North Star Portable Generator 13000 PTOG User Manual

MODEL 13000 PTOG  
ITEM # 165929  
Power Take-Off Generator  
P r o v e n P e r f o r m a n c e  
M165929A  
OWNER’S MANUAL  
00293  
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  
 
SPECIFICATIONS  
Item Number  
Maximum Output  
Continuous Output  
Voltage  
#165929  
13000 Watts (W)  
12000 Watts (W)  
120 / 240 Volt (V)  
Phase  
Single phase (4-wire)  
Frequency  
59.0-63.0 Hertz (Hz)  
Power Factor  
Minimum PTO HP  
Input Shaft  
100 %  
24 HP at 540 RPM  
1 3/8” Diameter, 6 spline  
120VReceptacle  
(2) 20 Amp (A) duplex (NEMA5-20R)  
30 Amp (A) twistlock (NEMAL5-30R)  
50 Amp (A) Straight blade (NEMA14-50R)  
(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  
120/240VReceptacle  
Circuit Breaker  
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  
00294  
Figure 1 (Ref. 1-10)  
Ref. Description  
Ref. Description  
1
2
3
4
5
6
7
8
50A Circuit Breakers  
10  
11  
12  
13  
14  
15  
16  
17  
120/240V 50A Receptacle  
Shield  
Gear Box  
Grounding Screw  
Mounting Holes  
Fan Vents  
Oil Level Sight  
Breather/Oil Fill Plug  
30A Circuit Breaker  
20A Circuit Breakers  
Warning Decals  
1 3/8”, 6 Spline Input Shaft  
Oil Drain Plug  
Voltmeter  
120V 20A Duplex  
Receptacles  
9
120V 30A Twistlock  
Receptacle  
3
 
receptacle accepts NEMA plug number L5-30P,  
which is supplied with the generator.  
GENERATOR FEATURES  
Reference 10 - 120/240V Receptacle. This  
straight blade receptacle is 120/240V 50A. This  
receptacle accepts a NEMA plug number 14-50P.  
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  
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.  
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.  
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.  
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  
Reference 16 - Oil Level Sight. When oil is  
even with the red dot, the oil level is correct. Check  
in  
a
common housing). National Electrical  
Manufacturer’s Association (NEMA) number is 5-  
20R.  
oil level daily. Sight is mounted on the gear box  
00295  
service panel. If panel is removed for whatever  
eal using Dow Corning sealant #732.  
Reference 9 - This twistlock receptacle is a  
120V 30A receptacle, NEMA number L5-30R. 
Figure 2 (Ref. 10-16)  
4
 
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.  
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.  
INTRODUCTION  
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.  
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.  
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:  
RULES FOR SAFE OPERATIONS  
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.  
Safety precautions are essential when operating  
this generator. Respectful and cautious operation  
will considerably lessen the possibilities of  
personal injury. This manual will warn of specific  
personal injury potential, and these will be  
designated by the symbol:  
a
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 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.  
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.  
ALWAYS use electrical cords that are in good  
condition.  
Worn, bare, frayed or otherwise  
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.  
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.  
INSTALLATION  
5
 
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  
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.  
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 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  
DANGER Trailer may tip over and cause  
00345  
stay clear of the rotating PTO driveline. From the  
serious injury or death.  
Never stand near an  
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.  
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.  
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 lbft. Re-torque securing stud nut to 88ft.  
00346  
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  
120V,  
60  
Hz  
Starting Amps  
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  
Motors  
Hp motor Running RI type  
Watts  
Cap  
type  
SP  
type  
1/6  
1/4  
1/3  
1/2  
1
1 1/2  
2
3
525  
700  
875  
1175  
1925  
2400  
2900  
4075  
6750  
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-224  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
5
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.  
00402  
system.  
NOTE:  
If wattage is not given o
equipment nameplate, approximate wattage may  
be determined by multiplying nameplate voltage  
by nameplate amperage.  
VOLTS X AMPS = WATTS  
Example: 120V  
600W  
X 5A  
=
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  
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.  
overload may stall the engine.  
operate at very low speeds, the electric motor starter  
winding will burn out in a short time. The  
If allowed to  
Always allow the generator to reach operating  
speed before a load is applied.  
generator head winding might also be damaged.  
Running the generator under these conditions  
may result in damage to the generator stator as well  
7
 
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.  
Freezer  
Furnace Fan (1/3 HP)  
Hair Dryer  
800 (b)  
1200 (a)  
1200  
1100  
875  
Hand Drill (1”)  
Hand Drill (1/2”)  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
500  
250  
450  
150  
EXTENSION CORDS  
500  
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  
800 (a)  
1200  
100  
700  
1100 (a)  
300  
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  
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/Powe Maximum Extension Cord Length  
r
Amps Load  
#10  
Ga.  
#12  
Ga.  
#14  
Ga.  
#16  
Ga.  
at  
(watts)  
240V  
Cord  
Cord  
Cord  
Cord  
10  
20  
30  
40  
50  
2400  
4800  
7200  
9600  
12000  
250’  
125’  
60’  
30’  
15’  
150’  
75’  
35’  
15’  
*
100’  
50’  
25’  
10’  
*
75’  
25’  
10’  
*
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  
*
*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.  
Water Heater  
Weed Trimmer  
3000  
500  
For Determining Generator Load Requirements  
(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.  
Device  
Running Watts  
1700 (a)  
500  
Air Conditioner (12,000 Btu)  
Battery Charger (20 Amp)  
Belt Sander (3”)  
1000  
Chain Saw  
1200  
Circular Saw (6-1/2”)  
Coffee Maker  
900  
1000  
Compressor (1 HP)  
Compressor (3/4 HP)  
2000 (a)  
1800 (a)  
Generator Load Requirements Continued  
PRE-START UP PREPARATIONS  
Compressor (1/2 HP)  
Curling Iron  
1400 (a)  
700  
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.  
Dishwasher  
Edge Trimmer  
1200  
500  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
1200  
1500  
1250  
8
 
GENERATOR CARE  
GROUNDING - All units must be grounded.  
Drive a 3/4” or 1” copper pipe or rod into the ground  
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.  
close to the generator.  
penetrate moist earth.  
The pipe/rod must  
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.  
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.  
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  
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.  
Load  
Output  
Frequency  
(Hz)  
Percent of  
Generator  
Output  
Speed  
(RPM)  
Generator  
voltage at  
120V  
Receptacle  
0 %  
50 %  
100 %  
3780  
3600  
3480  
63.0  
60.0  
58.0  
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
 
TROUBLESHOOTING  
Problem  
Possible Causes  
Possible Remedies  
Voltage too low.  
a)  
b)  
a)  
Engine speed too slow.  
Generator is overloaded.  
Defective load connected to  
a)  
b)  
Increase tractor RPMs.  
Reduce the load. (See Load  
Application section of this manual.)  
Circuit breaker trips.  
a)  
b)  
Disconnect load.  
Replace receptacle.  
generator.  
b)  
Defective receptacle.  
c) Reduce the load. (See Load  
c) Generator overloaded.  
Application section of this manual.)  
d)  
Contact Customer Service for  
d) Defective circuit breaker.  
the nearest service center.  
Voltage too high.  
a)  
a)  
b)  
Engine speed too high.  
Generator is overloaded.  
Insufficient ventilation.  
a)  
Contact Customer Service for  
the nearest service center.  
a)  
Application section of this manual.)  
b)  
Generator  
overheating.  
Reduce the load. (See Load  
Make sure there is at least 3  
feet of clearance on all sides of  
generator.  
No output voltage.  
a)  
Defective load connected to  
a)  
b)  
Disconnect load.  
Replace/tighten wire.  
generator.  
b)  
Broken or loose wire.  
c) Replace receptacle.  
d)  
Contact Customer Service for  
c) Defective receptacle.  
the nearest service center.  
d)  
Defective stator.  
e)  
Contact Customer Service for  
the nearest service center.  
f) Contact Customer Service for the  
nearest service center.  
e)  
Defective rotor.  
f) Defective capacitor.  
g)  
Contact Customer Service for  
the nearest service center.  
h) Increase tractor RPMs.  
I) Engage PTO.  
g)  
Defective circuit breaker.  
h) Engine speed too slow.  
I) PTO not engaged.  
j) Contact Customer Service for the  
nearest service center.  
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 d) Repostition the tractor or generator  
of greater than 15°.  
so the angle is reduced to less than 15°  
both vertically and horizontally.  
e) Disassemble PTO driveline and  
reassemble with CV joints  
e) Unsynchronized PTO driveline.  
synchronized.  
10  
 

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