P r o v e n P e r f o r m a n c e

MODEL 13000 PTOG

ITEM # 165929

Power Take-Off Generator

M165929A

OWNER’S MANUAL

00293

13000 PTOG

Any Questions, Comments, or Problems?

Call Customer Service at 1-800-270-0810

Hours: M onday - 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 generator’s 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 preparations

Generator care

Troubleshooting

1

2

2

3

4

4

4-5

5-6

6-7

7-8

8

9

1

SPECIFICATIONS

Item Number

Maximum Output

Continuous Output

Voltage

Phase

Frequency

Power Factor

Minimum PTO HP

Input Shaft

120V Receptacle

120/240V Receptacle

Circuit Breaker

#165929

13000 Watts (W)

12000 Watts (W)

120 / 240 Volt (V)

Single phase (4-wire)

59.0-63.0 Hertz (Hz)

100 %

24 HP at 540 RPM

1 3/8” Diameter, 6 spline

(2) 20 Amp (A) duplex (NEMA 5-20R)

30 Amp (A) twistlock (NEMA L5-30R)

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

Gear Box

Gear Ratio

Gear Oil

Oil Capacity

Dimensions

Length

Width

Height

Gross Weight

1:7

SAE 80W-90

.86 Qt. (.82 L)

28.38” (72.1 cm)

14.25” (36.2 cm)

12.50” (31.1 cm)

127 lb. (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.

2

MACHINE COMPONENT IDENTIFICATION

Figure 1 (Ref. 1-10)

Ref.

Description

6

7

4

5

8

1

2

3

9

50A Circuit Breakers

30A Circuit Breaker

20A Circuit Breakers

Warning Decals

1 3/8”, 6 Spline Input Shaft

Oil Drain Plug

Voltmeter

120V 20A Duplex

Receptacles

120V 30A Twistlock

Receptacle

Ref.

Description

10 120/240V 50A Receptacle

11 Shield

12 Gear Box

13 Grounding Screw

14 Mounting Holes

15 Fan Vents

16 Oil Level Sight

17 Breather/Oil Fill Plug

00294

3

GENERATOR FEATURES

References 1-3 Circuit Breakers.

• Reference 1 - two 50A push-to-reset circuit breakers.

• Reference 2 - one 30A push-to-reset circuit breaker.

• 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.

• 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

Manufacturer’s Association (NEMA) number is 5-

20R.

• Reference 9 - This twistlock receptacle is a

4 receptacle accepts NEMA plug number L5-30P, which is supplied with the generator.

Reference 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 Lev el Sight. When oil is even with the red dot, the oil level is correct. Check oil level daily. Sight is mounted on the gear box

00295 service panel. If panel is removed for whatever reason, reseal 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. The 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:

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 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.

5

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 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.

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.

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.

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 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 kit (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.

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 black line in the green area. A load can now be applied to the generator. Remember to 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 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 lb

•ft. Re-torque securing stud nut to 88.5 lb•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.

6

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.

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 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 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.

7

120V, 60 Hz

Motors

Hp motor Running

Watts

1/6

1/4

1/3

1/2

1

1 1/2

2

3

5

525

700

875

1175

1925

2400

2900

4075

6750

Starting Amps

RI type Cap type

7-11

9-15

11-18

15-25

9-18

12-23

14-29

20-40

24-40

30-50

36-60

51-85

32-64

40-80

48-96

68-136

84-140 112-224

SP type

16-22

22-32

26-35

NA

NA

NA

NA

NA

NA

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

Generators respond to severe overloading differently than the power line. When overloaded, the engine is not able to supply enough power to bring the electric motor up to operating speed. The generator responds to the high initial starting current, but the engine speed drops sharply. The overload may stall 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.

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 e r

Amps at

240V

Load

(watts)

Maximum Extension Cord Length

#10

Ga.

Cord

#12

Ga.

Cord

#14

Ga.

Cord

#16

Ga.

Cord

10

20

30

40

2400

4800

7200

9600

50 12000

250’

125’

60’

30’

15’

150’

75’

35’

15’

*

100’

50’

25’

10’

*

75’

25’

10’

*

*

*Not recommended

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

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

For Determining Generator Load Requirements

Dev ice Running Watts

Air Conditioner (12,000 Btu)

Battery Charger (20 Amp)

Belt Sander (3”)

Chain Saw

Circular Saw (6-1/2”)

Coffee Maker

Compressor (1 HP)

Compressor (3/4 HP)

1700 (a)

500

1000

1200

900

1000

2000 (a)

1800 (a)

Generator Load Requirements Continued

Compressor (1/2 HP)

Curling Iron

Dishwasher

Edge Trimmer

Electric Nail Gun

Electric Range (one element)

Electric Skillet

1400 (a)

700

1200

500

1200

1500

1250

8

Freezer

Furnace Fan (1/3 HP)

Hair Dryer

Hand Drill (1”)

Hand Drill (1/2”)

Hand Drill (3/8”)

Hand Drill (1/4”)

Hedge Trimmer

Home Computer

Impact Wrench

Jet Pump

Lawn Mower

Light Bulb

Microwave Oven

Milk Cooler

Oil Burner on Furnace

Oil Fired Space Htr (140,000 Btu)

Oil Fired Space Htr (85,000 Btu)

Oil Fired Space Htr (30,000 Btu)

Oven

Paint Sprayer, Airless (1/3 HP)

Paint Sprayer, Airless (handheld)

Radio

Refrigerator

Slow Cooker

Submersible Pump (1-1/2 HP)

Submersible Pump (1 HP)

Submersible Pump (1/2 HP)

Sump Pump

Table Saw (10”)

Television

Toaster

Vacuum cleaner

VCR

Water Heater

Weed Trimmer

(a) 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.

400

225

150

4500

600 (a)

150

200

600 (b)

200

2800 (a)

2000 (a)

1500 (a)

600 (a)

2000 (a)

500

1000

250

70

3000

500

800 (b)

1200 (a)

1200

1100

875

500

250

450

150

500

800 (a)

1200

100

700

1100 (a)

300

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.

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 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

Load

Percent of

Generator

Output

Speed

(RPM)

0 %

50 %

100 %

3780

3600

3480

Output

Frequency

(Hz)

63.0

60.0

58.0

Generator voltage at

120V

Receptacle

125V

122V

118V

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.

9

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 ev ery four w eeks. 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.

Problem

Voltage too low.

Circuit breaker trips.

Voltage too high.

Generator overheating.

No output voltage.

Excessive gear box noise.

TROUBLESHOOTING

Possible Causes

a) Engine speed too slow.

b) Generator is overloaded.

Possible Remedies

a) Increase tractor RPMs.

b) Reduce the load. (See Load

Application section of this manual.) a) generator.

b)

Defective load connected to

Defective receptacle.

c) Generator overloaded.

d) Defective circuit breaker.

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) a) b) a) generator.

b)

Defective load connected to

Broken or loose wire.

c) Defective receptacle.

d) e)

Defective stator.

f) Defective capacitor.

g)

Engine speed too high.

Generator is overloaded.

Insufficient ventilation.

Defective rotor.

Defective circuit breaker.

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.

h) Engine speed too slow.

I) PTO not engaged.

j) Gear box is malfunctioning.

a) Defective bearing.

b) Defective gear.

c) No or low gear oil.

d) PTO driveline is operating at an angle of greater than 15

°.

e) Unsynchronized PTO driveline.

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.

10