North Star Portable Generator 27500 User Manual

MODEL 27500 PTOG  
ITEM # 165937  
Power Take-Off Generator  
P r o v e n P e r f o r m a n c e  
M165937D  
OWNER’S MANUAL  
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  
 
Maximum Output  
Continuous Output  
Voltage  
27500 Watts (W)  
24000 W  
120 / 240 Volt (V)  
Phase  
Frequency  
Single phase (4-wire)  
59.0-63.0 Hertz (Hz)  
Power Factor  
Minimum PTO HP  
Input Shaft  
1.0  
48 HP at 540 RPM  
1 3/8” Diameter, 6 spline  
(2) 20 Amp (A) duplex (NEMA 5-20R)  
30ATwistlock (NEMAL5-30R)  
60AStraight blade (NEMA14-60R)  
100A Pin and sleeve (4100R12W)  
(2) 20A thermal, push to reset style  
30A thermal, push to reset style  
60Athermal magnetic  
120VReceptacle  
120/240VReceptacle  
Circuit Breaker  
100Athermal magnetic  
Gear Box  
Gear Ratio  
Gear Oil  
Oil Capacity  
Dimensions  
Length  
Width  
Height  
Gross Weight  
1:7  
SAE 80W-90  
.53 Qt. (.5 L)  
36.95” (93.9 cm)  
16.85” (42.8 cm)  
20.79” (52.8 cm)  
425 lb. (193.2 kg)  
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  
2
 
00410  
Figure 1 (Ref. 1-12)  
Ref. Description  
Ref. Description  
1
2
Voltmeter  
11  
12  
13  
14  
15  
16  
17  
18  
19  
30A Circuit Breaker  
120/240V 60A Receptacle  
Gear Box  
Lifting Eye  
3
4
5
Breather/Oil Fill Plug  
1 3/8”, 6 Spline Input Shaft  
Sight Glass  
Warning Decals  
Grounding Clamp  
100A Circuit Breaker  
120/240V 100A Pin and Sleeve  
60A Circuit Breaker  
Shield  
6
7
Fan Vents  
Mounting Holes  
8
9
10  
120V 30A Twistlock Receptacle  
120V 20A Duplex Receptacles  
20A Circuit Breakers  
References 1 - Voltmeter. Voltmeter needle  
should be in green area during all generator load  
00411  
GENERATOR FEATURES  
conditions. The black line in the center on the green  
Figure 2 (Ref. 13-19)  
3
 
area indicates 120V. During no load conditions, the  
needle should be at or above the black line.  
References 2 - Lifting Eye. Use when lifting or  
moving generator.  
Reference 3 - 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.  
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.  
References 4 - 1 3/8” Diameter 6 Spline Input  
Shaft. 540 RPM. PTO driveline is available from  
Northern, Item #165936.  
References 5 - Sight Glass. Fill gear box until oil  
is in the middle of the glass.  
Reference 6 - 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 7 - Mounting Holes. Use these four  
locations to mount the generator head in place with  
four 5/8” grade 5 bolts/anchors (see Installation  
secti on ).  
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:  
Reference 8 - 120V Receptacle. This twistlock  
receptacle is a 120V  
30A receptacle, National  
Electrical Manufacturer’s Association (NEMA) number  
L5-30R. This receptacle accepts NEMA plug number  
L5-30P.  
Reference 9 - 120V Receptacle. The generator  
has a control panel with two 120V 20A straight blade  
receptacle duplexes (two receptacles in a common  
housing). NEMA number is 5-20R.  
Reference 10 - Circuit Breaker. Two 20A push-  
to-reset thermal circuit breakers.  
WARNING This generator is equipped  
with a grounding clamp, located on the generator  
frame for your protection.  
Always complete the  
Reference 11 - Circuit Breaker. One 30A push-  
to-reset thermal circuit breaker.  
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.  
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 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.  
Reference 12 - 120/240V Receptacle.  
straight blade receptacle is 120/240V 60A.  
receptacle accepts a NEMA plug number 14-60P.  
This  
This  
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 13 - Gear Box. Cast iron frame. 1:7  
gear ratio.  
References 14 - Warning Decals. Read and  
follow all warnings.  
Reference 15 - Grounding Clamp. Ground the  
generator via the grounding clamp, to a copper pipe or  
rod that is driven into moist soil.  
Reference 16 - 100A Circuit Breaker. One 100A  
thermal magnetic breaker.  
ALWAYS remove all oil or gasoline deposits and  
accumulated dirt 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.  
Reference 17 - 120/240V 100A Pin and Sleeve.  
This extremely safe and durable receptacle can be  
used for all large loads, including transfer switches.  
IEC 309-1 number 4100R12W. A plug (part #32802)  
can be ordered from NorthStar at 1-800-270-0810.  
Reference 18 60A Circuit Breaker. One 60A  
thermal magnetic breaker.  
References 11 - Shield.  
Plastic implement  
NEVER operate the generator continuously when  
PTO driveline is at angle greater than 15° both  
horizontally and vertically .  
shi eld. NEVER operate generator without shield in  
place.  
INTRODUCTION  
4
 
NEVER operate the generator while wearing loose  
fitting clothing such as neckties, scarves or untucked  
shi rts.  
fatigue of the trailer base if the steel used is not thick  
enough.  
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:  
DANGER Trailer may tip over and cause  
serious injury or death. Never stand near an operating  
PTO generator.  
Use four, grade 5, 5/8” bolts to mount  
generator.  
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.  
L. Without proper guarding in place.  
After the generator is firmly mounted , attach the  
PTO driveline to the generator then the tractor. Use a  
synchronized PTO driveline rated at 48 HP minimum.  
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 Never attach PTO driveline  
while tractor is running.  
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.  
DANGER Always have proper guarding  
of rotating parts.  
Failure to guard the power  
transm i ssi on m echani sm s m ay resul t in seri ous inj ury  
or death.  
While seated on the tractor and the engine at idle,  
00506  
engage the PTO. Slowly increase the throttle ue  
needle in the generator voltmeter is at or above the  
black line in the green area. A load can now be  
applied to the generator. Remember to stay clear of  
the rotating PTO driveline. From the tractor seat re-  
adjust the speed until the needle on the generator  
voltmeter is close to the black line in the green area. If  
the needle will not rise to the green area no matter  
what the engine speed, the generator is either  
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.  
overloaded or there is a problem.  
Use the  
troubleshooting guide at the end of the manual for  
assistance with possible problems.  
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  
Before each use check the gear box oil level. Use  
80W-90 SAE synthetic gear oil and fill to the middle of  
the oil level sight plug.  
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  
sy stem .  
Design the application to minimize the angle of the  
driveline, 15° maximum. The smaller the angle of  
operation, the longer the driveline will last.  
When trailer mounting the generator select a  
trailer 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  
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  
5
 
become excessively hot and cause the insulation to  
break down, reducing its ability to resist corrosive  
contaminants. Over time the effectiveness of the  
insulation is eliminated and a dead short can result.  
Always compare the generator nameplate data  
with that of the equipment to be used to ensure that  
watts, volts, amperage, and frequency requirements  
are suitable for operating equipment. The wattage  
listed on the equipment nameplate is its rated output.  
However, some equipment may require three to ten  
times more wattage than its rating on the nameplate,  
as the wattage is influenced by the equipment  
efficiency, power factor and starting system. NOTE: If  
wattage is not given on equipment nameplate,  
approximate wattage may be determined by  
1 1/2  
2400  
2900  
4075  
6750  
30-50  
36-60  
51-85  
84-140  
40-80  
48-96  
68-136  
NA  
NA  
NA  
NA  
2
3
5
112-224  
The figures given above are for an average load  
such as a blower or fan. If the electric motor is  
connected to a hard starting load such as an air  
compressor, it will require more starting current. If it is  
connected to a light load or no load such as a power  
saw, it will require less starting current. The exact  
requirement will also vary with the brand or design of  
the motor.  
Generators respond to severe overloading  
differently than the power line. When overloaded, the  
engine is not able to supply enough power to bring the  
electric motor up to operating speed. The generator  
responds to the high initial starting current, but the  
engine speed drops sharply. The overload may stall  
the engine. If allowed to operate at very low speeds,  
the electric motor starter 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  
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.  
multiplying  
amperage.  
nameplate voltage by nameplate  
VOLTS X AMPS = WATTS  
Example: 120V X 5A  
= 600W  
When connecting a resistive  
load such as  
incandescent lights, heaters or common electric power  
tools, a capacity of up to the generator full rated  
wattage output can be used.  
When connecting a resistive-inductive load such  
as a fluorescent or mercury light, transformers or  
inductive coils, a capacity of up to 0.6 times the  
generator’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.  
EXTENSION CORDS  
When electric power is to be provided to various  
loads at some distance from the generator, extension  
cords can be used. These cords should be sized to  
allow for distance in length and amperage so that the  
voltage drop between the set and point of use is held  
to a minimum.  
Current/Power Maximum Extension Cord Length  
Amps  
at  
Load  
(watts)  
#10  
Ga.  
#12  
Ga.  
#14  
Ga.  
Cord  
100’  
50’  
25’  
10’  
*
#16  
Ga.  
Cord  
75’  
25’  
10’  
*
240V  
Cord  
Cord  
10  
20  
30  
40  
50  
2400  
4800  
7200  
9600  
12000  
250’  
125’  
60’  
30’  
15’  
150’  
75’  
35’  
15’  
*
*
*Not recommended  
CAUTION: Equipment damage can result from the  
low voltage caused by using an extension cord with a  
sm all wi re si ze.  
Starting Amps  
RI type Cap type SP type  
120V, 60 Hz Motors  
Hp motor Running  
Watts  
1/6  
1/4  
1/3  
1/2  
1
525  
700  
875  
1175  
1925  
7-11  
9-15  
11-18  
15-25  
24-40  
9-18  
16-22  
22-32  
26-35  
NA  
Use this chart to estimate the total load on your  
generator.  
12-23  
14-29  
20-40  
32-64  
For Determining Generator Load Requirements  
NA  
6
 
Device  
Running Watts  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
Chain Saw  
Circular Saw (6-1/2”)  
1700 (a)  
500  
1000  
1200  
900  
1000  
2000 (a)  
1800 (a)  
1400 (a)  
700  
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-  
270-0810.  
Coffee Maker  
Compressor (1 HP)  
Compressor (3/4 HP)  
Compressor (1/2 HP)  
Curling Iron  
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.  
Dishwasher  
Edge Trimmer  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
Freezer  
Furnace Fan (1/3 HP)  
Hair Dryer  
Hand Drill (1”)  
1200  
500  
1200  
1500  
1250  
800 (b)  
1200 (a)  
1200  
1100  
875  
OPERATING SPEED  
Hand Drill (1/2”)  
The generator must be run at the correct speed in  
order to produce the proper electrical voltage and  
frequency.  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
500  
250  
450  
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.  
Home Computer  
Impact Wrench  
Jet Pump  
Lawn Mower  
Light Bulb  
150  
500  
800 (a)  
1200  
100  
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 effected if correct RPM is  
not maintained. See Load vs. Output chart  
Microwave Oven  
Milk Cooler  
700  
1100 (a)  
300  
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  
400  
225  
150  
4500  
600 (a)  
150  
200  
600 (b)  
Refrigerator  
Slow Cooker  
200  
2800 (a)  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
Load  
Output  
Frequency  
Submersible Pump (1-1/2 HP)  
Submersible Pump (1 HP)  
Submersible Pump (1/2 HP)  
Sump Pump  
Table Saw (10”)  
Television  
Percent of  
Generator  
Output  
0 %  
50 %  
100 %  
Speed  
(RPM)  
Generator  
voltage at 120V  
Receptacle  
(Hz)  
3780  
3600  
3480  
63.0  
60.0  
58.0  
125V  
122V  
118V  
Toaster  
1000  
Vacuum cleaner  
250  
VCR  
Water Heater  
70  
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.  
Output voltage should 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.  
7
 
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  
is operating 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 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.  
8
 
TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Voltage too low.  
a) Engine speed too slow.  
a) Increase tractor RPMs.  
b) Reduce the load. (See Load  
b) Generator is overloaded.  
Application section of this manual.)  
Circuit breaker trips.  
Voltage too high.  
a) Defective load connected to generator.  
b) Defective receptacle.  
c) Generator overloaded.  
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.  
d) Defective circuit breaker.  
a) Engine speed too high.  
a) Contact Customer Service for the  
nearest service center.  
Generator overheating. a) Generator is overloaded.  
b) Insufficient ventilation.  
a) Reduce the load. (See Load  
Application section of this manual.)  
b) Make sure there is at least 3 feet of  
clearance on all sides of generator.  
a) Disconnect load.  
No output voltage.  
a) Defective load connected to generator.  
b) Broken or loose wire.  
b) Replace wire.  
c) Replace receptacle.  
c) Defective receptacle.  
d) Defective stator.  
d) Contact Customer Service for the  
nearest service center.  
e) Contact Customer Service for the  
nearest service center.  
e) Defective rotor.  
f) Contact Customer Service for the  
nearest service center.  
g) Contact Customer Service for the  
nearest service center.  
f) Defective capacitor.  
g) Defective circuit breaker.  
h) Increase tractor RPMs.  
I) Engage PTO.  
j) Contact Customer Service for the  
nearest service center.  
h) Engine speed too slow.  
I) PTO not engaged.  
j) Gear box is malfunctioning.  
Excessive gear box  
noise.  
a) Defective bearing.  
a) Contact Customer Service for the  
nearest service center.  
b) Defective gear.  
b) Contact Customer Service for the  
nearest service center.  
c) No or low gear oil.  
c) Fill gear box to oil level sight.  
d) PTO driveline is operating at an angle of d) Reposition the tractor or generator so  
greater than 15°.  
the angle is reduced to less than 15° both  
vertically and horizontally.  
e) Unsynchronized PTO driveline.  
e) Disassemble PTO driveline and  
reassemble with CV joints synchronized.  
9
 

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