North Star M165920S User manual

M165920S
Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Industrial Gasoline Generator
6,600 Watt Continuous (8,000 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: 165920
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
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 8000 Watts of
electrical power (6600 watts continuous, 8000 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.
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.

About Your Generator (cont’d)
5
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 165920
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 1.0 p.f.
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 Electric Start / Recoil
120 V Receptacle (2) 20 Amp (A) duplex GFCI (NEMA 5-20R)
(1) 30 Amp (A) locking device (2) (NEMA L5-30R)
(1) 50 Amp (A) straight blade (NEMA 5-50R)
120/240 V Receptacle 30 Amp (A) locking device (NEMA L14-30R)
Circuit Breaker (2) 20 Amp (A) Thermal, push to reset
(1) 30 Amp (A) Thermal, push to reset
(1) 50 Amp (A) Thermal, push to reset
(1) 30 Amp (A) Magnetic, 2 Pole
Grounding Post Receives 10 Ga. wire or fork terminal
Battery (not included) 12 Volt, Group size U1
170 CCA, 18 amp-hr
Dimensions
Length 31.75” (80.6 cm)
Width 23.63” (60.0 cm)
Height 22.25” (56.5 cm)
Dry Weight 225 lb (103 kg)
Gross Weight 280 lb (128 kg)

Safety Label Locations
7
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
39260 Burn Warning
779422 NorthStar
779423 Warning
779396 Battery Warning
BATTERIES:
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 chargerinstructions.
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 charged battery ensures reliable engine starting.
PN 779396
©2007 NT+E 1-800-270-0810
• Commercial-grade electric start engine
• Extend run 6.5 gallon fuel tank
• Maintenance-free brushless alternator design
• Smooth running focus mount isolation system
• Commercial-grade electric start engine
• Extend run 6.5 gallon fuel tank
• Maintenance-free brushless alternator design
• Smooth running focus mountisolation system
PN 39260
BURN HAZARD
Do not touch
hot muffler.
©2005 NT+E 1-800-270-0810
WARNING

Machine Component Identification - Item #165920S
8
Figure 1 (Ref. 1-13)
Ref. Description Ref. Description
1 Air Cleaner 11 Gas Cap with Gauge
2 Oil Drain Plug 12 6.5 Gallon Gas Tank
3 Full Power Switch 13 Super Silent Muffler
4 Voltmeter 14 Generator Head
5 Idle Control On/Off Switch 15 Battery Box
6 Hour Meter 16 Vibration Isolation Mount
7 Main Line Circuit Breaker 30A 17 Recoil
8 50A Circuit Breaker 18 Fuel Shut-Off Valve
9 30A Circuit Breaker 19 Choke Lever
10 20A Circuit Breaker 20 Engine Starting Key
Figure 2 (Ref. 14-20)

Machine Component Identification - Item #165920S
9
REFERENCE GUIDE
Reference 1 – Air Cleaner Refer to your Honda engine manual for air cleaner care.
Reference 2 – Oil Drain Plug Refer to your Honda engine manual for oil change
recommendations.
Reference 3 – Full Power Switch The switch reconnects the two generator windings from
parallel (120V only) to series (120/240V).
• 120V Only:Allows all 6600 watts (55A) to be used in
any combination of 120 volt receptacles. The 120/240V
30A locking device receptacle is 120V only at this time.
• 120/240V :Allows all 6600 watts to be used for 240V.
However, only half the power or 3300 watts (27.5A), can
be used at any one 120V receptacle. 120V output can
total 6600 watts.
Reference 4 – Voltmeter Voltmeter needle should be in green area during all generator
load conditions.
Reference 5 – Idle Control On/Off
Switch This feature senses the load on the generator. With no load
on the generator the engine speed drops to idle. This saves
fuel and lengthens engine life. When a load is applied, the
engine speed returns to 3600 - 3780 RPMs. Turning the
switch off disables the sensing device and the generator will
run at 3600 - 3750 RPM whether or not a load is applied.
Note: When the engine is idling, it is normal for the
voltmeter needle to be in the red range.
Reference 6 – Hour Meter Allows for better maintenance scheduling of generator.
Reference 7 – Main Line Circuit
Breaker 30A 30 amp (A) magnetic 2-pole main circuit breaker to protect
against electrical overloads.
Reference 8 – 50A Circuit Breaker 50 amp (A) push-to-reset circuit breaker
Reference 9 – 30A Circuit Breaker 30 amp (A) push-to-reset circuit breaker
Reference 10 – 20A Circuit Breaker 20 amp (A) push-to-reset circuit breaker
Reference 11 – Gas Cap with
Gauge The gas cap is extra large, creating a large hole for
refueling. You can monitor the fuel level without removing
the cap by using the fuel level indicator built into the gas
cap.
Reference 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
completely full.
Reference 13 – Super Silent Muffler 4 dB less than Honda’s standard muffler.
Reference 14 – Generator Head The electricity producing part of the generator.
Reference 15 – Battery Box The battery box provides protection for the battery and will
accept a standard lawn tractor size battery (Group U1-7).
The engine requires a 12-volts battery, with a minimum
rating of 18Ah (Amp-Hour). See battery section for sizing.
Reference 16 – Vibration Isolation
Mount The engine and generator are mounted on rubber cylinders
that absorb most of the engine vibration. This feature
eliminates the tendency of the machine to “walk” which is
common in engine powered equipment.
Reference 17 – Recoil Grasp firmly when starting engine. Consult engine manual
for further instruction.
Reference 18 – Fuel Shut-Off Valve The engine is equipped with an ON-OFF valve located on
the left side of the recoil. ALWAYS keep this valve closed
when the generator is not in use.
Reference 19 – Choke Lever Used during cold starts. Refer to the starting/stopping
instructions and the Honda engine manual for usage.
Reference 20 – Engine Starting Key The engine key is located on the engine. Always locate this
switch and be familiar with its location before operating the
generator.

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

Power Load Planning & Management (cont’d)
11
Device Running Watts Device Running Watts
Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a)
Freezer 800 (b) Submersible pump (1 HP) 2000 (a)
Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a)
Hand drill (1”) 1100 Sump pump 600 (a)
Hand drill (1/2”) 875 Table saw 2000 (a)
Hand drill (3/8”) 500 Television 500
Hand drill (1/4”) 250 Toaster 1000
Hedge trimmer 450 Vacuum cleaner 250
Home computer 150 VCR 70
Impact wrench 500 Water Heater 3000
Weed trimmer 500
(a) Hard-starting motors require 3-5 times the rated running watts
(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to
determine maximum wattage
To calculate the running and starting wattage requirements for the devices you will be
powering, follow these steps:
1. Make a list of all electrical devices you will be powering at the same time with the generator.
2. List the greater of the running or starting wattage next to each device as obtained from the
devices’ nameplate or Table 1. If only the running wattage for a device with an electric
motor is known, the starting wattage can be estimated to be at least 3 times the running
wattage.
3. Add the wattages for all devices on your list. This total must be lower than the continuous
output rating of your generator.
Example:
Device to be Powered Greater of Starting/Running Wattage
Light Bulb 75 W
Refrigerator – 18 Cu. Ft. 1600 W
Microwave 700 W
Window AC 1800 W
Sump pump (1/3 hp) 2100 W
Total 6275W
In this example, the generator must have a continuous output of at least 6275 W in order to
power all of the devices simultaneously.
You can increase the number of devices your generator can power by staggering the load on the
generator. For example, you could alternately power your refrigerator and air conditioner for
limited periods of time -- powering only one of the devices at a time and never powering both at the
same time.
STAGGERING LOADS

Installation / Initial Set-Up
12
There are a number of important steps required to set up your generator for initial use. These steps
are:
Steps for Installation / Initial Set-Up
1. Unpacking & delivery inspection.
2. Planning the power load to stay within the generator’s rated
capacity.
3. Setting up generator for the type of power generation you need:
a. portable power source, or
b. connected to a building as a back-up power source.
4. Selecting a site for using the generator.
5. Grounding.
6. Battery installation (electric start models only).
Each of these steps is discussed in detail below:
1. Unpacking & Delivery Inspection
You should inspect the generator immediately after you receive delivery.
See the “Machine Component Identification” section of this manual for a
diagram of the generator and its components.
• If you have missing components, contact Product Support at 1-800-270-0810.
• If you have damaged components, contact the freight company that delivered the unit and file a
claim.
2. Planning the Power Load
Plan your power load so that you do not exceed the generator’s rated capacity.
See the “Power Load Planning & Management” section of this manual to review how to plan and
manage power loads for the generator.

Installation / Initial Set-Up
13
3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source
This generator is designed to provide up to 8000W of electrical power. It can supply electricity in
two ways:
1. As a back-up, standby power source for a building. For this application, you must arrange
for a licensed electrician to connect the generator to your building’s electrical system via the
installation of an UL-approved transfer switch. The transfer switch must be installed in
accordance with building electrical code and guidelines supplied by your power company.
2. As a portable power source. You can plug appliances or tools directly into the generator’s
electrical outlets.
Specific requirements for each are given below.
Note: Regardless of whether you use your generator as a back-up power source connected to a
building or as a portable power source, you must not overload the generator. Overloading
may cause serious damage to the generator and attached electrical devices.
Using as a
Back-up Power
Source for a
Building
Contact a licensed electrician to install an UL-approved transfer switch if
you want to use your generator as a back-up power source for a building.
What does a transfer switch do? It:
a) Safely connects the generator to your building’s electrical system by
isolating your generator from your utility company’s power lines,
AND
b) Connects your generator to a critical subset of your building’s circuits
that are needed for emergency power needs.
If your generator will be connected to your building’s electrical system, it
MUST ALWAYS be isolated from the utility power grid with a UL-approved
transfer switch installed by a licensed electrician in compliance with all
applicable building and electrical codes, and in accordance with guidelines
supplied by your power company.
DANGER:
A transfer switch must be installed in order to isolate your
generator from the utility power grid. If your generator is
NOT properly isolated from the utility system, serious
hazards will arise:
♦ When your generator is running, it’s output will back feed
into the utility power line and transformer that are
normally used to provide you with power. The
transformer will step up the current to the normal line
voltage. An unsuspecting utility line worker working on
what he thinks is a deactivated line could be electrocuted.
♦ If your generator is connected (running or not) when
utility power is restored, your generator will be destroyed.
It could also explode or cause fire.
In addition to isolating your generator from the utility system, the transfer
switch connects your generator to a limited set of circuits in your building
that have been chosen as critical to operate during a power outage.

Installation / Initial Set-Up
14
The generator cannot power your entire home -- you must work with the
installing electrician to determine which devices/appliances you wish to
power during an outage. The electrician can help you determine which
circuits and devices can be powered simultaneously without overloading the
generator.
(See the previous section of this manual entitled “Power Load Planning &
Management” for more information on load application and selection.)
Using as a
Portable Power
Source
When using the generator as a portable power source, you can plug
electric devices and appliances directly into the generator’s electrical
outlets.
There are four different kinds of electrical outlets on the generator:
1. One 120 Volt, 50 Amp straight-blade receptacle (NEMA 5-50R
receptacle compatible with NEMA 5-50P mating plug)
2. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R
locking receptacle compatible with L14-30P mating plug)
3. One 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle
compatible with NEMA L5-30P mating plug)
4. Two 120 Volt, 20 Amp, duplex GFCI-protected straight-blade
receptacles (NEMA 5-20R duplex receptacles compatible with
NEMA 5-20P or 5-15P mating plugs) – with a single, shared trip
light and reset button.
Note: This generator is equipped with a Full Power Switch that allows you
to switch between 120V only or 120/240V power at the outlets. See
the “Machine Component Identification” section of this manual for
more information about the use of the Full Power Switch.
(See more technical detail about these receptacles and their associated
circuit breakers in the “Machine Component Identification” section of this
manual.)
DELA
Y
HOUR METER
A
DJUSTABLEIDLE
IDL E CONTROL RECEPTACLES
120V X
H
N
G
Y
H
N
EM
A
L14-30
R
N
EMA
L5-30
R
N
EMA
5-50
R
2X
N
EMA
5-20R
FULL POWER
SWITCH

Installation / Initial Set-Up
15
♦ Make sure you plug each electrical device/appliance into the correct
generator outlet based on the device’s plug configuration and
voltage/amperage rating. Never exceed the amperage rating of an outlet.
♦ Extension cords may be used to power devices that are located at a
distance from the generator. However, use only UL-listed, outdoor-rated,
grounded extension cords of the proper size. Use Table 2 below to choose
an adequately sized extension cord according to the amperage of the
device being used and the length of the cord.
Table 2
WARNING:
Use of under sized extension cords can cause electric shock,
fire, or damage to connected devices.
♦ All extension and appliance cords must be in good condition and not worn,
bare, frayed, or otherwise damaged.
WARNING:
Use of damaged electric cords can cause electric shock or fire.
Note: If an extension cord becomes hot to the touch, it is overloaded or
damaged and must be replaced.
Northern Tool is NOT responsible for damage or injury resulting from
customer use of inadequate extension cords.
Current/Power Maximum Extension Cord Length
Amps at Load #10 Ga. #12 Ga. #14 Ga. #16 Ga.
240V (watts) Cord Cord Cord 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' * * *

Installation / Initial Set-Up
16
4. Select a Suitable Site
Before using the generator, you must select a suitable OUTDOOR location for installation and
operation. This location should meet all of the criteria listed below.
WARNING:
You must choose a suitable site for operating your generator to avoid equipment
damage and/or injury and possible death from carbon monoxide poisoning, electric
shock, or fire. Choose a site that meets all of the criteria specified.
Dry, level surface The generator should be positioned on a dry, firm, level surface.
Ensure that the generator sits level and will not slide or shift during operation.
If applicable, block the generator’s wheels to prevent sliding and shifting.
Outdoors only –
dangerous carbon
monoxide exhaust
WARNING: Carbon monoxide poisoning hazard
The exhaust from your generator contains carbon monoxide
(CO), a poisonous gas that can kill. You cannot smell it, see it,
or taste it. Carbon monoxide exhaust is given off whether you
are using gasoline, natural gas, or propane as the fuel source to
power the generator. Follow the directions below for choosing
a location to operate your generator in order to avoid carbon
monoxide poisoning.
The location you choose to operate the generator must be OUTDOORS
and away from all air intakes:
• Never run the generator inside any closed or semi-enclosed spaces (even if
outdoors), including homes, garages, basements, sheds, or boxes. These
spaces can trap poisonous gases, even if you run a fan or open windows.
• Place the generator so that the exhaust fumes will not be directed towards
people or building air intakes.
• Ensure that working, battery-operated or battery back-up carbon monoxide
alarms are used in any dwelling/structure that is in close proximity to the
running generator.
• Note that this generator is NOT designed or approved for use in vehicles
or marine applications. Never run the generator inside RVs or other
vehicles, on boats, or on pick-up truck beds.
WARNING:
Never attempt to attach ductwork to the muffler system to allow
for installation inside an enclosure. This could cause hot air
deflection, heat build-up, and increased exhaust backpressure,
resulting in possible exhaust leakage or damage to the generator.

Installation / Initial Set-Up
17
Adequate cooling
ventilation The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head.
WARNING:
Heat build-up from inadequate ventilation can result in fire,
posing a serious risk to nearby persons and structures.
• Situate so there is adequate clearance around generator to allow for
cooling airflow so that heat does not build up.
• Never place the generator immediately adjacent to a building or other
structure – allow at least a 7’ clearance.
• Do not run the generator in close proximity to other heat-generating
equipment, such as another generator. The combined heat that is
generated may raise air temperature in the immediate area and there will
not be adequate cooling ventilation.
• Do not allow debris to accumulate and block airflow.
• Do not operate with a tarp, blanket, or cover surrounding the generator.
No wet conditions Choose a location where the generator will NOT be exposed to rain,
snow, or direct sunlight. Exposure to water can cause electric shock.
You may operate the generator under an outdoor, canopy-like structure of
heat-resistant material that is open on all sides. Make sure that all parts of
canopy are at least 7’ from exhaust, and allow for adequate clearance above
generator so that heat does not build up.
Hot exhaust
clearance The exhaust gas from your generator is extremely hot and can cause combustible materials to catch on fire.
• Make sure your generator’s exhaust system is at least 7 feet from all
combustible materials and buildings/structures.
• Equip the engine with a spark arrestor if the generator will be used near
any ignitable forest, brush, or grassy land. (See the “Specifications”
section of this manual to determine if your generator is already equipped.)
Make sure you comply with applicable local, state, and federal codes.
• Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged
and be familiar with its use.
Away from
dust/dirt Do not use the generator in extremely dusty or dirty conditions.
Excessive dust and dirt can cause premature failure of the machine.
Hearing
protection Generators can produce noise levels of up to 95 dB in close proximity, which can be dangerous to human hearing with prolonged exposure.
Hearing protection may be required for persons working within 15-20 feet of
the running generator for an extended period of time.
WARNING:
Never attempt to attach ductwork to the muffler system to lower
noise levels. This could cause hot air deflection, heat build-up,
and increased exhaust backpressure, resulting in possible
exhaust leakage or damage to the generator.

Installation / Initial Set-Up
18
10 Ga. wire
Coppe
r
Pipe/Ro
d
Grounding Post
Groun
d
5. Grounding the generator
Always ensure the generator is properly grounded to prevent electrical shock.
You must always ground the generator by the following method when using the generator as a
portable electrical source:
1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod
must penetrate moist earth – the depth required will be dictated by local soil conditions.
Consult with an electrician.
2) Connect an approved ground clamp to the pipe.
3) Run a 10 gauge wire from the clamp to the generator grounding post located on the rear of
the generator head.
4) Do not connect the generator grounding post to a water pipe or a ground used by a radio
system.
If a licensed electrician installs the generator with a connection to your building’s electrical circuit
for use as a back-up power system, grounding may alternatively be completed through the
building’s grounding system. Ask your electrician. If the generator is not grounded through your
building’s electrical system, follow the procedure above.
WARNING:
Operating the generator when it is not properly grounded can result in electrical
shock.

Installation / Initial Set-Up
19
6. Battery Installation
Your generator’s engine is equipped with an electric starter which requires the installation of a 12-
volt lawn tractor size battery (Group U1). See the “Specifications” section of this manual for more
specific battery requirements for this generator model, such as minimum amperage or CCA rating.
The battery is to be supplied by the customer and should be installed in the protective battery box
located near the engine. Follow the instructions detailed below for connecting and disconnecting
the battery.
WARNING: Battery hazards
Batteries are hazardous because they contain caustic acid, can emit explosive gases,
and can cause electric shock. Caution must be exercised when making connections
to a battery to avoid shock and contact with the acid, and to prevent any sparking
that could lead to an explosion.
ALWAYS follow the general battery safety rules and instructions listed below.
General Battery
Safety Rules • ALWAYS use eye protection when handling batteries.
• NEVER smoke or work near sparks or other sources of ignition.
• NEVER touch both battery terminals at the same time with your hand or
any non-insulated tools.
• If battery acid contacts skin or clothing, flush immediately with water and
neutralize with baking soda.
Connecting the
battery Always connect the cables in the following sequence to avoid possible shock:
1. Find the battery cables located inside the battery box.
2. Connect the red cable to the positive (+) terminal of the battery.
3. Then connect the black cable to the negative (-) terminal of the battery.
Disconnecting the
battery Always disconnect cables in the following sequence to avoid possible shock.
1. First, disconnect the black cable from the negative (-) terminal of the
battery.
2. Next, disconnect the red cable from the positive (+) terminal of the
battery.

Operation
20
Once you have set up your generator for use, it is time to start your generator. The following
are the procedures necessary for safe, successful operation of your generator.
Operation Procedures
1. General Safety Rules for Operation
2. Preparing for Operation
3. Starting the Engine
4. Checking Generator Output
5. Connecting Electrical Loads (Portable Power Generation)
6. Stopping
7. Storage & Exercise of Generator
Each of these procedures is discussed in detail below:
1. General safety rules for operation
Before starting the generator, review the following general safety rules for operation:
WARNING:
Failure to follow safety rules may result in serious injury or death to the
operator or bystanders.
• Know proper use/how to stop. Be thoroughly familiar with proper use of the equipment and all
generator controls, output receptacles, and connections. Know how to stop the generator quickly
if needed (see “Operation, Step 6 - Stopping the Engine”).
• Instruct operators. The generator owner must instruct all operators in safe generator set-up and
operation. Only trained adults should set up and operate the generator – Do not let children
operate.
• Intended use. Carefully read about and understand the intended use of this generator. Do not
use for other purposes, as unforeseen hazards or equipment damage may result.
• Under the influence. Never operate, or let anyone else operate, the generator while under the
influence of alcohol, drugs, or medication.
• Safety equipment / controls. Do not operate the generator unless all safety covers, guards, and
barriers are in place and in good working order, and all controls are properly adjusted for safe
operation.
• Damaged. Do not operate the generator with damaged, missing, or broken parts.
• Modifications. Do not modify the generator in any way. Modifications can create serious
safety hazards and will also void the warranty.
• Engine speed. Never attempt to modify the engine speed setting. The engine speed is preset at
3600 RPM for safe and optimal performance of the generator. If speed needs adjusting, it must
be done by factory-authorized personnel.
• External fuel sources. Never attempt to connect external gasoline/diesel sources in order to
increase engine run time. Larger tank at pressure or higher elevation will cause gasoline to leak
from carburetor during operation. Fire or explosion could result.