MODEL 5500 PPG, ITEM # 165950

Professional Portable Generator

M165950A 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

THANK YOU

Thank you for purchasing a NorthStar Pro Series Generator. Your machine is designed for long life, dependability, and the top performance you demand. Please take time now to read through this manual so you can better understand the machines operation, maintenance and safety precautions. Everyone who operates this generator must read and understand this manual.

The time you take now will prolong your generator’s life and prepare you for its safe operation.

Enjoy the exceptional performance of your NorthStar Pro Series Generator.

IMPORTANT

If this machine is used by anyone who is not the owner or is loaned or rented, make certain the operator:

- Is instructed in safe and proper operation of this machine.

- Reads and understands the manuals pertaining to this machine.

NOTICE

K-BAR Industries Incorporated reserves the right to make improvements in design and/or changes in specifications at any time without incurring any obligation to install them on units previously sold.

TABLE OF CONTENTS

Thank you

Specifications

Machine component identification

Generator features

Introduction

ANSI safety definitions

Rules for safe operation

Installation

Load application

Pre-start up preparation

Starting

Stopping

Engine care

Generator care

Troubleshooting

8

8

8

5

5

6-7

7-8

8

3

4

1

2

4

4-5

9

1

Item Number

Ma ximum Output

Continuous Output

Voltage

Phase

Frequency

Power Factor

Engine

Engine Speed

Fuel Type

Fuel Capacity

Oil Capacity

Starting Method

120 V Receptacle

SPECIFICATIONS

120/240 V Receptacle

#165950

5500 Watts (W)

4000 Watts (W)

120 / 240 Volt (V)

Single phase (4-wire)

56.5-63.3 Hertz (H z)

100 %

8 Hp Honda GX240

3390 - 3798 RPM

Non-leaded automobile gasoline

6.5 gallons (24.6 L)

1.16 US quarts (1.1 L)

Recoil

20 Amp (A) duplex (NEMA 5-20R)

20 Amp (A) locking device

(NEMA L14-20R)

20 Amp (A) locking device

(NEMA L14-20R)

20 Amp (A) thermal, push to reset

Receives 12 Ga. wire or fork terminal

Circuit Breaker

Grounding Post

Dimensions

Length

Width

Height

Dry Weight

Gross Weight

31.75” (80.6 cm)

23.63” (60.0 cm)

22.25” (56.5 cm)

180 lb. (82 kg)

220 lb. (100 kg)

2

MACHINE COMPONENT IDENTIFICATION

3

4

5

6

7

8

Ref.

Description

1

2

Circuit Breakers

120/240V 20A

Locking device Rec.

Grounding Post

120V 20A Duplex Rec.

Oil Drain Plug

Engine Stop Switch

Warning Decal

Air Cleaner

Figure 1 (Ref. 1-9)

Ref.

Description

9 Super Silent Muffler

10 Gas Cap with Gauge

11 6.5 Gal. Gas Tank

12 Generator Head

13 Vibration Isolation Mount

14 Recoil

15 Choke Lever

16 Fuel Valve Lever

00581

Figure 2 (Ref. 10-16)

01795

3

GENERATOR FEATURES

Reference 1 - Circuit Breakers. This portable single phase generator has 2, 20 amp (A) push to reset circuit breakers to protect against electrical overloads.

Reference 2 - 120/240V Receptacle. The locking device is a 120/240V 20A NEMA L14-20R receptacle.

This receptacle accepts a NEMA plug number L14-

20P.

ALWAYS use grounded male plugs. The neutral line of the generator is mechanically grounded to the frame. Matching NEMA male plugs must always be used.

Reference 3 - Grounding Post. Ground the generator via the grounding post, to a copper pipe or rod that is driven into moist soil.

Reference 4 - 120V Receptacle. The generator has a control panel with one duplex (two receptacles in a common housing) receptacle and one locking device receptacle. The duplex is a 120 volt (V) 20 amp (A) straight blade receptacle, National Electrical

Manufacturer’s Association (NEMA) number 5-20R.

This receptacle accepts NEMA plug numbers 5-15P and 5-20P. Each receptacle on the duplex is capable of drawing 20A.

Reference 5 - Oil Drain Plug. Refer to your

Honda engine manual for oil change recommendations.

Reference 6 - Engine Stop Sw itch. 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 7 - Decal.

Reference 8 - Air Cleaner. Refer to your Honda engine manual for air cleaner care.

Reference 9 - Super Silent Muffler. 8 dB less than Honda’s standard muffler.

Reference 10 - Gas Cap w ith 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 11 - 6.5 Gallon Gas Tank. Large tank allows for extended run capabilities. Always allow room for gasoline expansion by not filling the gas tank completely full.

Reference 12 - Generator Head. The electricity producing part of the generator.

Reference 13 - Vibration Isolation Mounts. The engine and generator head, are mounted on rubber cylinders that absorb most of the engine vibration.

Reference 14 - Recoil. Grasp firmly when starting engine.

Reference 15 - Choke Lever. Used during cold starts. Refer to the Honda engine manual for usage.

Reference 16 – Fuel Valve Lever. The Honda engine has an ON-OFF valve. Always keep this valve closed when the generator is not in use. Always keep this valve closed while transporting the generator.

4

Low Oil Shutdow n. 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.

INTRODUCTION

Before starting your generator, thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator. Proper preparation, operation and maintenance will result in operator safety, best 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 8 Hp engine as a GX240).

NorthStar is constantly improving its products.

The specifications outlined herein are subject to change without prior notice or obligation. The purchaser and/or user assumes liability of any modification and/or alterations on this equipment from original design and manufacture.

Before using, the user shall determine the suitability of this product for its intended use and assumes liability therein.

ANSI SAFETY DEFINITIONS

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.

WARNING

indicates a potentially hazardous situation which, if not avoided, could result in a death or serious injury.

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.

RULES FOR SAFE OPERATIONS

Safety precautions are essential when operating this generator.

Respectful and cautious operation will considerably lessen the possibilities of a personal injury. This manual will warn of specific personal injury potential, and these will be designated by the symbol:

WARNING

This generator is equipped with a grounding post, located on the control panel for your protection. Always complete the grounding path from the generator to a copper pipe/rod that is driven into moist earth, to prevent electrical shock.

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.

ALWAYS remove the spark plug or spark plug wire before working on the engine or generator, to prevent accidental starting.

ALWAYS provide adequate ventilation. Do not operate generator in any enclosed or narrow space.

Engines consume oxygen and give off deadly carbon monoxide poisonous gas. Improper ventilation will cause damage to generator and possible injury to people.

NEVER touch hot muffler, hot exhaust manifold or engine cooling fins.

ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area.

Keep generator head and engine clean.

NEVER operate the generator under the following conditions:

A. Excessive change in engine speed, slow or

fast.

B. 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.

H. Enclosed compartments, or confined areas.

J. Rain, snow or wet conditions.

K. Operator non-attendance.

WARNING

Check fuel system on a regular basis. Look for signs of leaks, deterioration, chafed or spongy fuel hose, loose or missing fuel hose clamps, damaged fuel tank or a defective fuel shut-off valve. Correct any defects before operation.

5

WARNING

Keep fire extinguisher close by your generator and be familiar on how to use it.

Consult your local fire department for correct extinguisher type.

INSTALLATION

OUTDOORS: Choose a location where the generator will not be exposed to rain, snow or direct sunlight. Position the generator on secure, level ground 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 sy stem will deteriorate and result in grounding or shorting out the generating system.

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.

NEVER install your generator inside confined areas. Inside installation can cause health hazards or death.

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 allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head.

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 can attack the wiring insulation. If the generator is overloaded, the wires become excessively hot and cause the insulation to break down, reducing its ability to resist corrosive contaminants. Over time the effectiveness of the 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

multiplying nameplate voltage by nameplate amperage.

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’s full rated output can be used.

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.

120V, 60 Hz Motors

Hp motor Running

Watts

1/6

1/4

1/3

1/2

1

1 1/2

2

3

5

525

700

875

1175

1925

2400

2900

4075

6750

RI type

Starting Amps

Cap type

7-11

9-15

11-18

15-25

24-40

30-50

9-18

12-23

14-29

20-40

32-64

40-80

36-60

51-85

48-96

68-136

84-140 112-224

SP type

16-22

22-32

26-35

NA

NA

NA

NA

NA

NA

The figures given above are for an average load such as a blower or fan. If the electric motor is connected to a hard starting load such as an air compressor, it will require more starting current. If it is connected to a light load or no load such as a power saw, it will require less starting current. The exact requirement will also vary with the brand or design of 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

6 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.

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.

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/Pow er Maximum Extension Cord Length

Amps at

240V

Load

(watts)

#10

Ga.

Cord

#12

Ga.

Cord

#14

Ga.

Cord

#16

Ga.

Cord

10

20

30

40

50

2400

4800

7200

9600

12000

250’

125’

60’

30’

15’

150’

75’

35’

15’

*

100’

50’

25’

10’

*

75’

25’

10’

*

*

*Not recommended

CAUTION: Equipment damage can result from the low voltage caused by using an extension cord with a small wire size.

Use this chart to estimate the total load on your generator.

For Determining Generator Load Requirements

Dev ice

Air Conditioner (12,000 Btu)

Battery Charger (20 Amp)

Belt Sander (3”)

Chain Saw

Circular Saw (6-1/2”)

Coffee Maker

Compressor (1 HP)

Compressor (3/4 HP)

Compressor (1/2 HP)

Curling Iron

Dishwasher

Edge Trimmer

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”)

Running Watts

1700 (b)

500

1000

1200

900

1000

2000 (b)

1800 (b)

1400 (b)

700

1200

500

1200

1500

1250

1200 (b)

800 (c)

1200

1100

875

500

250

Hedge Trimmer

Home Computer

Impact Wrench

Jet Pump

Lawn Mower

Light Bulb

Microwave Oven

Milk Cooler

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

Refrigerator

Slow Cooker

Submersible Pump (1-1/2 HP)

Submersible Pump (1 HP)

Submersible Pump (1/2 HP)

Sump Pump

Table Saw (10”)

Television

Toaster

Vacuum cleaner

VCR

Water Heater

Weed Trimmer

(a) Always use a voltage surge protector between the generator and these voltage sensitive loads. To order a surge protector call customer service at 1-

800-270-0810 and ask for item # 30793.

(b) Hard-starting motors require 3 to 5 times the rated running watts.

(c) These loads may require up to 15 minutes to restart due to its normal build up of compressor head pressure.

NOTE: For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to determine the maximum wattage.

450

150 (a)

500

800 (b)

1200

100

700

1100 (b)

300

400

225

150

4500

600 (b)

150

200 (a)

600 (c)

200

2800 (b)

2000 (b)

1500 (b)

600 (b)

2000 (b)

500 (a)

1000

250

70 (a)

3000

500

PRE-START PREPARATIONS

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 or loose or missing nuts and bolts. If the aforementioned problems occur, call customer service at 1-800-270-0810.

GROUNDING - All units must be grounded. Drive a 3/4” or 1” copper 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.

7

CAUTION: The engine has been shipped without oil. Fill the crankcase with oil before trying to start.

Low oil shut-down prevents your generator from starting without sufficient oil.

OPERATING SPEED

The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. The speed of the engine was carefully adjusted 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.

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 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.

Load

Percent of

Generator

Output

0 %

50 %

100 %

Speed

(RPM)

3750

3600

3540

Output

Frequency

(Hz)

62.5

60.0

59.0

Generator

Voltage at 120V

Receptacle

129V

120V

112V

Output voltage should be periodically checked to ensure continued proper operation of the generating plant and appliances, it 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. Engine speed adjustments should be done by a qualified technician.

BEFORE STARTING

1. Make sure the generator is positioned on firm level surface.

2. Check the crankcase for oil and maintain at a 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

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.

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.

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.

WARNING, Stand-by Operation

If your generator is to be used as a standby electric power source in case of utility failure, it must be installed by a registered and licensed electrician and in compliance with all applicable state and local electrical codes. Also, local Fire 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.

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.

GENERATOR CARE

The generator head is a two 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.

Exercising the Generator - The generator should be operated every three to four weeks. Warm the generator by starting the engine and letting it run for

10 to 15 minutes. This will dry out any moisture that 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 service technician. USE ONLY FACTORY

APPROVED REPAIR PARTS.

A. Bearing - The bearing used in these generators is a heavy duty sealed roller bearing. They require no maintenance or lubrication.

8

TROUBLESHOOTING

Problem

Engine will not start.

Voltage too low.

Possible Causes

a) Low oil level.

b) Fouled spark plug.

c) Out of fuel.

d) Stop switch in OFF position.

a) Engine speed too slow.

b) Generator is overloaded.

Circuit breaker trips.

a) Defective load connected to generator.

b) Defective receptacle.

c) Generator overloaded.

Voltage too high.

a) Engine speed too high.

Generator overheating.

a) Generator is overloaded.

No output voltage.

b) Insufficient ventilation.

a) Defective load connected to generator.

b) Broken or loose wire.

Engine lacks power.

Engine shuts down during operation.

c) Defective receptacle.

d) Defective stator.

e) Defective rotor.

f) Defective capacitor.

a) Generator is overloaded.

b) Dirty air filter.

a) Out of fuel.

b) Low oil level.

Possible Remedies

a) Fill crankcase to proper oil level.

b) Clean or replace spark plug.

c) Fill fuel tank.

d) Place switch in ON position.

a) Bring generator to a qualified technician for adjustment.

b) Reduce the load. (See Load

Application section of this manual.) a) Disconnect load.

b) Replace receptacle.

c) Reduce the load. (See Load

Application section of this manual.) a) Bring generator to a qualified technician for adjustment.

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.

b) Bring generator to a qualified technician for repair.

c) Replace receptacle.

d) Bring generator to a qualified technician for repair.

e) Bring generator to a qualified technician for repair.

f) Bring generator to a qualified technician for repair.

a) Reduce the load. (See Load

Application section of this manual.) b) Clean or replace air filter.

a) Fill fuel tank.

b) Fill crankcase to proper oil level.

9