGER THAN 2 MONTHS,
charge battery with a trickle charger that is rated for 3 amps maximum.
A changed battery ensures reliable engine starting.
©2007 NT+E 1-800-270-0810
BATTERIES:
PN 779396
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.
• Commercial-grade electric start engine
• Extend run 10 gallon fuel tank
• Maintenance-free brushless alternator design
• Smooth running focus mount isolationsystem
Only use OUTSIDE and
far away from windows,
doors, and vents.
NEVER use inside a home
or garage. EVEN IF doors
and windows are open.
DANGER
Using a generator indoors CAN KILL YOU IN
MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Avoid other generator hazards.
READ MANUAL BEFORE USE.
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 1-800-270-0810.
On-Product Warning Labels
Part numbers Description
779396 Battery Warning
779399 NorthStar

Machine Component Identification - Item #165967M
8
Figure 1 (Ref. 1-9)
Ref. Description Ref. Description
1 Air Cleaner 10 10.0 Gallon Gas Tank
2 Circuit Breakers 11 Engine Key Switch
3 120/240V, 50A Receptacle 12 Recoil
4 120/240V, 30A Locking Receptacle 13 Oil Filter
5 120V, 30A Locking Receptacle 14 Muffler
6 120V, 20A Duplex Receptacle 15 Battery Box
7 Oil Drain Plug 16 Gas Line Valve
8 Vibration Isolation Mount 17 Generator Head
9 Optional Wheel Kit (#165919) 18 Gas Cap with Gauge
Figure 2 (Ref. 10-18)

Machine Component Identification - Item #165967M
9
REFERENCE GUIDE
Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care.
Reference 2 – Circuit Breakers This portable single phase generator has 1 - 40 amp (A)
thermal magnetic 2 pole breaker, 1 - 30 amp (A) thermal
magnetic 2 pole breaker 1 - 30 amp (A) push to reset circuit
breaker, and 2 - 20 amp (A) push to reset circuit breakers.
Circuit breakers protect against electrical overloads.
Reference 3 – 120/240V, 50A
Receptacle This receptacle is a 120/240V 50A NEMA 14-50R receptacle.
This receptacle accepts a NEMA 14-50P plug. Use this
receptacle if installing a transfer switch.
Reference 4 - 120/240V, 30A Locking
Receptacle This locking receptacle is a 120/240V 30A NEMA L14-30R
receptacle. This receptacle accepts a NEMA L14-30P plug.
Reference 5 - 120V, 30A Locking
Receptacle This locking receptacle is a 120V 30A NEMA L5-30R
receptacle. This receptacle accepts a NEMA L5-30P plug.
Reference 6 - 120V, 20A Duplex
Receptacle The generator has a control panel with two duplex (two
receptacles in a common housing) receptacles. Each duplex is
a 120 volt (V) 20 amp (A) straight blade receptacle, National
Electrical Manufacturer’s Association (NEMA) number 5-20R.
This receptacle accepts NEMA plug numbers 5-15P and 5-20P.
Each duplex is capable of drawing 20A at 120V.
Reference 7 - Oil Drain Plug Refer to your Honda engine manual for oil change
recommendations.
Reference 8 - Vibration Isolation
Mount The engine and generator head 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 9 - Optional Wheel Kit
(#165919)Optional heavy-duty wheel kit (Item # 165919).
Reference 10 - 10.0 Gallon Gas Tank Large tank allows for extended run capabilities. Always allow
room for gasoline expansion by not filling the gas tank
completely.
Reference 11 - Engine Key Switch The engine key is located on the engine. Always locate this
switch and be familiar with its location before operating the
generator. Consult the Honda engine owner’s manual for
further instructions.
Reference 12 - Recoil Optional starting method. Grasp firmly when starting engine.
Reference 13 - Oil Filter Refer to your Honda engine manual for oil filter maintenance.
Reference 14 – Muffler This generator is equipped with a quiet style muffler. The
muffler is designed to allow moisture (condensation) to drain
from the bottom of the canister. Always check for loose
fasteners. Included spark arrestor is shipped loose. See Spark
Arrestor Installation section of this manual for information.
Reference 15 - Battery Box The battery box provides protection for the battery, and will
accept the standard lawn tractor size battery (Group U1-7). The
engine requires a 12-volt battery. See battery section for sizing.
Reference 16 - Gas Line Valve The generator tank has an ON-OFF valve mounted underneath
the tank. Always keep this valve closed when the generator is
not in use.
Reference 17 - Generator Head The electricity producing part of the generator.
Reference 18 - Gas Cap with Gauge The gas cap is extra large, creating a large hole for refilling and
a comfortable grip. You can always monitor the fuel level
without removing the cap by using the fuel level indicator built
into the gas cap.

Power Load Planning & Management
10
WARNING
NEVER exceed the rated wattage capacity of your generator.
OVERLOADING may cause SERIOUS DAMAGE to the generator and
attached electrical devices, and may result in fire.
Your generator MUST BE SIZED 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 Running Watts Device Running Watts
Air conditioner (12.000 BTU) 1700 (a,b) Jet pump 800 (a)
Battery charger (20 Amp) 500 Lawn mower 1200
Belt sander (3”) 1000 Light bulb (100 Watt) 100
Chain saw 1200 Microwave oven 700
Circular saw (6½”) 2000 (a,b) Milk cooler 1100 (a)
Coffee maker 1800 (a,b) Oil burner on furnace 300
Compressor (1 HP) 1400 (a,b) Oil-fired space heater (140,000 Btu) 400
Compressor (3/4 HP) 1800 (a) Oil-fired space heater (85,000 Btu) 225
Compressor (1/2 HP) 1400 (a) Oil-fired space heater (30,000 Btu) 150
Curling iron 700 Oven 4500
Dishwasher 1200 Paint sprayer, Airless (1/3 HP) 600 (a)
Edge trimmer 500 Paint sprayer, Airless (handheld) 150
Electric nail gun 1200 Radio 200
Electric range (1 element) 1500 Refrigerator 600 (b)
Electric skillet 1250 Slow cooker 200