North Star 5500 Users Manual

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MODEL 5500 PPG, ITEM # 165950
Professional Portable Generator
Pr ov e n

Pe rf o rma nc e

OWNER’S MANUAL

Call Customer Service at 1-800-270-0810

M165950A

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

1

1
2
3
4
4
4-5
5
5
6-7
7-8
8
8
8
8
9

SPECIFICATIONS
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

120/240 V Receptacle
Circuit Breaker
Grounding Post
Dimensions
Length
Width
Height
Dry Weight
Gross Weight

#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
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

Figure 1 (Ref. 1-9)
Ref.
1
2
3
4
5
6
7
8

Description

Ref.

Circuit Breakers
120/240V 20A
Locking device Rec.
Grounding Post
120V 20A Duplex Rec.
Oil Drain Plug
Engine Stop Switch
Warning Decal
Air Cleaner

Description

9
10

Super Silent Muffler
Gas Cap with Gauge

11
12
13
14
15
16

6.5 Gal. Gas Tank
Generator Head
Vibration Isolation Mount
Recoil
Choke Lever
Fuel Valve Lever

Figure 2 (Ref. 10-16)
3

00581

01795

GENERATOR FEATURES

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.

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 L1420P.
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.

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:

4

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.

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.

INSTALLATION

ALWAYS use electrical cords that are in good
condition. Worn, bare, frayed or otherwise damaged
cords can cause electric shock.

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
system 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 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.

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 allowed to flow 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.
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.
I. Flame or smoke.
J. Rain, snow or wet conditions.
K. Operator non-attendance.

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

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

multiplying
amperage.

nameplate

voltage

by

nameplate

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.

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.

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
Load
#10
#12
#14
#16
at
(watts)
Ga.
Ga.
Ga.
Ga.
240V
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’
*
*
*
*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.

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 SplitPhase (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
525
1/4
700
1/3
875
1/2
1175
1
1925
1 1/2
2400
2
2900
3
4075
5
6750

RI type
7-11
9-15
11-18
15-25
24-40
30-50
36-60
51-85
84-140

Starting Amps
Cap type SP type
9-18
12-23
14-29
20-40
32-64
40-80
48-96
68-136
112-224

For Determining Generator Load Requirements
Dev ice
Running Watts
Air Conditioner (12,000 Btu)
1700 (b)
Battery Charger (20 Amp)
500
Belt Sander (3”)
1000
Chain Saw
1200
Circular Saw (6-1/2”)
900
Coffee Maker
1000
Compressor (1 HP)
2000 (b)
Compressor (3/4 HP)
1800 (b)
Compressor (1/2 HP)
1400 (b)
Curling Iron
700
Dishwasher
1200
Edge Trimmer
500
Electric Nail Gun
1200
Electric Range (one element)
1500
Electric Skillet
1250
Furnace Fan (1/3 HP)
1200 (b)
Freezer
800 (c)
Hair Dryer
1200
Hand Drill (1”)
1100
Hand Drill (1/2”)
875
Hand Drill (3/8”)
500
Hand Drill (1/4”)
250

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

Hedge Trimmer
450
Home Computer
150 (a)
Impact Wrench
500
Jet Pump
800 (b)
Lawn Mower
1200
Light Bulb
100
Microwave Oven
700
Milk Cooler
1100 (b)
Oil Burner on Furnace
300
Oil Fired Space Htr (140,000 Btu)
400
Oil Fired Space Htr (85,000 Btu)
225
Oil Fired Space Htr (30,000 Btu)
150
Oven
4500
Paint Sprayer, Airless (1/3 HP)
600 (b)
Paint Sprayer, Airless (handheld)
150
Radio
200 (a)
Refrigerator
600 (c)
Slow Cooker
200
Submersible Pump (1-1/2 HP)
2800 (b)
Submersible Pump (1 HP)
2000 (b)
Submersible Pump (1/2 HP)
1500 (b)
Sump Pump
600 (b)
Table Saw (10”)
2000 (b)
Television
500 (a)
Toaster
1000
Vacuum cleaner
250
VCR
70 (a)
Water Heater
3000
Weed Trimmer
500
(a) Always use a voltage surge protector between
the generator and these voltage sensitive loads. To
order a surge protector call customer service at
1800-270-0810 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.

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
Generator
(Hz)
Voltage at 120V
Receptacle
62.5
129V
60.0
120V
59.0
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.

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.

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.

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
system.
7

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.

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.

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.

STOPPING
1. Disconnect all loads to generator.
2. Place engine on-off switch to OFF position.
3. Turn gas line valve to OFF position.

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

Possible Causes

Possible Remedies

Engine will not start.

a)
b)
c)
d)
a)

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.

Voltage too low.

Low oil level.
Fouled spark plug.
Out of fuel.
Stop switch in OFF position.
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.
b) Insufficient ventilation.

No output voltage.

a) Defective load connected to generator.
b) Broken or loose wire.
c) Defective receptacle.
d) Defective stator.
e) Defective rotor.
f) Defective capacitor.

Engine lacks power.

a) Generator is overloaded.

Engine shuts down
during operation.

b) Dirty air filter.
a) Out of fuel.
b) Low oil level.

9



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