North Star 5500 User manual

Proven Performance
MODEL 5500 PPG,ITEM # 165950
Professional Portable Generator
M165950A
OWNER’S MANUAL
Call Customer Service at 1-800-270-0810

1
THANK YOU
Thank you forpurchasing a NorthStar Pro 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 machines operation, maintenance and
safety precautions. Everyone whooperatesthisgeneratormust readand understand this manual.
The time you take now will prolong your generator’s life and prepare you for its safe operation.
Enjoy the exceptional performanceof your NorthStarPro SeriesGenerator.
IMPORTANT
If thismachineisused by anyone whoisnotthe owner orisloaned or rented, make certain the
operator:
- Isinstructed in safe and proper operation of thismachine.
- Readsand understandsthemanualspertaining to 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
Introduction 4
ANSI safety definitions 4-5
Rules forsafe operation 5
Installation 5
Load application 6-7
Pre-startup preparation 7-8
Starting 8
Stopping 8
Engine care 8
Generator care 8
Troubleshooting 9

2
SPECIFICATIONS
Item Number #165950
Maximum Output 5500 Watts (W)
Continuous Output 4000 Watts (W)
Voltage 120 /240 Volt(V)
Phase Single phase (4-wire)
Frequency 56.5-63.3 Hertz(Hz)
Power Factor 100 %
Engine 8 Hp Honda GX240
Engine Speed 3390 - 3798 RPM
Fuel Type Non-leaded automobile gasoline
Fuel Capacity 6.5 gallons (24.6 L)
Oil Capacity 1.16 US quarts (1.1 L)
Starting Method Recoil
120 VReceptacle 20 Amp (A) duplex(NEMA 5-20R)
20 Amp (A) locking device
(NEMAL14-20R)
120/240 VReceptacle 20 Amp (A) locking device
(NEMAL14-20R)
CircuitBreaker 20 Amp (A) thermal, push to reset
Grounding Post Receives 12 Ga.wire or fork terminal
Dimensions
Length 31.75” (80.6 cm)
Width 23.63” (60.0 cm)
Height 22.25” (56.5 cm)
DryWeight 180 lb.(82 kg)
Gross Weight 220 lb.(100 kg)

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MACHINE COMPONENT IDENTIFICATION
Figure 1 (Ref. 1-9) 00581
Ref. Description Ref. Description
1Circuit Breakers 9 Super Silent Muffler
2 120/240V20A
Locking device Rec. 10 GasCap with Gauge
3Grounding Post 11 6.5Gal. GasTank
4 120V 20A Duplex Rec. 12 Generator Head
5Oil Drain Plug 13 Vibration Isolation Mount
6 Engine Stop Switch 14 Recoil
7Warning Decal 15 Choke Lever
8 Air Cleaner 16 Fuel Valve Lever
Figure 2 (Ref. 10-16) 01795

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GENERATOR FEATURES
Reference 1 - Circuit Breakers. This portable
single phase generator has 2, 20 amp (A) push to
reset circuit breakers to protect against electrical
overloads.
Reference 2 - 120/240V Receptacle. The locking
deviceisa 120/240V 20A NEMA L14-20R receptacle.
This receptacle accepts a NEMA plug number L14-
20P.
ALWAYS use grounded male plugs. The neutral
line of the generatoris mechanically grounded to the
frame. Matching NEMA male plugs must always be
used.
Reference 3 - Grounding Post. Ground the
generator via the grounding post, to a copper pipe or
rod thatisdrivenintomoist soil.
Reference 4 - 120V Receptacle. The generator
hasa control panel withoneduplex (two receptaclesin
a common housing) receptacle and one locking device
receptacle. The 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
and5-20P. Each receptacle on the duplex is capable
of drawing 20A.
Reference 5 - Oil Drain Plug. Refer to your
Honda engine manual for oil change
recommendations.
Reference 6 - Engine Stop Switch. The red
engine stop switch is located on the engine. Always
locate this switch and be familiar with its location
before operatingthegenerator.
Reference 7 - Decal.
Reference 8 - Air Cleaner. Refer to your Honda
engine manual forair cleaner care.
Reference 9 - Super Silent Muffler. 8 dB less
than Honda’sstandardmuffler.
Reference 10 - Gas Capwith Gauge. The gas
cap is extra large, creating a large hole for refilling and
a comfortablegrip.You can always monitor the
fuel level without removing the cap by using the
fuel level indicatorbuiltinto thegascap.
Reference 11 - 6.5 Gallon Gas Tank. Large tank
allows for extended run capabilities. Always allow
room for gasoline expansion by not filling the gas tank
completelyfull.
Reference 12 - Generator Head. The electricity
producingpartof thegenerator.
Reference 13 - Vibration Isolation Mounts. The
engine and generator head, are mounted on rubber
cylindersthatabsorbmost oftheengine vibration.
Reference 14 - Recoil. Grasp firmly when
starting engine.
Reference 15 - Choke Lever. Used during cold
starts. Referto the Honda engine manual forusage.
Reference 16 – Fuel Valve Lever. The Honda
enginehasanON-OFF valve. Always keep this valve
closed whenthe generator is not in use. Always keep
thisvalve closed whiletransporting the generator.
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 shutsoff (theengine stop switch remains
in the on position). The engine will not start until the
oil isrefilled to above the safelevel.
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 performanceandlonglifeofthegenerator.
For detailedengine operation andmaintenancealways
refer to the Honda engine owner’s manual furnished
with the generator (Honda refersto the 8 Hp engine as
a GX240).
NorthStar 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, the user shall determine the
suitability of this product for its intended use and
assumesliabilitytherein.
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 extremesituations.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a
death or serious injury.
CAUTION indicates a potentially hazardous
situation, whichifnotavoided, may resultinminor or
moderateinjury. Itmay also be used toalert against
unsafepractices.
RULES FOR SAFE OPERATIONS
Safety precautions are essential when operating
thisgenerator.
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:

5
WARNING This generator is equipped
withagrounding 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
intomoist earth, to prevent electrical shock.
ALWAYS use electrical cords that are in good
condition. Worn, bare, frayed or otherwise damaged
cordscan 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 shockmay result.
ALWAYS use a ground fault circuit interrupter
(GFCI) in damp or highly electrical conductive areas
andonconstructionjob-sitesto preventelectric shock.
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 poisonous gas. Improper ventilation will
cause damage to generator and possible injury to
people.
NEVER touch hotmuffler, 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. Overheatinginload connectingdevices.
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 or wet conditions.
K. Operator non-attendance.
WARNING Check fuel system on a
regular basis. Look for signs of leaks, deterioration,
chafed or spongyfuel hose,loose ormissing fuel hose
clamps, damagedfuel tank or a defective fuel shut-off
valve. Correctanydefectsbefore operation.
WARNING Keep fire extinguisher close
by your generator and be familiar on how to use it.
Consult your local fire department for correct
extinguisher type.
INSTALLATION
OUTDOORS: Choose a location where the
generator will not be exposed to rain, snow or direct
sunlight. Position the generator on secure, level
ground soit will nottip or slide down a hill. Place the
generator so that the exhaust fumes will not be
directedtowardspeople.
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
shortingout the generating system.
Foreign matters, such as dust, dirt, sand, lint, or
abrasivematerialscan cause damage to the generator
head andengine if allowedintoitscooling system.
NEVER install your generator inside confined
areas. Inside installation can cause health hazards or
death.
DANGER Remember,exhaust fumesare
deadly carbon monoxide gas, and must be vented to
theoutside wherethere 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.
LOAD APPLICATION
Itisimportanttodetermine thetotal electrical load
beforeitisconnected to thegenerator. Thetwomajor
factorsin determining thelife of a generator head are:
heat build up, caused by overloading the generator,
andcorrosive 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
insulationiseliminatedanda 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 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

6
multiplying nameplate voltage by nameplate
amperage.
VOLTS X AMPS = WATTS
Example: 120V X 5A = 600W
When connecting a resistive load such as
incandescentlights, heatersor common electric power
tools, a capacity of up to the generator full rated
wattageoutputcanbe 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
generator’sfull rated output canbeused.
Always allow the generator to reach operating
speed before aloadisapplied.
STARTING ELECTRICMOTORS
Electric motors require much more current (amps)
to start than to run. Some motors, particularlylow cost
split-phasemotors, are very hard to start and require 5
to 7timesmore currentto start than to run. Capacitor
motors are easier to start and usually require 2 to 4
timesasmuch current to start than to run. Repulsion
Induction motors are the easiest to start and require
1.5to2.5timesasmuch to start thantorun.
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 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 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
themotor.
Generators respond to severe overloading
differently than the power line. When overloaded, the
engineisnotable tosupply 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
theengine. If allowed to operate at very low speeds,
the electric motor starting winding will burn out in a
short time. The generatorhead winding might also be
damaged.
Running the generator underthese conditionsmay
result in damageto the generator stator as well as the
motor windings. Because the heavy surge of current
isrequired foronly an instant, the generator will not be
damagedifit canbring themotorup to speed in a few
seconds. If difficulties in starting a motor are
experienced, turn off all other electrical loads and if
possible reduce theload on the electric motor.
EXTENSION CORDS
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
allowfor distance in length and amperage so that the
voltage dropbetween the set and point of use is held
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 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.
For Determining Generator Load Requirements
Device Running Watts
Air Conditioner (12,000Btu) 1700 (b)
Battery Charger (20Amp) 500
Belt Sander (3”) 1000
Chain Saw 1200
Circular Saw (6-1/2”) 900
Coffee Maker 1000
Compressor (1 HP) 2000 (b)
Compressor (3/4 HP) 1800 (b)
Compressor (1/2 HP) 1400 (b)
CurlingIron 700
Dishwasher 1200
EdgeTrimmer 500
Electric Nail Gun 1200
Electric Range (one element) 1500
ElectricSkillet 1250
FurnaceFan (1/3HP) 1200 (b)
Freezer 800(c)
Hair Dryer 1200
Hand Drill (1”) 1100
Hand Drill (1/2”) 875
Hand Drill (3/8”) 500
Hand Drill (1/4”) 250

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HedgeTrimmer 450
Home Computer 150(a)
Impact Wrench 500
Jet Pump 800 (b)
Lawn Mower 1200
LightBulb 100
Microwave Oven 700
MilkCooler 1100 (b)
Oil Burneron Furnace 300
Oil FiredSpace Htr(140,000 Btu) 400
Oil FiredSpace Htr (85,000 Btu) 225
Oil FiredSpace Htr (30,000 Btu) 150
Oven 4500
Paint Sprayer, Airless (1/3 HP) 600 (b)
PaintSprayer, Airless(handheld) 150
Radio 200(a)
Refrigerator 600(c)
Slow Cooker 200
Submersible Pump (1-1/2 HP) 2800 (b)
SubmersiblePump (1 HP) 2000 (b)
Submersible Pump (1/2 HP) 1500 (b)
Sump Pump 600 (b)
TableSaw (10”) 2000 (b)
Television 500(a)
Toaster 1000
Vacuum cleaner 250
VCR 70 (a)
Water Heater 3000
WeedTrimmer 500
(a) Alwaysuse a voltage surge protector between
the generator and these voltage sensitive loads. To
order a surge protector call customer service at 1-
800-270-0810 and askfor item # 30793.
(b) Hard-starting motors require 3 to 5 times the
rated running watts.
(c) 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 dealerto determine the maximum wattage.
PRE-START PREPARATIONS
Yourgenerator hasbeenthoroughly tested priorto
shipment from 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 problems occur, call customer
service at1-800-270-0810.
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 an approvedgroundclamp to thepipe.
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 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. The speed of the engine was carefully
adjusted atthe factory so that the generator produces
theproper voltage and frequency.
The output voltage should be checked to ensure
thegenerator is working properly before connecting a
loadto the generator. Failure to do so could result in
damage to equipment plugged into the unit and
possible injury to the individual.
All engineshave a tendency to slow down when a
loadisapplied. 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 whenthegeneratorisloaded to itsfull capacity
than when it is running with no load. The slight
variationhas no appreciable effect in the operation of
motors, lights and most appliances. Electronic
equipmentand clockswill be affectedif correct RPM is
notmaintained. See Load vs. Output chart.
Load Output
Percent of
Generator
Output
Speed
(RPM) Frequency (Hz) Generator Voltage at120V
Receptacle
0 % 3750 62.5 129V
50 % 3600 60.0 120V
100% 3540 59.0 112V
Output voltage should be periodically checked to
ensure continued proper operation of the generating
plantand appliances, it can be checked witha 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. Engine speed
adjustmentsshould bedone by a qualifiedtechnician.
BEFORESTARTING
1. Make sure the generator is positioned on firm
level surface.
2. Check the crankcase for oil and maintain at a
properlevel.
3. Check fuel level and fill tank 7/8 full with fresh
unleaded automotive 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.

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STARTING
1. Disconnectall loadsto generator.
2.Turngasline valve to ONposition.
3. Turn engine on-off switch located on engine to
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. Grasp recoil handleand pull.
6. When engine starts, move choke lever to RUN
position.
7. Loadsmaynowbe connected togenerator.
STOPPING
1. Disconnectall loadsto generator.
2. Placeengineon-off switchto 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 overshootthe oil drain hole on the generator
base.
GENERATOR CARE
The generator headisa two pole, 3600 RPM, 60
Hz, brushless, revolving field and synchronous type
withone sealed radial roller 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 thegenerator head casting.
Exercising the Generator -Thegenerator should
be operated every three to four weeks. Warm the
generator by starting the engine and letting it run for
10 to 15 minutes. This will dry out any moisture that
hasaccumulated in the windings. If left, this moisture
can cause corrosion in the winding. Frequent
operation ofthe engine generator will also ensure that
the setisoperating 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 FACTORY
APPROVED REPAIR PARTS.
A. Bearing- Thebearing used in these generators
isa heavy duty sealed rollerbearing. 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 anddestructiveto 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 Departmentsmust be
consulted concerning proper and safe handling
procedures for gasoline. NEVER connect any
generator to any existing electrical system without an
isolating, UL approved transfer switch, installed by a
licensedelectrician.

9
TROUBLESHOOTING
Problem Possible Causes Possible Remedies
Engine will not start. a) Low oil level.
b) Fouled sparkplug.
c) Out of fuel.
d) StopswitchinOFF position.
a) Fill crankcase to properoil level.
b) Cleanor replace sparkplug.
c) Fill fuel tank.
d) Place switchin ONposition.
Voltage too low. a) Engine speed too slow.
b) Generatorisoverloaded.
a) Bring generator to a qualified
technician for adjustment.
b) Reduce theload.(SeeLoad
Application section ofthismanual.)
Circuit breaker trips. a) Defectiveload connected to generator.
b) Defectivereceptacle.
c) Generator overloaded.
a) Disconnectload.
b) Replacereceptacle.
c) Reduce theload.(SeeLoad
Application section ofthismanual.)
Voltage too high. a) Engine speed toohigh. a) Bring generator to a qualified
technician for adjustment.
Generatoroverheating. a) Generatorisoverloaded.
b) Insufficient ventilation.
a) Reduce theload.(SeeLoad
Application section ofthismanual.)
b) Make sure there isatleast 3 feetof
clearance on all sides of generator.
No output voltage. a) Defective load 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 theload.(SeeLoad
Application section ofthismanual.)
b) Cleanor replace air filter.
Engine shutsdown
during operation. a) Outof fuel. b) Lowoillevel. a) Fill fuel tank. b) Fill crankcase to properoil level.