North Star 5500 IPG User manual

Proven Performance
MODEL 5500 IPG,ITEM # 165926
Industrial Portable Generator
M165926A
OWNER’S MANUAL
5500 IPG
Shown with Optional Wheel Kit (Item # 165916)
AnyQuestions, Comments,or Problems?
Call Customer Service at 1-800-270-0810
Hours: Monday - Friday 7:30 AM to 5:30 PM
Saturday 7:30 to 11:30 AM CST
00219

1
THANK YOU
Thankyouforpurchasinga North Star Industrial Portable Series Generator. Your machine is
designed for long life, dependability, and the top performance you demand. Please take time
now to read through this manual so you can better understand the machine’s operation,
maintenance and safety precautions. Everyone who operates this generator must read and
understand this manual. The time you take now will prolong your generator’s life and prepare
you for itssafe operation. Enjoytheexceptional performanceof your North Star Industrial Series
Generator.
IMPORTANT
Make certain the operator:
- Readsand understandsthemanualspertaining to thismachine.
- Isinstructedin safe and proper operationof thismachine.
NOTICE
K-BAR Industries Incorporated reserves the right to make improvements in design and/or
changes in specifications at any time without incurring any obligation to install them on units
previously sold.
TABLE OF CONTENTS
Thank you 1
Specifications 2
Machine componentidentification 3
Generator features 4-5
Introduction 5
ANSI safety definitions 5
Rules forsafe operation 5-6
Installation 6
Load application 6-8
Pre-startup preparation 8
Starting - Manual 9
Starting - Electric 9
Stopping 9
Engine care 9
Generator care 9
Troubleshooting 10

2
SPECIFICATIONS
Item Number #165926
Maximum Output 5500 Watts (W)
Continuous Output 4500 Watts (W)
Voltage 120 /240 Volt(V)
Phase Single phase (4-wire)
Frequency 58.0-63.0 Hertz(Hz)
Power Factor 1.0 p.f.
Engine 9 HP Honda GX270
Engine Speed 3480-3780 RPM
Fuel Type Unleaded gasoline
Fuel Capacity 6.5 gallons (24.6 L)
Oil Capacity 1.16 US quarts (1.1 L)
Starting Method Electric Start / Recoil
120 VReceptacle (2) 20 Amp (A) duplexGFCI (NEMA 5-20R)
(1) 30 Amp (A) twistlock (NEMA L5-30R)
(1) 50 Amp (A) StraightBlade (NEMA 5-50R)
120/240 VReceptacle 20 Amp (A) twistlock (NEMA L14-20R)
CircuitBreaker (2) 20 Amp (A) Thermal, push to reset
(1) 30 Amp (A) Thermal,push to reset
(1) 20 Amp (A) Magnetic,2 Pole
Grounding Post Receives 10 Ga.wire orfork terminal
Dimensions
Length 31.75” (80.6 cm)
Width 23.63” (60.0 cm)
Height 22.25” (56.5 cm)
DryWeight 195 lb.(88.6 kg)
Gross Weight 240 lb.(109 kg)

3
MACHINE COMPONENT IDENTIFICATION
Ref. Description Ref. Description
1Air Cleaner 9 GasLineValve
2 Starting/StoppingInstructions 10 Generator Head
3Oil Drain Plug 11 Battery & Box
4 Control Panel 12 Vibration Isolation Mount
5GasCap with Gauge 13 Recoil
6 6.5 Gallon GasTank 14 Fuel Valve Lever
7Super Silent Muffler 15 Choke Lever
8 GasDrainValve 16 ElectricStop/StartSwitch
Figure 2 (Ref. 8-16) 00230
Figure 1 (Ref. 1-7) 00229

4
GENERATOR FEATURES
Reference 1 - Air Cleaner. Refer to your Honda
engine manual forair cleaner care.
Reference 2 - Starting/Stopping Instructions.
Reference 3 - Oil Drain Plug. Refer to your Honda
engine manual foroil 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 refilling and a
comfortable grip. You can always monitor the fuel level
without removing the cap by using the fuel level indicator
builtinto the gascap.
Reference 6 - 6.5 Gallon Gas Tank. Large tank
allowsfor extended run capabilities. ALWAYS allow room
for gasoline expansion by not filling the gas tank
completelyfull.
Reference 7 - Super Silent Muffler. 8 dB less than
Honda’s standard muffler. NEVER operate generator
without the exhaust deflector attached in the upright
position.
Reference 8 - Gas Drain Valve. The generator is
equipped with a unique feature. A gas drain valve is
installed to drain gasoline from the tank without
disconnecting the gas line feeding the engine. This valve
is intended to be used to drain gas prior to extended
periodsofnon use. Itisrecommendedthatif the period of
nonuse islonger than 30 days, thegasshould be drained,
andthe engine ran until all the gas is evacuated from the
carburetor. ALWAYS make sure this valve is closed prior
to filling the gastank.
Reference 9 - Gas Line Valve. The generator tank
has an ON-OFF valve mounted underneath the tank.
ALWAYS keep thisvalve closed when the generatoris not
inuse or being transported.
Reference 10 - Generator Head. The electricity
producing partof thegenerator.
Reference 11 - Battery and Box. The power source
for electric starter.
Reference 12 - Vibration Isolation Mounts. 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”
whichiscommonin enginepowered equipment.
Reference 13 - Recoil. Grasp firmly when starting
engine.
Reference 14 - Fuel Valve Lever. Additional valve for
fuel shutoff.
Reference 15 - Choke Lever. Used during cold
starts. Refer to the starting/stopping instructions and the
Honda engine manual for usage.
Reference 16 - Electric Start/Stop Switch. The
engine key is located on the engine. Always locate this
switch and be familiar withitslocationbefore operating the
generator.
CONTROL PANEL IDENTIFICATION
Figure 3 (Ref. 17-29) 00242
Ref. Description
17 Voltmeter
18 Full Power Switch
19 Idle Control On/Off Switch
20 AdjustableIdleDelay
21 120/240V20ATwistlockReceptacle
22 Grounding Post
23 120V 30ATwistlockReceptacle
24 120V 50AStraight Blade Receptacle
25 120V 20AGFCI Duplex Receptacle
26 30A CircuitBreaker
27 20A CircuitBreaker
28 Main Line Circuit Breaker 20A
29 Hour Meter
Reference 17 - Voltmeter. Voltmeter needle should
bein green areaduring all generator load conditions.
Reference 18 - Full Power Switch. The switch
reconnectsthetwo generator windingsfrom parallel (120V
only) to series(120/240V).
•120V Only: Allowsall 4500 watts (37.5A) to be used
in any combination of 120 volt receptacles. The
120/240V receptacleisdisabled.
•120/240V : Allowsall 4500 wattsto beused for240V.
However, only half the power or 2250 watts (18.8A),
canbeused atanyone 120V receptacle. 120V output
can total 4500 watts.
Reference 19 - Idle Control - On/Off Switch. This
feature sensestheloadonthegenerator. With no load on
the generator the engine speed drops to idle. This saves
fuel and lengthensengine life. When a load is applied, the
engine speed returns to 3600 RPM nominal. Turning the
switch off disables the sensing device and the generator
will run at 3600-3780 RPM whether or not a load is
applied.
Reference 20 - Adjustable Idle Delay. Adjusts the
amount of time from whenthe generator senses there is no
load to when the generator actually idles down. The
minimum delay is 5 seconds. The maximum is
approximately 1minute.

5
Reference 21 - 120/240V 20A Receptacle. One
twistlock 120/240V receptacle capable of drawing 20
amps, (NEMA) number L14-20R. This receptacle accepts
only NEMA 14-20Pplugs, oneof which is shipped with the
generator. Use thisreceptacleif installing a transfer switch.
Compatible with Gentran transfer switch,item #16411.
Reference 22 - Grounding Post. Ground the
generator via the grounding post, to a copper pipe or rod
thatisdrivendown until it reaches moist soil.
References 23-25 - 120V Receptacles. The
generator hasa control panel with:
•Reference 23 - two duplex (two receptacles in a
common housing) 120V GFCI straight-blade
receptacles capable of drawing 20 amp, National
Electrical Manufacturer’s Association (NEMA) part
number 5-20R. These receptacles accept NEMA
numbers5-15P or5-20P plugs.
•Reference 24 - one straight-blade 120V receptacle
capable of drawing 50 amp, NEMA 5-50R. This
accepts only NEMA 5-50P plugs, one of which is
shipped with the generator.
•Reference 25 - one twistlock 120V receptacle
capable ofdrawing30 amps, (NEMA) number L5-30R.
This receptacle accepts only NEMA number 5-30P
plugs, one of whichisshipped with the generator.
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.
WARNINGContact a licensed electrician to
wire electrical plugs and/or cordsets. Improper wiring
could result in a fire or electrical shock. Never use
defectiveor broken plugsor receptacles.
References 26-28 - Circuit Breakers. This portable
single phase generator has
•Reference 26 - (2) 20 amp (A) push-to-reset circuit
breakers.
•Reference 27 - (1) 30A push-to-reset circuit breaker
•Reference 28 - (1) 20A magnetic 2 pole main circuit
breaker toprotectagainst electrical overloads.
Reference 29 - Hour Meter. Allows for a better
maintenance schedule of thegenerator.
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 isrefilled toabove the safe
level.
INTRODUCTION
Before starting your generator, thoroughly study the
instructionsand cautionsin 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
engine operation and maintenance always refer to the
Honda engine owner’s manual furnished with the
generator (Honda refersto the 9HP engineasa GX270).
North Star is constantly improving its products. The
specifications outlined herein are subject to change
without prior notice or obligation. The purchaser and/or
user assumes liability of any modification and/or
alterations on this equipment from original design and
manufacture.
Before using,theuser shall determine the suitability of
this product for its intended use and assumes liability
therein.
ANSI SAFETY DEFINITIONS
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
seriousinjury. Thissignal wordisto belimited to the most
extreme situations.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a death or
seriousinjury.
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
unsafepractices.
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,
andthese will be designated bythe symbol:
WARNING Thisgeneratorisequipped 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,topreventelectrical shock.
ALWAYS use electrical cords that are in good
condition. Worn,bare,frayed orotherwise damaged cords
can cause electric shock.
NEVER operate thegenerator, orhandleanyelectrical
equipment while standing in water, while barefoot, while
handsare wetor whilein 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-sitestoprevent electricshock.

6
ALWAYS remove the spark plug or spark plug wire
before working on the engine or generator, to prevent
accidental starting.
ALWAYS provide adequate ventilation. Do not operate
generator in any enclosed or narrow space. Engines
consume oxygen and give off deadly carbon monoxide
poisonousgas. Improper ventilation will cause damage to
generator and possible injury topeople.
NEVER touch hot muffler, hot exhaust manifold or
engine cooling fins.
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:
A. Excessive change in engine speed, slow or
fast.
B. Overheating inload connecting devices.
C. Sparking orarcsfrom generator.
D. Lossof electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
H. Enclosed compartments, or confined areas.
I. Flame or smoke.
J. Rain, snow orwet conditions.
K. Operator non-attendance.
L. Excessive overload of generator.
M. Wire with too small a gauge forthe load.
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 anydefectsbeforeoperation.
WARNING Keep fire extinguisher close by
yourgenerator and be familiar on how to use it. Consult
yourlocal fire departmentfor correctextinguisher type.
INSTALLATION
OUTDOORS: Choose alocation where the generator
will not be exposed to rain, snow or direct sunlight.
Position the generatoron secure, level ground so it will not
tip or slide down a hill. Place the generator so that the
exhaust fumeswill not be directed towardspeople.
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.
Foreign matters, such as dust, dirt, sand, lint, or
abrasive materials can cause damage to the generator
head andengineif allowedintoitscooling system.
NEVER install your generatorinside confined areas.
Inside installation cancausehealth hazardsor death.
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
exhaustedoutto ensure proper cooling of the engine and
generator head.
LOAD APPLICATION
It is important to determine the total electrical load
before it is connected to the generator. The two major
factorsin determiningthe lifeofa generatorhead are:heat
build up, caused by overloading the generator and
corrosive contaminants, thatattackthe wiring insulation. If
thegeneratorisoverloaded,the wiresbecome 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.
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
equipmentnameplate 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 bymultiplying nameplate voltageby nameplate
amperage.
VOLTS X AMPS = WATTS
Example: 120V X 5A = 600W
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 beused.
When connecting a resistive-inductive load such as a
fluorescent or mercury light, transformers or inductive
coils, a capacityofupto0.6 timesthegenerator’sfull rated
output can beused.
Always allow the generator to reach operating speed
before aload isapplied.
STARTING ELECTRICMOTORS
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

7
are easier tostart and usually require 2 to4timesasmuch
current to start than to run. Repulsion Induction motors
are the easiest to start and require 1.5 to 2.5 times as
much to start than to run.
Most fractional motorstake aboutthe 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
volt60 cycle electric motorsunder variousconditions.
120V,60 HzMotors Starting Amps
Hp motor Running
Watts RI type Cap type SP type
1/6 525 7-11 9-18 16-22
1/4 700 9-15 12-23 22-32
1/3 875 11-18 14-29 26-35
1/2 1175 15-25 20-40 NA
11925 24-40 32-64 NA
1 1/2 2400 30-50 40-80 NA
22900 36-60 48-96 NA
3 4075 51-85 68-136 NA
56750 84-140 112-224 NA
The figuresgivenaboveare for an average load such
asa bloweror fan. If the electric motoris connected to a
hard startingload such asan air compressor, it will require
more starting current. Ifitisconnected toa lightloadorno
load such as a power saw, it will require less starting
current. The exact requirement will also vary with the
brand or design ofthe motor.
Generators respond to severe overloading differently
than the power line. When overloaded, the engine is not
ableto supplyenough powertobring the electric motor up
to operating speed. The generator responds to the high
initial starting current,butthe engine speed drops sharply.
The overloadmay stall the engine. Ifallowedtooperate at
very low speeds, the electric motor starting winding will
burn out in a short time. The generator head winding
might also be damaged.
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. Ifdifficultiesin starting amotor are experienced,
turn offall other electrical loads and if possible reduce the
load onthe electricmotor.
EXTENSION CORDS
When electricpower isto beprovided to various loads
at somedistancefrom the generator, extension cords can
be used. These cords should be sized to allow for
distancein length and amperage so that the voltage drop
between the set andpointofuse isheld to a minimum.
Current/Power Maximum Extension Cord Length
Amps
at
240V
Load
(watts) #10 Ga.
Cord
#12
Ga.
Cord
#14
Ga.
Cord
#16
Ga.
Cord
10 2400 250’ 150’ 100’ 75’
20 4800 125’ 75’ 50’ 25’
30 7200 60’ 35’ 25’ 10’
40 9600 30’ 15’ 10’ *
50 12000 15’ ***
*Not recommended
CAUTION: Equipment damage can resultfrom thelow
voltage caused by using an extension cord with a small
wire size.
Use this chart to estimate the total load on your
generator.
For Determining Generator Load Requirements
Device Running Watts
Air Conditioner (12,000 Btu) 1700 (a)
Battery Charger (20 Amp) 500
Belt Sander (3”) 1000
Chain Saw 1200
Circular Saw (6-1/2”) 900
Coffee Maker 1000
Compressor (1 HP) 2000 (a)
Compressor (3/4 HP) 1800 (a)
Compressor (1/2 HP) 1400 (a)
Curling Iron 700
Dishwasher 1200
Edge Trimmer 500
Electric Nail Gun 1200
Electric Range (oneelement) 1500
ElectricSkillet 1250
Freezer 800(b)
Furnace Fan (1/3 HP) 1200 (a)
Hair Dryer 1200
Hand Drill (1”) 1100
Hand Drill (1/2”) 875
Hand Drill (3/8”) 500
Hand Drill (1/4”) 250
HedgeTrimmer 450
HomeComputer 150
Impact Wrench 500
Jet Pump 800 (a)
LawnMower 1200
LightBulb 100
MicrowaveOven 700
Load Requirements Continued
MilkCooler 1100 (a)
Oil Burneron Furnace 300
Oil FiredSpace Htr (140,000 Btu) 400
Oil Fired Space Htr (85,000 Btu) 225
Oil Fired Space Htr (30,000 Btu) 150
Oven 4500
Paint Sprayer, Airless (1/3 HP) 600 (a)
PaintSprayer, Airless(handheld) 150
Radio 200
Refrigerator 600 (b)

8
Slow Cooker 200
Submersible Pump (1-1/2 HP) 2800 (a)
SubmersiblePump (1 HP) 2000 (a)
Submersible Pump (1/2 HP) 1500 (a)
Sump Pump 600 (a)
TableSaw (10”) 2000 (a)
Television 500
Toaster 1000
Vacuum cleaner 250
VCR 70
Water Heater 3000
Weed Trimmer 500
(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 todetermine the maximum wattage.
PRE-START PREPARATIONS
Your generator has been thoroughly tested prior to
shipmentfrom the factory. A factory test report has been
included with this manual. However, damage can occur
during shipping,so be sure to check for damaged parts or
loose or missing nuts and bolts. If the aforementioned
problemsoccur, call CustomerService at 1-800-270-0810.
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 anapproved groundclamp to the pipe. Runa no.
10 Ga. wire from the clamp to the generator grounding
post located on the control panel. Do not connect to a
waterpipe or aground used bya radio system.
CAUTION: The engine has been shipped without oil.
Fill the crankcase with oil before trying to start. Low oil
shut-down prevents your generator from starting without
sufficient oil.
OPERATING SPEED
The generator must be run at the correct speed in
order to produce the proper electrical voltage and
frequency.Thespeedoftheengine 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
thegenerator. Failure to do so could result in damage to
equipmentpluggedinto the unit and possible injury to the
individual.
All engineshave atendency to slowdownwhen 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, resultsin a slightlylowervoltage when the generator
isloaded to itsfull capacity than when it is running with no
load. The slight variation has no appreciable effect in the
operation ofmotors, lightsandmost appliances. Electronic
equipmentand clockswill be affectedif correct RPM is not
maintained.See Load vs. Outputchart.
Load Output
Percent of
Generator
Output
Speed
(RPM) Frequency (Hz) Generator Voltage at120V
Receptacle
0 % 3780 63.0 129V
50 % 3600 60.0 120V
100% 3480 58.0 112V
Output voltage should be checked periodically to
ensure continued proper operation of the generating plant
and appliances, it can be checked with a portable meter.
Frequency can be checked by using an electric clock with
a sweep second hand. Timed against a wrist watch or a
stop watchthe clockshould be correctwithin +/- 2 seconds
per minute. All speed settingadjustments should be done
by aqualifiedtechnician.
BEFORESTARTING
1.Make sure the generatoris positioned on firm level
surface.
2. Checkthe crankcase for oil and maintain ata proper
level.
3. Check fuel level and fill tank with fresh unleaded
gasoline. Never fill fuel tankcompletelyto the top. Always
wipeup and removeany spilledgasoline.
4. Make sure that the exhaust fumes are directed
away from people.
STARTING - MANUAL
1. Disconnect all loadstogenerator.
2. Turn gasline valveto ONposition.
3. Turn key to the ON position.
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. Firmlygrasp recoil handle andpull.
6. When engine starts, move choke lever to RUN
position.
7. Loadsmaynowbe connectedtogenerator.

9
STARTING - ELECTRIC
1. Disconnect all loadstogenerator.
2. Turn gasline valveto ONposition.
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 startposition.
5. When engine starts, move choke lever to RUN
position.
6. Loadsmaynowbe connectedtogenerator.
STOPPING
1. Disconnectall loadsto generator.
2. Place key tothe OFFposition.
3.Turngasline valve to OFFposition.
ENGINE CARE
Refer to your Honda Owner’s Manual for proper care
andmaintenance.
NOTE: When changing the oil on a hot engine, the oil
might overshoot the oil drain hole on the generator base.
Use a deflector(piece of cardboard or paper) to direct the
oil down the hole.
GENERATOR CARE
The generator head isa two pole, 3600 RPM, 60 Hz,
brushless, revolving field and synchronous type with one
sealed ball bearing. The rotor of the generator head is
directlyconnectedtothe engine crank shaft 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 corrosionin the winding. Frequent operation of the
engine generator will also ensure that the set is operating
properly should itbe neededin anemergency.
Generator Maintenance - The generator head is
brushless and maintenance free. Any major generator
service including the 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 bearingusedin these generators is a
heavy duty sealed ball bearing. They require no
maintenance orlubrication.
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 destructiveto 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 andlicensed electrician and in compliance
with all applicable state and local electrical codes. Also,
local Fire Departments must be consulted concerning
properand safehandlingproceduresfor gasoline. NEVER
connect any generator to any existing electrical system
withoutanisolating, UL approved transfer switch, installed
by a licensedelectrician.

10
TROUBLESHOOTING
Problem Possible Causes Possible Remedies
Engine will not start. a) Low oil level.
b) Fouled sparkplug.
c) Outof fuel.
d) Stopswitch in OFF position.
e) Battery haslost itscharge.
a) Fill crankcase to properoil level.
b) Clean or replace sparkplug.
c) Fill fuel tank.
d) Place switchin ONposition.
e) Battery haslow electrolyteand/or
needsto be charged or replaced.
Voltage too low. a) Engine speed too slow.
b) Generatorisoverloaded.
c) Idle controlismalfunctioning.
a) Bring generator to a qualified
technician for adjustment.
b) Reduce the load.(SeeLoad
Application section ofthismanual.)
c) Bringgenerator toa qualified
technician forinspection.
Circuit breaker trips. a) Defective load connected to generator.
b) Defectivereceptacle.
c) Generator overloaded.
a) Disconnectload.
b) Replacereceptacle.
c) Reduce the load.(SeeLoad
Application section ofthismanual.)
Voltage too high. a) Engine speed too high. a) Bring generator to a qualified
technician for adjustment.
Generatoroverheating. a) Generatorisoverloaded.
b) Insufficient ventilation.
a) Reduce the load.(SeeLoad
Application section ofthismanual.)
b) Make sure thereisatleast 3 feetof
clearance on all sides of generator.
No output voltage. a) Defectiveload connected to generator.
b) Broken orloose wire.
c) Defective receptacle.
d) Defectivestator.
e) Defective rotor.
f) Defective capacitor.
a) Disconnectload.
b) Bring generator to a qualified
technician for repair.
c) Replacereceptacle.
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.
Engine lacks power. a) Generator is overloaded.
b) Dirty air filter.
a) Reduce the load.(SeeLoad
Application section ofthismanual.)
b) Clean or replace air filter.
Idle control doesn’t
work. a) Switchisin OFFposition. b) Solenoid failure.
c) Defective circuit board.
d) Defective capacitor.
e) Circuitbreaker tripped
a) Place switch in ONposition.
b) Checkfor24VDCat solenoid. Check
coil resistance,it should be 73.9Ω±5%.
Checkfor stickingin mechanism and
solenoid. Replaceidleassemblyif
necessary.
c) Bringgenerator toa qualified
technician for repair.
d) Bring generatorto a qualified
technician for repair.
e) Reset circuit breaker.
Engine shutsoffduring
operation. a) Out of fuel. b) Lowoil level. a) Fill fuel tank. b) Fill crankcase to properoil level.