NorthStar 165165 User manual

M165165A.2
Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, and Storage
Portable, Outdoor Use-Only, Industrial Diesel Generator
6,120 Watt Continuous (6,500 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-listed
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-listed 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 feet 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 and 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
and 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: 165165
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 and Management.....................................................................................10
Installation / Initial Set-Up:
1. Unpacking and Delivery Inspection.......................................................................................12
2. Planning the Power Load........................................................................................................12
3. Set-up as either a BUILDING BACK-UP or PORTABLE 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 ...............................................................................................................29
7. Storage and Exercise ..............................................................................................................29
Maintenance and Repair ..............................................................................................................31
Troubleshooting.............................................................................................................................33
Summary of Important Safety Information for Operation.......................................................34
Generator Exploded View ............................................................................................................38
Wiring Diagram.............................................................................................................................40
Generator Head Exploded View..................................................................................................41
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 6500 Watts of
electrical power (6120 watts continuous, 6500 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-listed
transfer switch. (See the “Installation and 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
and 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 and Initial Set-up,
Steps 5 and 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-listed transfer switches, and extension cords.
Contact NorthStar Product Support at 1-800-270-0810 with questions about optional
accessories or to order.
Read this Manual
WARNING
Improper use or maintenance of this generator can result in serious injury or death from
carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.
Read this manual completely before using the generator and follow all instructions and
safety rules.
You must follow all instructions and safety precautions presented throughout this manual. A
summary of important safety information can be found at the end of the manual. Keep this
manual for reference and review.

About Your Generator (cont’d)
5
Proper preparation, operation, and maintenance will result in operator safety, as well as best
performance and long life of the generator. For detailed engine operation and maintenance
information, always refer to the engine Owner’s Manual furnished with the generator.
NorthStar is constantly improving its products. The specifications outlined herein are subject
to change without prior notice or obligation. The purchaser and/or user shall assume liability
for any modification and/or alterations of this equipment from original design and
manufacture.
Before using, the user shall determine the suitability of this product for its intended use and
assumes liability therein.
Contact NorthStar Product Support at 1-800-270-0810 for any questions about the
appropriate use of this generator.
Warranty Registration
Please fill out and submit the warranty registration card so that we have your contact
information for any future product literature or replacement parts you may need.
ATTENTION:
All Rental Companies and Private Owners who loan this
equipment to others!
All persons to whom you rent/loan this generator must have access to and read this manual.
Keep this owner’s manual with the generator at all times and advise all persons who will
operate the machine to read it. You must also provide personal instruction on how to safely
operate the generator and remain available to answer any questions a renter/borrower might
have.

Specifications –Item #165165A
6
SPECIFICATIONS
Item Number
165165
Maximum Output
6500 Watts (W)
Continuous Output
6120 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
9.4 HP Kubota OC95
Engine Speed
3600 RPM
Fuel Type
Diesel
Fuel Capacity
6.5 gallons (24.6 L)
Oil Capacity
1.76 US quarts (1.65 L)
Starting Method
Electric
120V Receptacle
20 Amp (A) Duplex GFCI (NEMA 5-20R)
30 Amp (A) Locking device
(NEMA L5-30R)
120/240V Receptacle
30 Amp (A) Locking device
(NEMA L14-30R)
Circuit Breakers
30 Amp (A) Magnetic, Qty. 1
20 Amp (A), Thermal type, Qty. 2
Grounding Screw
Receives 10 Ga. Fork Terminal
Battery (not included)
12 Volt, 36 Amp-Hour minimum,
Group size U1
Dimensions
Length
34.00" (86.4 cm)
Width
23.25" (59.1 cm)
Height
22.25" (56.5 cm)
Dry Weight
315 lb. (143 kg)
Gross Weight
330 lb. (150 kg)

Safety Label Locations –Item #165165A
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
779396
Battery Warning
791697
NorthStar
791724
Warning
793520
Fuel Warning
786635
Burn Hazard
793562
Fire Hazard
fig05699

Machine Component Identification - Item #165165A
8
Figure 1 (Ref. 1-13)
Ref.
Description
Ref.
Description
1
Main Line Breaker
11
Oil Fill and Dip Stick
2
Thermal Circuit Breakers
12
Air Cleaner Housing
3
Voltmeter
13
Decompression Lever
4
120 Volt-20 Amp GFCI Duplex Receptacles
14
Muffler
5
Hour Meter
15
Ignition Fuse
6
Engine Stop Lever
16
Isolation Mounts
7
120 Volt-30 Amp Locking Receptacle
17
Battery Box
8
Engine Starting Key
18
Generator Head
9
120/240 Volt-30 Amp Locking Receptacle
19
6.5 Gallon Fuel Tank
10
Oil Drain Plug
20
Fuel Cap with Gauge
Figure 2 (Ref. 14-20)

Machine Component Identification - Item #165165A
9
REFERENCE GUIDE
Reference 1 –Main Line Breaker
The main line breaker is a two-pole thermo-magnetic circuit breaker.
The circuit breaker will protect the generator from overload and short
circuit conditions. To reset the circuit breaker move the toggle to the
OFF position, then back to the ON position. When this circuit breaker
is in the OFF position, all receptacles will be off.
Reference 2 –Thermal Circuit Breakers
The control panel has two thermal circuit breakers. If the circuit breaker
trips, a black post will extend from the circuit breaker, push the black
post to reset the circuit breaker. If the circuit breaker will not reset, wait
two minutes and try again.
Reference 3 –Voltmeter
The voltmeter allows for monitoring of the generator. The needle
should be in the green area for all load conditions.
Reference 4 –120 Volt-20 Amp GFCI
Duplex Receptacles
The control panel is equipped with four 120 Volt-20 Amp ground fault
circuit interrupt (GFCI) receptacles (NEMA 5-20R). The receptacles
will accept either NEMA 5-15P or NEMA 5-20P plugs. In the center of
each duplex receptacle there is both a test/reset button and indicator
lamp. If there is a fault condition with a load connected to a duplex
receptacle, the indicator lamp will glow and the reset button will extend.
To test the GFCI press the test button and the reset button should
extend. The reset button must be pushed to reset the receptacle.
Reference 5 –Hour Meter
The hour meter allows for monitoring of engine maintenance
schedules.
Reference 6 - Engine Stop Lever
The engine is stopped by pushing and holding the engine stop lever.
Turning the engine key to the OFF position will not stop the engine.
Reference 7 –120 Volt-30 Amp Locking
Receptacle
The control panel is equipped with one NEMA L5-30R receptacle. This
receptacle accepts only NEMA L5-30P plugs.
Reference 8 –Engine Starting Key
To start the engine, turn the key to the START position.
Reference 9 –120/240 Volt-30 Amp
Locking Receptacle
The control panel is equipped with one NEMA L14-30R receptacle.
This receptacle accepts only NEMA L14-30P plugs. This receptacle is
popular for connection to a transfer switch for home standby power.
Reference 10 –Oil Drain Plug
Removal of plug allows drainage of oil from the engine. Consult your
Kubota engine manual for further details.
Reference 11 –Oil Fill and Dip Stick
Consult your Kubota engine owner’s manual for details concerning oil
change intervals.
Reference 12 –Air Cleaner Housing
Refer to the Kubota engine manual for air cleaner care.
Reference 13 –Decompression Lever
Reduces the load on the engine during starting for a smoother start.
Reference 14 –Muffler
Muffler can be very hot during operation and will burn you.
Reference 15 –Ignition Fuse
Your engine is equipped with a 30 Amp fuse located on the wire
harness below the generator head.
Reference 16 –Isolation Mounts
The engine and generator are mounted on rubber mounts that absorb
most of the engine vibration. This feature eliminates the tendency of
the machine to “walk” which is common with engine powered
equipment.
Reference 17 –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 volt battery, with a minimum rating of 36 Ah (Amp-hour). See
battery section for sizing.
Reference 18 –Generator Head
Your NorthStar product is equipped with a high quality brushless
generator. The generator is maintenance free and will provide years of
dependable service.
Reference 19 –6.5 Gallon Fuel Tank
Large tank allows for extended run capabilities. Always allow room for
fuel expansion by not filling the tank completely full.
Reference 20 –Fuel Cap with Gauge
The fuel cap is extra large, creating a large hole for refilling and a
comfortable grip. You can always monitor the fuel level without
removing the cap by using the fuel level indicator built into the fuel cap.

Power Load Planning and 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 and 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 and 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 and 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 or damaged components, contact Product Support at 1-800-270-0810.
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 and 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 as either a BUILDING BACK-UP or PORTABLE Power Source
This generator is designed to provide up to 6500W 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-listed 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 a UL-listed 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-listed
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, its 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 and
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 three different kinds of electrical outlets on the generator:
1. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R
locking receptacle compatible with L14-30P mating plug)
2. One 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle
compatible with NEMA L5-30P mating plug)
3. Two 120 Volt, 20 Amp duplex GFCI straight-blade receptacles
(NEMA 5-20R duplex receptacles compatible with NEMA 5-20P or
5-15P mating plugs).
(See more technical detail about these receptacles and their associated
circuit breakers in the “Machine Component Identification” section of this
manual.)
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.
NEMA
5-20R
duplex
NEMA
L5-30R
NEMA
L14-30R

Installation / Initial Set-Up
15
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
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’
*
*
*
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.

Installation / Initial Set-Up
16
4. Selecting 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,
diesel, 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 back-pressure, resulting in
possible exhaust leakage or damage to the generator.
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 foot clearance.

Installation / Initial Set-Up
17
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 feet 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
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.
Grounding Post
Copper
Pipe/Rod
10 Ga. wire
Ground

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 and 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.
Malfunction during operation. Immediately turn off the generator if any of the following conditions
arise during operation: