North Star 13000 PTOG User's Manual
Contents
1. MODEL 13000 PTOG ITEM 165929 Power Take Off Generator M165929A 13000 PTOG Any Questions Comments or Problems Call Customer Service at 1 800 270 0810 Hours Monday Friday 7 30 AM to 5 30 PM Saturday 7 30 to 11 30 AM CST THANK YOU Thank you for purchasing a NorthStar Power Take Off 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 machine s operation maintenance and safety precautions Everyone who operates this generator must read and understand this manual The time you take now will prolong your generators life and prepare you for its safe operation Enjoy the exceptional performance of your NorthStar PTO 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 ANSI safety definitions Machine component identification Generator features Introduction Rules for safe operation Installation Load application Pre start up pr2. Loss of electrical output Damaged receptacles Engine misfire Excessive vibration Enclosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance Without proper guarding in place FACT TOMmMIOD WARNING Keep fire extinguisher close by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type DANGER Remember exhaust fumes are deadly carbon monoxide a poisonous 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 INSTALLATION Choose a location where the generator will not be exposed to rain snow or direct sunlight Common places for mounting your PTO generator are to a trailer or a cement slab However you choose to mount the generator make sure it can get as close to the load as possible This will make using the generator more convenient and reduce voltage drop The installation site must be free from water moisture or dust Foreign matters such as dust dirt sand lint or abrasive materials can cause damage if allowed inside the generator All electrical components should be protected from excessive moisture or the insulation system will deteriorate and result in grounding or shorting out of the generating system When trailer mounting the generator select a trailer
3. that is wide enough to withstand the torque of start up and loading torque Wheels that are not spaced properly could cause the trailer to tip over The constant vibration of the generator can cause metal fatigue of the trailer base if the steel used is not thick enough DANGER Trailer may tip over and cause serious injury or death Never stand near an operating PTO generator When mounting the generator on a cement slab use the optional mount Kt item 165935 available in the Northern catalog and the NorthStar parts catalog The kit comes with two mounting plates and three grade 5 7 16 14 bolts Use grade 5 3 8 anchor bolts to mount plates to the concrete YT Ta VAL LAGE i SUPPLED WITH KNX After the the generator is firmly mounted attach the PTO driveline to the generator then the tractor Use a synchronized PTO driveline rated at 24 HP minimum DANGER Always have proper guarding of rotating parts Failure to guard the power transmission mechanisms may result in serious injury or death While seated on the tractor and the engine at idle engage the PTO Slowly increase the throttle until the needle in the generator voltmeter is at or above the blackline in the green area A load can now be applied to the generator Remember to stay clear of the rotating PTO driveline From 45 tractor seat re adjust the speed until the needle on the generator voltmeter is close to the black line in the green area I
4. 11 Shield 3 20A Circuit Breakers 12 Gear Box 4 Warning Decals 13 Grounding Screw 5 1 3 8 6 Spline Input Shaft 14 Mounting Holes 6 Oil Drain Plug 15 Fan Vents 7 Voltmeter 16 Oil Level Sight 8 120V 20A Duplex 17 Breather Oil Fill Plug Receptacles 9 120V 30A Twistlock Receptacle GENERATOR FEATURES References 1 3 Circuit Breakers e Reference 1 two 50A push to reset circuit breakers e Reference 2 one 30A push to reset circuit breaker e Reference 3 two 20A push to reset circuit breakers References 4 Warning Decals Read and follow all warnings References 5 1 3 8 Diameter 6 Spline Input Shaft 540 RPM PTO driveline is available from Northern Item 165936 References 6 Oil Drain Plug Change oil after the first 50 hours of use then after every 500 hours References 7 Voltmeter Voltmeter needle should be in green area during all generator load conditions The black line in the center on the green area indicates 120V During no load conditions the needle should be at or above the black line References 8 9 120V Receptacles e Reference 8 120V Receptacle The generator has a control panel with two 120V 20A straight blade receptacle duplexes two receptacles in a common housing National Electrical Manufacturers Association NEMA number is 5 20R e Reference 9 This twistlock receptacle isa receptacle accepts NEMA plug number L5 30P which is supplied with the generator Refe
5. 70 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 8 gauge wire from the clamp to the generator ground screw Do not connect to a water pipe or a ground used by a radio system OPERATING SPEED The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency The output voltage should be checked to ensure the generator is working properly subsequent to 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 sow 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 effected if correct RPM is not maintained See Load vs Output chart Generator voltage at Percent of Frequency Generator Hz Output 120V Receptacle Output voltage sh
6. alfunctioning Defective bearing Defective gear c No or low gear oil d PTO driveline is operating at an angle of greater than 15 e Unsynchronized PTO driveline Increase tractor RPMs 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 d Contact Customer Service for the nearest service center a Contact Customer Service for the nearest service center 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 Replace tighten wire c Replace receptacle d Contact Customer Service for the nearest service center e Contact Customer Service for the nearest service center f Contact Customer Service for the nearest service center g Contact Customer Service for the nearest service center h Increase tractor RPMs I Engage PTO j Contact Customer Service for the nearest service center a Contact Customer Service for the nearest service center b Contact Customer Service for the nearest service center c Fill gear box to oil level sight d Repostition the tractor or generator so the angle is reduced to less than 15 both vertically and horizontally e Disassemble PTO driveline and reassemble with CV joints synchronized
7. d condition Worn bare frayed or otherwise damaged cords can cause electric shock ALWAYS use a ground fault circuit interrupter GFCl in damp or highly electrical conductive areas and on construction job sites to prevent electric shock ALWAYS remove PTO driveline before working on the generator ALWAYS provide adequate ventilation Do not operate generator in any enclosed or narrow space Engines consume oxygen and give off deadly carbon monoxide a poisonous gas Improper ventilation will cause damage to generator and possible injury to people ALWAYS remove all oil or gasoline deposits and accumulated dit from generator and immediate area Keep generator head and engine clean ALWAYS wear ear protection while operating generator ALWAYS keep area around generator clean NEVER operate the generator without proper guarding NEVER operate the generator continuously when PTO driveline is at angle greater than 15 both horizontally and vertically NEVER operate the generator while wearing loose fitting clothing such as neckties scarves or untucked shirts 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 NEVER operate the generator under the following conditions A Excessive change in engine speed slow or fast Overheating in load connecting devices Sparking or arcs from generator
8. e gear box is shipped with temperary plastic plug remove and replace with the metal breather plug that is in the manual bag INTRODUCTION Before attempting to mount 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 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 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 A WARNING This generator is equipped with a grounding screw located on the generator frame 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 u electrical cords that are in goo
9. eparations Generator care Troubleshooting Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Minimum PTO HP Input Shaft 120V Receptacle 120 240V Receptacle Circuit Breaker Gear Box Gear Ratio Gear Oil Oil Capacity Dimensions Length Width Height Gross Weight SPECIFICATIONS 165929 13000 Watts W 12000 Watts W 120 240 Volt V Single phase 4 wire 59 0 63 0 Hertz Hz 100 24 HP at540 RPM 1 3 8 Diameter 6 spline 2 20 Amp A duplex NEMA 5 20R 30 Amp A twistlock NEMAL5 30R 50 Amp A Straight blade NEMA 14 50R 2 20 Amp A thermal push to reset style 30 Amp A thermal push to reset style 2 40 Amp A thermal push to reset style 17 SAE 80W 90 86 Qt 82 L 28 38 72 1 cm 14 25 36 2 cm 12 50 31 1 cm 127 Ib 57 7kg 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 MACHINE COMPONENT IDENTIFICATION 1 50A Circuit Breakers 10 120 240V 50A Receptacle 2 30A Circuit Breaker
10. erator under these conditions may result in damage to the generator stator as well as the electric 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 isheld to a minimum Maximum Extension Cord Length r Amps Load 10 12 14 16 at watts Ga Ga Ga Ga 240V Cord Cord Cord Cord 10 20 30 40 50 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 Air Conditioner 12 000 Btu 1700 a 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 a Compressor 3 4 HP 1800 a Compressor 1 2 HP 1400 a Curling Iron 700 Dishwasher 1200 Edge Trimmer 500 Electric Nail Gun 1200 Electric Range one element 1500 Electric Skille
11. f the needle will not rise to the green area no matter what the engine speed the generator is either overloaded or there is a problem Use the troubleshooting guide at the end of the manual for assistance with possible problems Before each use check the gear box oil level Use SAE gear oil and fill to the dot on the sight glass If the control box is not located on the correct side for your application it can be rotated to the opposite side First remove the fan vents then remove the four drive end bracket bolts Remove securing stud cap loosen the securing stud nut Rotate the drive end bracket 180 re torque bolts to 17 lbeft Re torque securing stud nut to 8 oo346 ft Reinstall the fan vents Remove the four screws at the base of control box rotate the control box 180 The voltmeter is now on the back of the machine instead of the front See below for terminology SECURNC REMOVE SCREWS TDP STUG CAP ORIVE ENG GRACKET DLTS ORIVE END BRACKET 18T 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 t
12. he 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 asthe wattage is influenced by the equipment efficiency power factor and starting system NOTE If wattage is not given 00402 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 us
13. 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 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 TROUBLESHOOTING Problem Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Excessive gear box noise Possible Causes Possible Remedies Engine speed too slow b Generator is overloaded a Defective load connected to generator b Defective receptacle c Generator overloaded d Defective circuit breaker Engine speed too high Generator is overloaded Insufficient ventilation a Defective load connected to generator Broken or loose wire Defective receptacle Defective stator Defective rotor Defective capacitor Defective circuit breaker Engine speed too slow PTO not engaged Gear box is m
14. ould be checked periodically to ensure continued proper operation of the generating plant and appliances it can be checked with a portable meter Frequency can be checked by using an electric clock with a sweep second hand Timed against a wrist watch or a stop watch the clock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician GENERATOR CARE The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with two sealed radial bearings Proper care and maintenance are necessary to ensure a long trouble free life Exercising The Generator The generator should be operated every four weeks This is accomplished by starting the engine and applying a load for 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 generator will also ensure that the set isoperating properly should it be needed in an emergency Generator Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technician USE ONLY NorthStar APPROVED REPAIR PARTS AVAILABLE AT 1 800 270 0810 A Bearing The bearings used in this generator are a heavy duty sealed ball bearing type They require no maintenance
15. rence 10 120 240V Receptacle This straight blade receptacle is 120 240V 50A This receptacle accepts a NEMA plug number 14 50P 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 References 11 Shield Plastic implement shield NEVER operate generator without shield in place Reference 12 Gear Box Cast iron frame 1 7 gear ratio Reference 13 Grounding Screw Ground the generator via the ground screw to a copper pipe or rod that is driven into moist soil Reference 14 Mounting Holes Use these three locations to mount the generator head in place with 7 16 grade 5 bolts Mounting plates item 165935 for mounting generator to a cement pad are available through Northern and the NorthStar parts catalog Reference 15 Fan Vents Never block the vent slots or insert objects through the slots The closest object should be at least 3 feet away from the vents Reference 16 Oil Level Sight When oil is even with the red dot the oil level is correct Check oil level daily Sight is mounted e gear box 00295 service panel If panel is removea tor whatever 120V 30A receptacle NEMA number L5 30R Figure 2 Ref 10 16 2 Using Dow Corning sealant 732 Reference 17 Breather Oil Fill Plug Use SAE 90 gear oil Maintain the correct oil level Over filling can cause the oil to over heat and damage seals and bearings Th
16. t 1250 Freezer 800 b Furnace Fan 1 3 HP 1200 a Hair Dryer 1200 Hand Drill 1 1100 Hand Drill 1 2 875 Hand Drill 3 8 500 Hand Drill 1 4 250 Hedge Trimmer 450 Home Computer 150 Impact Wrench 500 Jet Pump 800 a Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 a 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 a Paint Sprayer Airless handheld 150 Radio 200 Refrigerator 600 b Slow Cooker 200 Submersible Pump 1 1 2 HP 2800 a Submersible Pump 1 HP 2000 a Submersible Pump 1 2 HP 1500 a Sump Pump 600 a Table Saw 10 2000 a Television 500 Toaster 1000 Vacuum cleaner 250 VCR 70 Water Heater 3000 Weed Trimmer 500 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 PRE START UP PREPARATIONS Your generator has been thoroughly tested prior to shipment from the factory However damage can occur during shipping so be sure to check for damaged parts loose or missing nuts and bolts If the these problems occur call Customer Service at 1 800 2
17. ually 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 Rl Capacitor Cap or Split Phase SP type The following chart shows the approximate current required to start and run various types and sizesof 120 volt 60 cycle electric motors under various conditions Motors Watts type type 9 18 12 23 14 29 20 40 32 64 40 80 48 96 68 136 112 224 The figures given above are for an average load such asa 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 asa 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 starter winding will burn out in a short time The generator head winding might also be damaged Running the gen
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