North Star 8000 PPG User manual

Proven Performance
MODEL 8000 PPG,ITEM # 165914
Professional Portable Generator
M165914G
OWNER’S MANUAL
Call Customer Service at 1-800-270-0810
Hours: Monday - Friday 7:30 AM to 5:00 PM
Saturday 7:30 to 11:30 AM CST

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 machine’s operation, maintenance and
safety precautions. Everyone who operatesthisgenerator must read and 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
Make certain the operator:
- Readsand understandsthemanualspertaining to thismachine.
- Isinstructedin safe and proper operation of 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 component identification 3
Generator features 4
Introduction 4
ANSI safety definitions 5
Rules forsafe operation 5
Installation 5-6
Load application 6-7
Pre-startup preparation 7-8
Starting 8
Stopping 8
Engine care 8
Generator care 8-9
Troubleshooting 10

2
SPECIFICATIONS
Item Number #165914
Maximum Output 8000 Watts (W)
Continuous Output 6600 Watts (W)
Voltage 120 /240 Volt(V)
Phase Single phase (4-wire)
Frequency 56.5-63.3 Hertz(Hz)
Power Factor 100%
Engine 13 HP Honda GX390
Engine Speed 3390 - 3798 RPM
Fuel Type Unleaded gasoline
Fuel Capacity 6.5 gallons (24.6 L)
Oil Capacity 1.16 US quarts (1.1 L)
Starting Method Recoil
120 VReceptacle 15 Amp (A) duplex
(NEMA 5-15R) & 20 Amp (A) duple
x
(NEMA 5-20R)
120/240 VReceptacle 30 Amp (A) locking device
(NEMAL14-30R)
CircuitBreakers 30 Amp (A), Qty. 2;20 Amp (A), Qty. 2;
15 Amp (A), Qty. 1; thermal, push to
reset style
Grounding Post Receives 12 Ga.wire orfork terminal
Dimensions
Length 31.75” (80.6 cm)
Width 23.63” (60.0 cm)
Height 22.25” (56.5 cm)
DryWeight 210 lb.(95 kg)
Gross Weight 250 lb.(114 kg)

3
MACHINE COMPONENT IDENTIFICATION
Figure 1 (Ref. 1-10) 00585
Ref. Description Ref. Description
1Circuit Breakers 10 Super Silent Muffler
2 120/240V 30A Locking Rec. 11 GasCap with Gauge
3Grounding Post 12 6.5Gal. GasTank
4 120V 20A Duplex Rec. 13 Generator Head
5120V 15A Duplex Rec. 14 Vibration Isolation Mount
6 Oil Drain Plug 15 Recoil
7Engine Stop Switch 16 Fuel Valve Lever
8 Starting/StoppingInstructions 17 Choke Lever
9Air Cleaner
Figure 2 (Ref. 11-17) 01805

4
GENERATOR FEATURES
Reference 1 - Circuit Breakers. This portable
single phase generator has1,15 amp (A) 2, 20A, and
2, 30Apush to reset circuit breakers to protect against
electrical overloads.
Reference 2 - 120/240V Receptacle. The locking
deviceisa 120/240V 30A NEMA L14-30R receptacle.
This receptacle accepts a NEMA plug number L14-
30P.Use this receptacle if installing a transfer switch,
which is compatible with a Gentran transfer switch,
item #16412.
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 cord-sets. Improper
wiring could resultinafire or electrical shock.
Reference 3 - Grounding Post. Ground the
generator via the grounding post, to a copper pipe or
rod thatisdriven intomoist soil.
Reference 4 - 120V Receptacle. The second
duplex is a 120V 20A straight blade receptacle,
National Electrical Manufacturer’sAssociation (NEMA)
number 5-20R. This receptacle accepts NEMA plug
numbers 5-15P and 5-20P. Each receptacle on this
duplexiscapable of drawing 20A.
Reference 5 - 120V Receptacle. The generator
hasa control panel with two duplex(two receptaclesin
a common housing) receptacles. The one duplex is a
120 volt (V) 15 amp (A) straight blade receptacle,
National Electrical Manufacturer’sAssociation (NEMA)
number 5-15R. This receptacle accepts NEMA plug
number5-15P. Theduplexis capable of drawing 15A
outofeither receptacle or a combination ofboth.
Reference 6 - Oil Drain Plug. Refer to your
Honda engine manual for oil change
recommendations.
Reference 7 - Engine Stop Switch. The red
engine stop switch is located on the engine. Always
locate this switch and be familiar with its location
before operating thegenerator.
Reference 8 - Starting/Stopping Instructions.
Reference 9 - Air Cleaner. Refer to your Honda
engine manual forair cleaner care.
Reference 10 - Super Silent Muffler. 4 dB less
than Honda’sstandard muffler.
Reference 11 - Gas Capwith 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 builtintothegascap.
Reference 12 - 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 13 - Generator Head. The electricity
producing partof thegenerator.
Reference 14 - Vibration Isolation Mounts. The
engineand generatorare mountedon rubber cylinders
thatabsorb most ofthe engine vibration. This feature
eliminatesthetendencyof the machine to“walk” which
iscommon inenginepoweredequipment.
Reference 15 - Recoil. Grasp firmly when
startingengine.
Reference 16 – FuelValve Lever. The generator
tank has an ON-OFF valve mounted underneath the
tank. Always keep this valve closed when the
generator isnotin use.
Reference 17 - Choke Lever. Used during cold
starts. Refer to the starting/stopping instructions and
the Hondaengine manual forusage.
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 performanceandlong lifeofthegenerator.
For detailed engine operation andmaintenancealways
refer to the Honda engine owner’s manual furnished
withthe generator (Honda refers to the 13 Hp engine
asa 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.
Before using, the user shall determine the
suitability of this product for its intended use and
assumesliabilitytherein.

5
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
deathor serious injury.
CAUTION indicates a potentially hazardous
situation, whichifnotavoided, may resultinminor or
moderateinjury. Itmay also beused 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, and these will be designated by the symbol:
WARNING This generator is equipped
witha grounding post, which is located on the control
panel. Always complete the grounding path from the
generator toa copper pipe/rod thatis driven into moist
earth,topreventelectrical 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
andonconstruction job-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 touchhotmuffler, 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 connecting devices.
C. Sparking orarcsfrom generator.
D. Lossof electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
H. Enclosed compartments, orconfined areas.
I. Flame or smoke.
J. Rain, snow orwet 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.
WARNINGKeep a 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 locations 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
shorting out thegenerating system.
Foreign matters, such as dust, dirt, sand, lint, or
abrasivematerialscan cause damage tothe generator
head andengineif allowedintoitscooling system.
NEVER install your generator inside confined
areas. Insideinstallation can cause health hazards or
death.
DANGERRemember, exhaust fumes are
deadly carbon monoxide gas, and must be vented to
theoutside where there are no people. Cooling air of
sufficient amounts must be brought in and exhausted
out to ensure proper cooling of the engine and
generator head.

6
LOAD APPLICATION
Itisimportanttodetermine the total electrical load
beforeitisconnected to thegenerator. Thetwo major
factorsindetermining the life of a generator head are:
heat build-up, caused by overloading the generator
and corrosive contaminants that 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 iseliminatedanda 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
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
wattage outputcanbe 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 full ratedoutputcan be used.
Always allow the generator to reach operating
speed before a loadisapplied.
STARTING ELECTRICMOTORS
Electric motors require much more current (amps)
to start than to run. Some motors, particularlylow cost
split-phase motors, 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
1.5to2.5timesasmuchto start than torun.
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 thanthe power line. When overloaded, the
engineisnotable tosupply enough powerto bring the
electric motorup 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 thegenerator underthese conditionsmay
resultin damage to the generator stator as well as the
motor windings. Because the heavy surge of current
is required foronly an instant, the generator will not be
damagedifit canbring themotor 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 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’

7
30 7200 60’ 35’ 25’ 10’
40 9600 30’ 15’ 10’ *
50 12000 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.
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 (one element) 1500
ElectricSkillet 1250
FurnaceFan(1/3HP) 1200 (a)
Freezer 800(b)
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
MilkCooler 1100 (a)
Oil Burneron Furnace 300
Oil Fired Space 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)
Slow Cooker 200
Submersible Pump (1-1/2 HP) 2800 (a)
Load Requirements, continued
Submersible Pump (1 HP) 2000 (a)
SubmersiblePump (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
equipmentdealer to determine the maximum wattage.
PRE-START PREPARATIONS
Yourgenerator hasbeen thoroughly testedpriorto
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
damagedparts,loose ormissing nutsandbolts. If the
aforementioned problems occur, call customer service
at 1-800-270-0810.
GROUNDING - All units must be grounded. Drive
a 3/4” or 1” copper pipeor rod intothe ground close to
the generator. The pipe/rod must penetrate moist
earth. Connect an approved ground clamp to the pipe.
Run ano. 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: Theengine 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.
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
adjustedatthe 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
load to the generator. Failure to do so could result in
damage to equipment plugged into the unit and
possible injury to theindividual.
All engineshave atendency to slow down when a
load isapplied. 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

8
variation has no appreciable effect in the operation of
motors, lights and most appliances. Electronic
equipmentand clockswill be affectedif correct RPM is
notmaintained. SeeLoad 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% 3510 58.5 112V
Output voltage should periodically be checked to
ensure continued proper operation of the generating
plant and appliances. Voltage 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. Speed
adjustments should be performed by a qualified
technician.
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.
STARTING
1. Disconnectall loadsto generator.
2.Turn gasline 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 handle and pull.
6. When engine starts, move choke lever to RUN
position.
7. Loadsmaynowbe connected to generator.
STOPPING
1. Disconnectall loadsto generator.
2. Place engineon-off switch to OFFposition.
3.Turn gasline 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 head isa 2-pole, 3600 rpm, 60 Hz,
brushless, revolving field and synchronous type with
one 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 thegeneratorhead casting.
Exercising the Generator - The generator
should be operated every four weeks. Warm the
unit by running the engine 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 itbeneededinanemergency.
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. Obtain factory parts
from Customer Service at 1-800-270-0810.
A. Bearing - The bearing used in these generators
isa heavy duty sealed roller 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 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) Stopswitch inOFF position.
a) Fill crankcase to properoil level.
b) Clean or replace sparkplug.
c) Fill fuel tank.
d) Place switch in 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) Defective load 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) Clean or replace air filter.
Engine shutsdown
duringoperation. a) Out of fuel. b) Lowoil level. a) Fill fuel tank. b) Fill crankcase to properoil level.