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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