Product Manual For Portable Outdoor Use-Only, Power Take .

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M165937H.6ITEM NUMBER: 165937SERIAL NUMBER:Owner’s ManualInstructions for Installation/Set-up, Operation, Servicing, & StoragePortable Outdoor Use-Only, Power Take-Off (PTO) Generator24,000 Watt Continuous (27,500 Watt Surge) CapacityCan be used to power individual appliances plugged directly into the generator’s outlets, or as a back-upconnection to a building’s power supply (via a professionally installed UL-approved transfer switch).WARNINGREAD and UNDERSTAND this manual completely before using the generator! Failure to properly set up, operate, and maintain thisgenerator could result in serious injury or death from carbon monoxide poisoning, electric shock, entanglement, fire, or burns. Inaddition, PTO shaft and generator can become airborne and cause severe injury if improperly secured. In particular, be aware of thefollowing hazards:CO PoisoningThe running tractor engine gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it. ONLY run tractor and generator OUTDOORS and AWAY from building air intakes. NEVER run inside any enclosed or semi-enclosedspaces, including homes, basements, garages, sheds, and boxes. These spaces can trap poisonous gases, EVEN if you run a fan or openwindows. Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).Electric shock / Electrocution High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly grounded. Use onlyUL-listed, outdoor-rated grounded GFCI-equipped extension cords of proper size. NEVER plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST ISOLATE THEGENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed electrician. Otherwise, back feedfrom the generator into the power grid could kill utility workers.Fire DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so generator doesnot overheat and possibly cause fire. Keep all objects at least 7’ from generator vent openings. Refer to tractor manual for minimumsafe clearance distance between hot tractor exhaust and nearby combustible materials and structures. ALWAYS keep a fire extinguisher rated “ABC” nearby.Power Take-Off (PTO) Failure to properly mount and secure the generator may cause the unit to flip violently during use, which could cause severe injury tothe operator or bystanders, or damage to surrounding objects. Never operate the generator without proper PTO guarding, including a freely rotating shaft guard as well as tractor and generator shieldsat each end. Clothing or hair can become rapidly entangled in unguarded rotating PTO shaft or connections, resulting in serious injuryor death. Make sure PTO driveline shaft is securely locked at both ends. An unlocked PTO shaft can whip or become dangerously airborne.STOP!CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power load Planning & Management” section of this manual todetermine your power load requirements and then compare to the generator’s rated capacity.INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking & DeliveryInspection” section for instructions on whom to contact to report missing or damaged parts.MOUNTING IS REQUIRED. You will need to mount this PTO generator to either a (reinforced?) concrete slab or a PTO trailer. See the“About Your Generator” and “Installation/Initial Set-Up” sections for more information on this requirement.ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to yourbuilding’s electrical system. See the “Installation/Initial Set-Up” section for more information about this requirement.Any Questions, Comments, Problems, or Parts OrdersCall NorthStar Product Support 1-800-270-0810

Hazard Signal Word Definitions2

Table of ContentsHazard Signal Word Definitions . 2About Your Generator . 4Specifications . 6Safety Label Locations . 7Machine Component Identification . 8Power Load Planning & Management . 10Installation / Initial Set-Up:1. Unpacking & Delivery Inspection . 122. Planning the Power Load. 133. Set-up as a PORTABLE or BUILDING BACK-UP Power Source . 134. Selecting a Suitable Site . 165. Mounting the Generator . 186. Grounding the Generator . 20Operation:1. General Safety Rules for Operation . 212. Preparing for Operation . 233. Connecting to the Tractor . 244. Starting the Generator. 265. Connecting Loads . 266. Stopping . 287. Storage & Exercise . 28Maintenance & Repair . 29Troubleshooting . 31Summary of Important Safety Information for Operation . 32Generator Exploded View . 35Wiring Diagram. 37Gearbox Exploded View . 39Limited Warranty . 41California Proposition 65 Information . 423

About Your GeneratorThank you for purchasing your NorthStar PTO generator!About Your GeneratorThis PTO-driven, portable generator is designed to provide up to 24,000 Watts ofelectrical power (24,000 watts continuous, 27,500 watts surge). Connected to your tractor’spower take-off (PTO)*, the generator can supply power:1. As a portable power source. You can plug appliances directly into the generator’selectrical outlets.2. As a back-up, standby power source for a building. A licensed electrician can connectthe generator to your building’s electrical system via the installation of an UL-approvedtransfer switch. (See the “Installation & Initial Set-up” section of this manual to learnmore about specific requirements and precautions relating to wiring the generator to yourbuilding’s electrical system.)* Your tractor’s PTO must produce a minimum of 48 HP at 540 RPM.You must select a generator adequately sized for your power needs. You need todetermine the power needs of all the appliances/tools you wish to power at the same time andchoose a generator rated to provide at least that power level. See the “Power Load Planning &Management” section of this manual to determine your specific power load requirements andthen compare them to this generator’s rated capacity. You must not overload the generator.Overloading will cause damage to the generator and attached electrical devices, and may alsoresult in fire.This generator must be mounted on a reinforced concrete slab or a PTO generatortrailer, so that the generator will not flip during use due to the rotational force of the PTO.The slab or trailer must be of adequate size and strength to withstand operating torque withoutflipping or structural failure. A trailer designed specifically for use with PTO generators ratedup to 60,000 Watts is available from NorthStar -- Item #165959. More detailed informationabout mounting can be found in the “Installation / Initial Set-Up” section of this manual.Be sure to read about site selection and grounding requirements for running thisgenerator. More detailed information can be found in the “Installation & Initial Set-up, Steps5 & 6” of this manual.Optional accessories available from NorthStar include PTO drivelines, UL-approved transferswitches and extension cords. Contact NorthStar Product Support at 1-800-270-0810 withquestions about optional accessories or to order.Read this ManualWARNINGImproper use or maintenance of this generator can result in serious injury or death fromcarbon monoxide poisoning, electric shock/electrocution, entanglement, flying objects,fire, or burns. In addition, PTO shaft and generator can become airborne and causesevere injury if improperly secured.Read this manual completely before using the generator and follow all instructions andsafety rules.4

About Your Generator (cont’d)You must follow all instructions and safety precautions presented throughout this manual. Asummary of important safety information can be found at the end of the manual. Keep thismanual for reference and review.Proper preparation, operation, and maintenance will result in operator safety as well as bestperformance and long life of the generator. Failure to follow the instructions in this manualfor proper mounting, set-up, operation, and maintenance of the generator will void themanufacturer’s warranty.Before using, the user shall determine the suitability of this product for its intended use andassumes liability therein. The purchaser and/or user shall assume liability for any modificationand/or alterations of this equipment from original design and manufacture, or for any nonstandard application, or for use as a subcomponent in another piece of equipment.NorthStar is constantly improving its products. The specifications outlined herein are subjectto change without prior notice or obligation.Contact NorthStar Product Support at 1-800-270-0810 for any questions about theappropriate use of this generator.Warranty RegistrationPlease fill out and submit the warranty registration card so that we have your contactinformation for any future product literature or replacement parts you may need.ATTENTION:All Rental Companies and Private Owners who loan thisequipment to others!All persons to whom you rent/loan this generator must have access to and read this manual.Keep this owner’s manual with the generator at all times and advise all persons who willoperate the machine to read it. You must also provide personal instruction on how to safelyoperate the generator and remain available to answer any questions a renter/borrower mighthave.5

Specifications – Item # 165937SPECIFICATIONSItem NumberMaximum OutputContinuous OutputVoltagePhaseFrequencyPower FactorMinimum PTO HPMinimum Operation TorqueInput Shaft120V Receptacle16593727500 Watts (W)24000 W120 / 240 Volt (V)Single phase (4-wire)59.0-63.0 Hertz (Hz)1.048 HP at 540 RPM358.7 pound-foot1-3/8” Diameter, 6 spline(2) 20 Amp (A) duplex (NEMA 5-20R)30A Locking device (NEMA L5-30R)60A Straight blade (NEMA 14-60R)175A Anderson Style.(2) 20A thermal, push to reset style30A thermal, push to reset style60A thermal magnetic100A thermal magnetic120/240V ReceptacleCircuit BreakerGear BoxGear RatioGear OilOil CapacityDimensionsLengthWidthHeightGross Weight1:7SAE 90W1.11 Qt. (1.05 L)36.95” (93.9 cm)16.85” (42.8 cm)20.79” (52.8 cm)425 lb. (193.2 kg)6

Machine Component Identification - Item #165937DANGERPoisonous Gas HazardTractor engines give off carbonmonoxide, an odorless gas thatcan kill youin minutes.ONLY run tractor & generatorOUTDOORS and AWAY from buildingair intakes.Never run inside homes, garages, orsheds, EVEN if you run a fan or openwindows.Install carbon monoxide alarms insidenearby structures/buildings.WARNINGElectric Shock/Electrocution HazardHigh voltage from generator can kill.NEVER connect generator directlyinto a wall outlet.ANY connection to a building'selectrical system MUST ISOLATEGENERATOR FROM UTILITYPOWER via a transfer switch.Be sure generator is properlygrounded.Use only outdoor-rated, groundedGFCI extension cords of propersize.DO NOT operate in wet locations. A Fire Hazard can arise from:Overloading the generatorLack of cooling ventilationContact with hot tractor exhaustDO NOT overload generator.OPE R ATE ONLY with adequate coolingventilation. Keep all objects at least7 feet from generator vent openings.Keep tractor exhause away from allcombustible objects.ALWAY S keep a fire extinguishernearby.Read Owner's Manual completely before using. Serious injury or death can result if safety directions are not followed.DANGERUsing a generator indoors CAN KILL YOU IN MINUTES.Generator exhaust contains carbon monoxide. This isa poison you cannot see or smell.NEVER use inside a homeor garage. EVEN IF doorsand windows are open.Only use OUTSIDE andfar away from windows,doors, and vents.DANGER!Rotating Driveline/PTO HazardContact with rotating driveline can cause death!Driveline guard, plus tractor and generator shields must be in place. Drivelineguard must turn freely and independently on driveline.Accidental contact with rotating driveline will cause hair or clothing nearrotating shaft to become rapidly entangled.Driveline must be securely locked at both ends.An unlocked PTO shaft can whip or become dangerously airborne.Generator must be properly mounted in accordance with instructions.Improper mounting may cause generator to flip dangerously during use.Always make sure safety labels are in place and in good condition. If a safety label ismissing or not legible, order new labels or unsafe operation could result.To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.On-Product Warning LabelsPart numbersDescription779781General Warning779770PTO Warning779407Danger Carbon Monoxide7

About Your Generator (cont’d)Figure 1 (Ref. 1-7)Ref. Description123456789Ref.VoltmeterLifting EyeBreather/Oil Fill Plug1 3/8”, 6 Spline Input ShaftSight Glass100A Circuit Breaker60A Circuit BreakerGear Box30A Circuit Breaker1011121314151617Figure 2 (Ref. 8-17)8Description120/240V 100A ConnectorLifting EyeGrounding Clamp120/240V 60A Receptacle120V 30A Locking Receptacle120V 20A Duplex Receptacles20A Circuit BreakersShield

Machine Component Identification – Item #165937 (cont’d)REFERENCE GUIDEReference 1 – VoltmeterVoltmeter needle should be in green areaduring all generator load conditions. Theblack line in the center on the green areaindicates 120V. During no load conditions,the needle should be at or above the blackline.Reference 2 – Lifting EyeUse when lifting or moving generator.Reference 3 – Breather/Oil Fill Plug Use SAE 90W gear oil. Maintain the correctoil level. Over filling can cause the oil toover heat and damage seals and bearings.Reference 4 – 1-3/8” Diameter 6A 540 RPM., PTO drive line is availableSpline Input Shaftfrom Northern, Item #165936.Reference 5 – Sight GlassFill gearbox until oil is in the middle of thesight glass.Reference 6 – 100A Circuit Breaker One 100A thermal-magnetic circuit breaker.Reference 7 – 60A Circuit BreakerOne 60A thermal-magnetic circuit breaker.Reference 8 – GearboxCast iron frame. 1:7 gear ratio.Reference 9 – Circuit BreakerOne 30A push-to-reset thermal circuitbreaker.Reference 10 – 120/240V 100AThis extremely safe and durable receptacleConnectorcan be used for all large loads, includingtransfer switches. A plug (part #37552) canbe ordered from NorthStar at 1-800-2700810.Reference 11 – Lifting EyeUse when lifting or moving generator.Reference 12 – Grounding ClampGround the generator via the groundingclamp, to a copper pipe or rod that is driveninto moist soil.Reference 13 – 120/240VThis straight blade receptacle is rated forReceptacle120/240V-60A. This receptacle accepts aNEMA plug number 14-60P.Reference 14 – 120V ReceptacleThis locking device receptacle is a �s Association (NEMA) numberL5-30R. This receptacle accepts NEMAplug number L5-30P.Reference 15 – 120V ReceptacleThe generator has a control panel with two120V-20A straight blade duplex receptacles(two receptacles in a common housing).NEMA number is 5-20R.Reference 16 – Circuit BreakerTwo 20A push-to-reset thermal circuitbreakers.Reference 17 - ShieldPlastic implement shield. NEVER operategenerator without shield in place.9

Power Load Planning & ManagementWARNINGNEVER exceed the rated wattage capacity of your generator.OVERLOADING may cause SERIOUS DAMAGE to the generator andattached electrical devices, and may result in fire.Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge)wattage of the devices you will be powering. Before using your generator, determine the runningand starting wattage requirements of all the electrical devices you will be powering simultaneously.The sum of the running and starting wattages of the devices being powered must not exceed thecontinuous output rating of your generator. (The continuous output rating of your generator is listedin the “Specifications” section of this manual.) Note that: Devices without electric motors such as light bulbs, radios, and televisions have the samerunning and starting wattage. Devices with electric motors such as refrigerators, compressors, and hand tools typicallyrequire a starting wattage that is 3 to 5 times greater than the running wattage.The running and starting wattage requirements are often listed on a device’s nameplate. If wattageis not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplatevoltage by nameplate amperage, Watts Volts X Amps.Example conversion to watts:120 Volts X 5 Amps 600 WattsIf only the running voltage is given on the nameplate for a device with an electric motor, the startingwattage can be approximated to be three to five times the running wattage.Estimates for the running wattage requirements for common devices are listed in Table 4 below.Guidance for starting wattages is provided in the table’s footnotes.Table 4DeviceAir conditioner (12.000 BTU)Battery charger (20 Amp)Belt sander (3”)Chain sawCircular saw (6½”)Coffee makerCompressor (1 HP)Compressor (3/4 HP)Compressor (1/2 HP)Curling ironDishwasherEdge trimmerElectric nail gunElectric range (1 element)Electric skilletRunningWatts1700 (a,b)500100012002000 (a,b)1800 (a,b)1400 (a,b)1800 (a)1400 (a)7001200500120015001250DeviceJet pumpLawn mowerLight bulb (100 Watt)Microwave ovenMilk coolerOil burner on furnaceOil-fired space heater (140,000 Btu)Oil-fired space heater (85,000 Btu)Oil-fired space heater (30,000 Btu)OvenPaint sprayer, Airless (1/3 HP)Paint sprayer, Airless (handheld)RadioRefrigeratorSlow cooker10RunningWatts800 (a)12001007001100 (a)3004002251504500600 (a)150200600 (b)200

Power Load Planning & Management (cont’d)DeviceFurnace fan (1/3 HP)FreezerHair dryerHand drill (1”)Hand drill (1/2”)Hand drill (3/8”)Hand drill (1/4”)Hedge trimmerHome computerImpact wrenchRunningWatts1200 (a)800 (b)12001100875500250450150500DeviceSubmersible pump (1-1/2 HP)Submersible pump (1 HP)Submersible pump (1/2 HP)Sump pumpTable sawTelevisionToasterVacuum cleanerVCRWater HeaterWeed trimmerRunningWatts2800 (a)2000 (a)1500 (a)600 (a)2000 (a)5001000250703000500(a) Hard-starting motors require 3-5 times the rated running watts(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer todetermine maximum wattageTo calculate the running and starting wattage requirements for the devices you will bepowering, follow these steps:1. Make a list of all electrical devices you will be powering at the same time with the generator.2. List the greater of the running or starting wattage next to each device as obtained from thedevices’ nameplate or Table 4. If only the running wattage for a device with an electricmotor is known, the starting wattage can be estimated to be at least 3 times the runningwattage.3. Add the wattages for all devices on your list. This total must be lower than the continuousoutput rating of your generator.Example:Device to be PoweredLight BulbRefrigerator – 18 Cu. Ft.MicrowaveWindow ACSump pump (1/3 hp)TotalGreater ofStarting/Running Wattage75 W1600 W700 W1800 W2100 W6275WIn this example, the generator must have a continuous output of at least 6275 W in order topower all of the devices simultaneously.STAGGERING LOADSYou can increase the number of devices your generator can power by staggering the load on thegenerator. For example, you could alternately power your refrigerator and air conditioner forlimited periods of time -- powering only one of the devices at a time and never powering both at thesame time.11

Installation / Initial Set-UpThere are a number of important steps required to set up your generator for initial use. Thesesteps are:1.2.3.4.5.6.Steps for Installation / Initial Set-UpUnpacking & delivery inspection.Planning the power load to stay within the generator’s ratedcapacity.Setting up generator for the type of power generation you need:a. portable power source, orb. connected to a building as a back-up power source.Selecting a site for using the generator.Mounting the generator.Grounding the generator.Each of these steps is discussed in detail below:1. Unpacking & Delivery Inspection1. You should inspect the generator immediately after you receive delivery.See the “Machine Component Identification” section of this manual for adiagram of the generator and its components. If you have missing or damaged components, contact Product Support at 1-800-270-0810.2. The gearbox is shipped with oil and a temporary shipping plug.a. Remove the temporaryshipping plug and replacewith the metal breather/oilfill plug that is in the manualbag.b. Make sure that the gear oillevel is in the middle of thesight glass, at the red dot.Add SAE 90W gear oil asrequired.Filler/Breather PlugShipping PlugSight Glass12

Installation / Initial Set-Up2. Planning the Power LoadPlan your power load so that you do not exceed the generator’s rated capacity.See the “Power Load Planning & Management” section of this manual to review how to plan andmanage power loads for the generator.3. Set-up either as a BUILDING BACK-UP or PORTABLE Power SourceThis generator is designed to provide up to 24,000W of continuous electrical power. It can supplyelectricity in two ways:1. As a back-up, standby power source for a building. For this application, you must arrangefor a licensed electrician to connect the generator to your building’s electrical system via theinstallation of an UL-approved transfer switch. The transfer switch must be installed inaccordance with building electrical code and guidelines supplied by your power company.2. As a portable power source. You can plug appliances or tools directly into the generator’selectrical outlets.Specific requirements for each are given below.Note: Regardless of whether you use your generator as a back-up power source connected to abuilding or as a portable power source, you must not overload the generator. Overloadingmay cause serious damage to the generator and attached electrical devices.Using as aBack-up PowerSource for aBuildingContact a licensed electrician to install a UL-approved transfer switch ifyou want to use your generator as a back-up power source for a building.What does a transfer switch do? It:a) Safely connects the generator to your building’s electrical system byisolating your generator from your utility company’s power lines,ANDb) Connects your generator to a critical subset of your building’s circuitsthat are needed for emergency power needs.If your generator will be connected to your building’s electrical system, itMUST ALWAYS be isolated from the utility power grid with a UL-approvedtransfer switch installed by a licensed electrician in compliance with allapplicable building and electrical codes, and in accordance with guidelinessupplied by your power company.DANGER:A transfer switch must be installed in order to isolate yourgenerator from the utility power grid. If your generator is NOTproperly isolated from the utility system, serious hazards willarise: When your generator is running, its output will back feed intothe utility power line and transformer that are normally used toprovide you with power. The transformer will step up thecurrent to the normal line voltage. An unsuspecting utility lineworker working on what he thinks is a deactivated line couldbe electrocuted.13

Installation / Initial Set-Up If your generator is connected (running or not) when utilitypower is restored, your generator will be destroyed. It couldalso explode or cause fire.In addition to isolating your generator from the utility system, the transferswitch connects your generator to a limited set of circuits in your buildingthat have been chosen as critical to operate during a power outage.This generator can power up to 24,000 watts, which may not power yourentire home or farm outbuilding -- you must work with the installingelectrician to determine which devices/appliances you wish to power duringan outage. The electrician can help you determine which circuits and devicescan be powered simultaneously without overloading the generator.(See the previous section of this manual entitled “Power Load Planning &Management” for more information on load application and selection.)Using as aPortable PowerSourceWhen using the generator as a portable power source, you can plugelectric devices and appliances directly into the generator’s electricaloutlets.There are four different kinds of electrical outlets on the generator:1. One 120/240 Volt, 60 Amp straight-blade receptacle (NEMA 14-60Rreceptacle compatible with NEMA 14-60P mating plug)2. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30Rlocking receptacle compatible with L14-30P mating plug)3. Two 120 Volt, 20 Amp duplex straight-blade receptacles (NEMA 520R duplex receptacles compatible with NEMA 5-20P or 5-15Pmating plugs).4. One 120/240 Volt, 100 Amp receptacle. This extremely safe anddurable receptacle can be used for all large loads, including transferswitches. To utilize this receptacle, specific connectors and contactsmust be used. A connector assembly for use with this receptacle canbe ordered from NorthStar at 1-800-270-0810 (NorthStar 100A14

Installation / Initial Set-Up(See more technical detail about these receptacles and their associatedcircuit breakers in the “Machine Component Identification” section of thismanual.) Make sure you plug each electrical device/appliance into the correctgenerator outlet based on the device’s plug configuration andvoltage/amperage rating. Never exceed the amperage rating of an outlet. Extension cords may be used to power devices that are located at adistance from the generator. However, use only UL-listed, outdoor-rated,grounded extension cords of the proper size. Additionally, if using thegenerator in damp or highly electrical conductive areas or on constructionjobsites, always use ground fault circuit interrupter (GFCI)-equippedextension cords to prevent electrical shock. Use Table 5 below to choosean adequately sized extension cord according to the amperage of thedevice being used and the length of the cord.Table 5Current/PowerAmps ximum Extension Cord Length#10 Ga.#12 Ga.#14 Ga.#16 5’***WARNING:Use of under sized extension cords can cause electric shock, fire, ordamage to connected devices. Failure to use GFCI extension cords indamp or wet conditions can result in severe electric shock orelectrocution. All extension and appliance cords must be in good condition and not worn,bare, frayed, or otherwise damaged.WARNING:Use of damaged electric cords can cause electric shock or fire.Note: If an extension cord becomes hot to the touch, it is overloaded ordamaged and must be replaced.Northern Tool is NOT responsible for damage or injury resulting fromcustomer use of inadequate extension cords.15

Installation / Initial Set-Up4. Select a Suitable SiteBefore using the generator, you must select a suitable OUTDOOR location for installation andoperation of your generator. If you will be mounting the generator to a concrete slab, you must choose the locationof the slab according to

Driveline guard, plus tractor and generator shields must be in place. Driveline guard must turn freely and independently on driveline. Accidental contact with rotating driveline will cause hair or clothing near rotating shaft

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