North Star Portable Generator 8000 PPG User Manual

MODEL 8000 PPG, ITEM # 165914  
Professional Portable Generator  
M165914G  
P r o v e n P e r f o r m a n c e  
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  
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SPECIFICATIONS  
Item Number  
Maximum Output  
Continuous Output  
Voltage  
#165914  
8000 Watts (W)  
6600 Watts (W)  
120 / 240 Volt (V)  
Phase  
Frequency  
Power Factor  
Engine  
Engine Speed  
Fuel Type  
Single phase (4-wire)  
56.5-63.3 Hertz (Hz)  
100%  
13 HP Honda GX390  
3390 - 3798 RPM  
Unleaded gasoline  
Fuel Capacity  
Oil Capacity  
Starting Method  
120 VReceptacle  
6.5 gallons (24.6 L)  
1.16 US quarts (1.1 L)  
Recoil  
15 Amp (A) duplex  
(NEMA 5-15R) & 20 Amp (A) duplex  
(NEMA 5-20R)  
120/240 VReceptacle  
Circuit Breakers  
30 Amp (A) locking device  
(NEMAL14-30R)  
30 Amp (A), Qty. 2; 20 Amp (A), Qty. 2;  
15 Amp (A), Qty. 1; thermal, push to  
reset style  
Grounding Post  
Dimensions  
Length  
Width  
Height  
Receives 12 Ga. wire or fork terminal  
31.75” (80.6 cm)  
23.63” (60.0 cm)  
22.25” (56.5 cm)  
210 lb. (95 kg)  
Dry Weight  
Gross Weight  
250 lb. (114 kg)  
2
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MACHINE COMPONENT IDENTIFICATION  
Figure 1 (Ref. 1-10)  
00585  
Ref. Description  
Ref. Description  
1
2
3
4
5
6
7
8
9
Circuit Breakers  
10  
11  
12  
13  
14  
15  
16  
17  
Super Silent Muffler  
120/240V 30A Locking Rec.  
Grounding Post  
120V 20A Duplex Rec.  
120V 15A Duplex Rec.  
Oil Drain Plug  
Engine Stop Switch  
Starting/Stopping Instructions  
Air Cleaner  
Gas Cap with Gauge  
6.5 Gal. Gas Tank  
Generator Head  
Vibration Isolation Mount  
Recoil  
Fuel Valve Lever  
Choke Lever  
Figure 2 (Ref. 11-17)  
01805  
3
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Reference 14 - Vibration Isolation Mounts. 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.  
GENERATOR FEATURES  
Reference 1 - Circuit Breakers. This portable  
single phase generator has 1, 15 amp (A) 2, 20A, and  
2, 30A push to reset circuit breakers to protect against  
electrical overloads.  
Reference 15 - Recoil.  
Grasp firmly when  
starting engine.  
Reference 2 - 120/240V Receptacle. The locking  
device is a 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.  
Reference 16 – Fuel Valve Lever. The generator  
tank has an ON-OFF valve mounted underneath the  
tank.  
Always keep this valve closed when the  
generator is not in use.  
Reference 17 - Choke Lever. Used during cold  
starts. Refer to the starting/stopping instructions and  
the Honda engine manual for usage.  
Low Oil Shutdown.  
The Honda engine is  
protected against damage resulting from low oil level.  
As the oil falls below the safe level, the engine  
automatically shuts off (the engine stop switch remains  
in the on position). The engine will not start until the  
oil is refilled to above the safe level.  
WARNINGContact a licensed electrician  
to wire electrical plugs and/or cord-sets. Improper  
wiring could result in a fire or electrical shock.  
Reference 3 - Grounding Post. Ground the  
generator via the grounding post, to a copper pipe or  
rod that is driven into moist soil.  
INTRODUCTION  
Reference 4 - 120V Receptacle. The second  
duplex is a 120V 20A straight blade receptacle,  
National Electrical Manufacturer’s Association (NEMA)  
number 5-20R. This receptacle accepts NEMA plug  
numbers 5-15P and 5-20P. Each receptacle on this  
duplex is capable of drawing 20A.  
Reference 5 - 120V Receptacle. The generator  
has a control panel with two duplex (two receptacles in  
a common housing) receptacles. The one duplex is a  
120 volt (V) 15 amp (A) straight blade receptacle,  
National Electrical Manufacturer’s Association (NEMA)  
number 5-15R. This receptacle accepts NEMA plug  
number 5-15P. The duplex is capable of drawing 15A  
out of either receptacle or a combination of both.  
Reference 6 - Oil Drain Plug. Refer to your  
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 performance and long life of the generator.  
For detailed engine operation and maintenance always  
refer to the Honda engine owner’s manual furnished  
with the generator (Honda refers to the 13 Hp engine  
as a 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  
assumes liability therein.  
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 the generator.  
Reference 8 - Starting/Stopping Instructions.  
Reference 9 - Air Cleaner. Refer to your Honda  
engine manual for air cleaner care.  
Reference 10 - Super Silent Muffler. 4 dB less  
than Honda’s standard muffler.  
Reference 11 - Gas Cap with Gauge. The gas  
cap is extra large, creating a large hole for refilling and  
a comfortable grip. You can always monitor the fuel  
level without removing the cap by using the fuel level  
indicator 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 - Generator Head. The electricity  
producing part of the generator.  
4
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ANSI SAFETY DEFINITIONS  
ALWAYS remove all oil or gasoline deposits and  
accumulated dirt from generator and immediate area.  
Keep generator head and engine clean.  
DANGER indicates an imminently hazardous  
situation which, if not avoided, will result in death or  
serious injury. This signal word is to be limited to the  
most extreme situations.  
NEVER operate the generator under the following  
conditions:  
A. Excessive change in engine speed, slow or  
WARNING indicates a potentially hazardous  
situation which, if not avoided, could result in a  
death or seri ous i nj ury.  
fast.  
B. Overheating in load connecting devices.  
C. Sparking or arcs from generator.  
D. Loss of electrical output.  
E. Damaged receptacles.  
F. Engine misfire.  
G. Excessive vibration.  
CAUTION indicates a potentially hazardous  
situation, which if not avoided, may result in minor or  
moderate injury. It may also be used to alert against  
unsafe practices.  
H. Enclosed compartments, or confined areas.  
I. Flame or smoke.  
J. Rain, snow or wet conditions.  
K. Operator non-attendance.  
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 Check fuel system on a  
regular basis. Look for signs of leaks, deterioration,  
chafed or spongy fuel hose, loose or missing fuel hose  
clamps, damaged fuel tank or a defective fuel shut-off  
valve. Correct any defects before 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.  
WARNING This generator is equipped  
with a grounding post, which is located on the control  
panel. Always complete the grounding path from the  
generator to a copper pipe/rod that is driven into moist  
earth, to prevent electrical shock.  
INSTALLATION  
OUTDOORS: Choose locations where the  
generator will not be exposed to rain, snow or direct  
sunlight. Position the generator on secure, level  
ground so it will not tip or slide down a hill. Place the  
generator so that the exhaust fumes will not be  
directed towards people.  
The installation site must be free from water,  
moisture, or dust. All electrical components should be  
protected from excessive moisture or the insulation  
system will deteriorate and result in grounding or  
shorting out the generating system.  
ALWAYS use electrical cords that are in good  
condition. Worn, bare, frayed or otherwise damaged  
cords can 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 shock may result.  
ALWAYS use a ground fault circuit interrupter  
(GFCI) in damp or highly electrical conductive areas  
and on construction job-sites to prevent electric shock.  
Foreign matters, such as dust, dirt, sand, lint, or  
abrasive materials can cause damage to the generator  
head and engine if allowed into its cooling system.  
ALWAYS remove the spark plug or spark plug  
wire before working on the engine or generator, to  
prevent accidental starting.  
NEVER install your generator inside confined  
areas. Inside installation can cause health hazards or  
death.  
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.  
DANGER Remember, exhaust fumes are  
deadly carbon monoxide gas, and must be vented to  
the outside where there are no people. Cooling air of  
sufficient amounts must be brought in and exhausted  
out to ensure proper cooling of the engine and  
generator head.  
NEVER touch hot muffler, hot exhaust manifold or  
engine cooling fins.  
5
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Starting Amps  
RI type Cap type SP type  
120V, 60 Hz Motors  
Hp motor Running  
Watts  
LOAD APPLICATION  
It is important to determine the total electrical load  
before it is connected to the generator. The two major  
factors in determining 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 is eliminated and a dead short can result.  
Always compare the generator nameplate data  
with that of the equipment to be used to ensure that  
watts, volts, amperage, and frequency requirements  
are suitable for operating equipment. The wattage  
listed on the 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  
1/6  
1/4  
1/3  
1/2  
1
1 1/2  
2
3
525  
700  
875  
1175  
1925  
2400  
2900  
4075  
6750  
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-224  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
5
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  
the motor.  
Generators respond to severe overloading  
differently than the power line. When overloaded, the  
engine is not able to supply enough power to bring the  
electric motor up to operating speed. The generator  
responds to the high initial starting current, but the  
engine speed drops sharply. The overload may stall  
the engine. If allowed to operate at very low speeds,  
the electric motor starting winding will burn out in a  
short time. The generator head winding might also be  
damaged.  
multiplying  
amperage.  
nameplate voltage by nameplate  
VOLTS X AMPS = WATTS  
Example: 120V X 5A  
= 600W  
When connecting a resistive load such as  
incandescent lights, heaters or common electric power  
tools, a capacity of up to the generator full rated  
wattage output can be 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 rated output can be used.  
Running the generator under these conditions may  
result in damage to the generator stator as well as the  
motor windings. Because the heavy surge of current  
is required for only an instant, the generator will not be  
damaged if it can bring the motor up to speed in a few  
seconds.  
If difficulties in starting a motor are  
experienced, turn off all other electrical loads and if  
possible reduce the load on the electric motor.  
Always allow the generator to reach operating  
speed before a load is applied.  
STARTING ELECTRIC MOTORS  
Electric motors require much more current (amps)  
to start than to run. Some motors, particularly low cost  
split-phase motors, are very hard to start and require 5  
to 7 times more current to start than to run. Capacitor  
motors are easier to start and usually require 2 to 4  
times as much current to start than to run. Repulsion  
Induction motors are the easiest to start and require  
1.5 to 2.5 times as much to start than to run.  
Most fractional 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 various conditions.  
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  
allow for distance in length and amperage so that the  
voltage drop between the set and point of use is held  
to a minimum.  
Current/Power Maximum Extension Cord Length  
Amps  
at  
Load  
(watts)  
#10  
Ga.  
#12  
Ga.  
#14  
Ga.  
#16  
Ga.  
240V  
Cord  
Cord  
Cord  
Cord  
10  
20  
2400  
4800  
250’  
125’  
150’  
75’  
100’  
50’  
75’  
25’  
6
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30  
40  
50  
7200  
9600  
12000  
60’  
30’  
15’  
35’  
15’  
*
25’  
10’  
*
10’  
*
*
Water Heater  
Weed Trimmer  
3000  
500  
*Not recommended  
CAUTION: Equipment damage can result from the  
low voltage caused by using an extension cord with a  
sm all wi re si ze.  
(a) Hard-starting motors require 3 to 5 times the  
rated running watts.  
(b) These loads may require up to 15 minutes to  
restart due to its normal build up of compressor head  
pressure.  
NOTE: For extremely hard to start loads such as  
air conditioners and air compressors, consult the  
equipment dealer to determine the maximum wattage.  
Use this chart to estimate the total load on your  
generator.  
For Determining Generator Load Requirements  
Device  
Running Watts  
1700 (a)  
500  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
PRE-START PREPARATIONS  
1000  
Chain Saw  
Circular Saw (6-1/2”)  
Coffee Maker  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling Iron  
1200  
900  
1000  
2000 (a)  
1800 (a)  
1400 (a)  
700  
Your generator has been thoroughly tested prior to  
shipment from the factory. A factory test report has  
been included with this manual. However, damage  
can occur during shipping, so be sure to check for  
damaged parts, loose or missing nuts and bolts. If the  
aforementioned problems occur, call customer service  
at 1-800-270-0810.  
Dishwasher  
1200  
Edge Trimmer  
500  
1200  
1500  
1250  
1200 (a)  
800 (b)  
1200  
1100  
875  
500  
250  
450  
150  
GROUNDING - All units must be grounded. Drive  
a 3/4” or 1” copper pipe or rod into the ground close to  
the generator. The pipe/rod must penetrate moist  
earth. Connect an approved ground clamp to the pipe.  
Run a no. 12 Ga. wire from the clamp to the generator  
grounding post located on the control panel. Do not  
connect to a water pipe or a ground used by a radio  
sy stem .  
CAUTION: The engine 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.  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
Furnace Fan (1/3 HP)  
Freezer  
Hair Dryer  
Hand Drill (1”)  
Hand Drill (1/2”)  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
Jet Pump  
500  
800 (a)  
Lawn Mower  
Light Bulb  
1200  
100  
OPERATING SPEED  
Microwave Oven  
Milk Cooler  
700  
1100 (a)  
The generator must be run at the correct speed in  
order to produce the proper electrical voltage and  
frequency. The speed of the engine was carefully  
adjusted at the factory so that the generator produces  
the proper voltage and frequency.  
The output voltage should be checked to ensure  
the generator is working properly before connecting a  
load to the generator. Failure to do so could result in  
damage to equipment plugged into the unit and  
possible injury to the individual.  
Oil Burner on Furnace  
Oil Fired Space Htr (140,000 Btu)  
Oil Fired Space Htr (85,000 Btu)  
Oil Fired Space Htr (30,000 Btu)  
Oven  
Paint Sprayer, Airless (1/3 HP)  
Paint Sprayer, Airless (handheld)  
Radio  
300  
400  
225  
150  
4500  
600 (a)  
150  
200  
Refrigerator  
Slow Cooker  
600 (b)  
200  
Submersible Pump (1-1/2 HP)  
2800 (a)  
Load Requirements, continued  
All engines have a tendency to slow down when a  
load is applied. When the electrical load is connected  
to the generator, the engine is more heavily loaded,  
and as a result the speed drops slightly. This slight  
decrease in speed, together with the voltage drop  
within the generator itself, results in a slightly lower  
voltage when the generator is loaded to its full capacity  
than when it is running with no load. The slight  
Submersible Pump (1 HP)  
Submersible Pump (1/2 HP)  
Sump Pump  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
Table Saw (10”)  
Television  
Toaster  
1000  
Vacuum cleaner  
VCR  
250  
70  
7
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variation has no appreciable effect in the operation of  
motors, lights and most appliances. Electronic  
equipment and clocks will be affected if correct RPM is  
not maintained. See Load vs. Output chart.  
ENGINE CARE  
Refer to your Honda Owner’s Manual for proper  
care and maintenance.  
NOTE: When changing the oil on a hot engine, the  
oil might overshoot the oil drain hole on the generator  
base.  
Load  
Output  
Frequency  
Percent of  
Generator  
Output  
0 %  
50 %  
100 %  
Speed  
(RPM)  
Generator  
Voltage at 120V  
Receptacle  
GENERATOR CARE  
(Hz)  
The generator head is a 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 the generator head casting.  
3750  
3600  
3510  
62.5  
60.0  
58.5  
129V  
120V  
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.  
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 it be needed in an emergency.  
Generator Maintenance - The generator head is  
brushless and maintenance free. Major generator  
service, including installation or replacement of parts  
should be performed only by a qualified electrical  
BEFORE STARTING  
1. Make sure the generator is positioned on firm  
l evel surface.  
service technician.  
APPROVED REPAIR PARTS. Obtain factory parts  
from Customer Service at 1-800-270-0810.  
USE ONLY FACTORY  
2. Check the crankcase for oil and maintain at a  
A. Bearing - The bearing used in these generators  
is a heavy duty sealed roller bearing. They require no  
maintenance or lubrication.  
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 destructive to the equipment.  
proper level.  
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  
WARNING, Stand-by Operation  
1. Disconnect all loads to generator.  
2. Turn gas line valve to ON position.  
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.  
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 Departments must 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  
licensed electrician.  
7. Loads may now be connected to generator.  
STOPPING  
1. Disconnect all loads to generator.  
2. Place engine on-off switch to OFF position.  
3. Turn gas line valve to OFF position.  
8
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TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Engine will not start.  
a) Low oil level.  
b) Fouled spark plug.  
c) Out of fuel.  
a) Fill crankcase to proper oil level.  
b) Clean or replace spark plug.  
c) Fill fuel tank.  
d) Stop switch in OFF position.  
a) Engine speed too slow.  
d) Place switch in ON position.  
a) Bring generator to a qualified  
technician for adjustment.  
Voltage too low.  
b) Generator is overloaded.  
b) Reduce the load. (See Load  
Application section of this manual.)  
a) Disconnect load.  
Circuit breaker trips.  
Voltage too high.  
a) Defective load connected to generator.  
b) Defective receptacle.  
b) Replace receptacle.  
c) Generator overloaded.  
c) Reduce the load. (See Load  
Application section of this manual.)  
a) Bring generator to a qualified  
technician for adjustment.  
a) Engine speed too high.  
Generator overheating. a) Generator is overloaded.  
b) Insufficient ventilation.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Make sure there is at least 3 feet of  
clearance on all sides of generator.  
a) Disconnect load.  
No output voltage.  
a) Defective load connected to generator.  
b) Broken or loose wire.  
b) Bring generator to a qualified  
technician for repair.  
c) Defective receptacle.  
d) Defective stator.  
c) Replace receptacle.  
d) Bring generator to a qualified  
technician for repair.  
e) Bring generator to a qualified  
technician for repair.  
e) Defective rotor.  
f) Defective capacitor.  
a) Generator is overloaded.  
f) Bring generator to a qualified  
technician for repair.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Clean or replace air filter.  
a) Fill fuel tank.  
Engine lacks power.  
b) Dirty air filter.  
a) Out of fuel.  
b) Low oil level.  
Engine shuts down  
during operation.  
b) Fill crankcase to proper oil level.  
9
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