NorthStar 165951 Owner's Manual

Portable outdoor use-only, power take-off (pto) generator

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Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable Outdoor Use-Only, Power Take-Off (PTO) Generator
Can be used to power individual appliances plugged directly into the generator's outlets, or as a back up
connection to a building's power supply (via a professionally installed UL-approved transfer switch).
READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up, operate, and
maintain this generator could result in serious injury or death from carbon monoxide poisoning, electric shock,
entanglement, fire, or burns. In addition, PTO shaft and generator can become airborne and cause severe injury if
improperly secured. In particular, be aware of the following hazards:
The running tractor engine gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
 ONLY run tractor and generator OUTDOORS and AWAY from building air intakes. NEVER run inside any enclosed or semi-
enclosed spaces, including homes, basements, garages, sheds, and boxes. These spaces can trap poisonous gases, EVEN if you run a
fan or open windows.
 Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
 High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly grounded. Use only
UL-listed, outdoor-rated grounded GFCI-equipped extension cords of proper size.
 NEVER plug the generator directly into a wall outlet. ANY connection to a building's electrical system MUST ISOLATE THE
GENERATOR FROM UTILITY POWER via a UL-approved transfer switch installed by a licensed electrician. Otherwise, back feed
from the generator into the power grid could kill utility workers.
 DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so generator
does not overheat and possibly cause fire. Keep all objects at least 7' from generator vent openings. Refer to tractor manual for
minimum safe clearance distance between hot tractor exhaust and nearby combustible materials and structures.
ALWAYS keep a fire extinguisher rated "ABC" nearby.
 Failure to properly mount and secure the generator may cause the unit to flip violently during use, which could cause severe injury to
the operator or bystanders, or damage to surrounding objects.
 Never operate the generator without proper PTO guarding, including a freely rotating shaft guard as well as tractor and generator
shields at each end. Clothing or hair can become rapidly entangled in unguarded rotating PTO shaft or connections, resulting in
serious injury or death.
 Make sure PTO driveline shaft is securely locked at both ends. An unlocked PTO shaft can whip or become dangerously airborne.
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the "Power load Planning & Management" section of this manual
to determine your power load requirements and then compare to the generator's rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the "Unpacking & Delivery
Inspection" section for instructions on whom to contact to report missing or damaged parts.
MOUNTING IS REQUIRED. You will need to mount this PTO generator to either a (reinforced?) concrete slab or a PTO trailer. See
the "About Your Generator" and "Installation/Initial Set-Up" sections for more information on this requirement.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to your
building's electrical system. See the "Installation/Initial Set-Up" section for more information about this requirement.
Owner's Manual
7,200 Watt Continuous (7,800 Watt Surge) Capacity
Electric shock / Electrocution
Power Take-Off (PTO)
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
M165951G.2
ITEM NUMBER: 165951
SERIAL NUMBER: _____________
WARNING
CO Poisoning
Fire
STOP!

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Summary of Contents for NorthStar 165951

  • Page 1 ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this requirement. Any Questions, Comments, Problems, or Parts Orders Call NorthStar Product Support 1-800-270-0810...
  • Page 2: Hazard Signal Word Definitions

    Hazard Signal Word Definitions...
  • Page 3: Table Of Contents

    Table of Contents Hazard Signal Word Definitions ....................2 About Your Generator ......................... 4 Specifications ..........................6 Safety Label Locations ........................7 Machine Component Identification ..................... 8 Power Load Planning & Management ..................10 Installation / Initial Set-Up: 1. Unpacking & Delivery Inspection ..................12 2.
  • Page 4: About Your Generator

    A trailer designed specifically for use with PTO generators rated up to 60,000 Watts is available from NorthStar -- Item #165959. More detailed information about mounting can be found in the “Installation / Initial Set-Up” section of this manual.
  • Page 5: Warranty Registration

    NorthStar is constantly improving its products. The specifications outlined herein are subject to change without prior notice or obligation.
  • Page 6: Specifications

    Specifications – Item #165951 SPECIFICATIONS Item Number 165951 Maximum Output 7800 Watts (W) Continuous Output 7200 Watts (W) Voltage 120 / 240 Volt (V) Phase Single phase (4-wire) Frequency 60.0 Hertz (Hz) Power Factor Minimum PTO HP 14 HP at 540 RPM Minimum Operating Torque 101.7 pound-foot...
  • Page 7: Safety Label Locations

    Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810. On-Product Warning Labels...
  • Page 8: Machine Component Identification

    Machine Component Identification - Item #165951G.2 Figure 1 (Ref 1-12) Ref. Description Ref. Description Alternator Filler/Breather Plug Grounding Screw Implement Shield Isomounts Fan Vents 30A Circuit Breaker Mounting Holes 120V Receptacle Voltmeter 1-3/8” Diameter 6 Spline Input Shaft 20A Circuit Breaker 120/240V Locking Receptacle Oil Fill Sight Glass Gearbox...
  • Page 9 Machine Component Identification – Item #165951G.2 (cont’d) REFERENCE GUIDE Reference 1 – Alternator The generator head produces energy. Reference 2 – Grounding Screw Use to ground the generator to a copper pipe or rod that is driven into moist soil. Reference 3 –...
  • Page 10: Power Load Planning & Management

    Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering.
  • Page 11 Power Load Planning & Management (cont’d) Running Running Device Watts Device Watts Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP) 2000 (a) Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a) Hand drill (1”) 1100...
  • Page 12: Installation / Initial Set-Up

    Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: Steps for Installation / Initial Set-Up 1. Unpacking & delivery inspection. 2. Planning the power load to stay within the generator’s rated capacity.
  • Page 13: Planning The Power Load

    Installation / Initial Set-Up 2. Planning the Power Load Plan your power load so that you do not exceed the generator’s rated capacity. See the “Power Load Planning & Management” section of this manual to review how to plan and manage power loads for the generator.
  • Page 14 Installation / Initial Set-Up  If your generator is connected (running or not) when utility power is restored, your generator will be destroyed. It could also explode or cause fire. In addition to isolating your generator from the utility system, the transfer switch connects your generator to a limited set of circuits in your building that have been chosen as critical to operate during a power outage.
  • Page 15 Installation / Initial Set-Up  Extension cords may be used to power devices that are located at a distance from the generator. However, use only UL-listed, outdoor-rated, grounded extension cords of the proper size. Additionally, if using the generator in damp or highly electrical conductive areas or on construction jobsites, always use ground fault circuit interrupter (GFCI)-equipped extension cords to prevent electrical shock.
  • Page 16: Selecting A Suitable Site

    Installation / Initial Set-Up 4. Select a Suitable Site Before using the generator, you must select a suitable OUTDOOR location for installation and operation of your generator.  If you will be mounting the generator to a concrete slab, you must choose the location of the slab according to all the criteria listed below.
  • Page 17 Installation / Initial Set-Up  Do not run the generator in close proximity to other heat-generating equipment, such as another generator. The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation. ...
  • Page 18: Mounting The Generator

    Centered side-to-side between the trailer’s wheels to minimize the possibility the trailer will flip due to operating torque. If using the NorthStar PTO trailer (Item #165959), specific mounting bolt patterns are illustrated in the trailer’s Owner’s Manual for various NorthStar PTO generator models.
  • Page 19 Installation / Initial Set-Up Mounting to a If you will be using the generator in a permanent location, you may concrete slab mount the generator to a reinforced concrete slab. 1. Choose a location for the slab that is as close to the load as possible (to minimize voltage drop) and which also meets all the criteria specified in the previous section, “4.
  • Page 20: Grounding The Generator

    Installation / Initial Set-Up 6. Grounding the generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –...
  • Page 21: Operation

    Operation Once you have set up your generator for use, it is time to start your generator. The following are the procedures necessary for safe, successful operation of your generator. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3.
  • Page 22: Preparing For Operation

    Operation (cont’d)  Adjusting / repairing. Always turn off generator and remove PTO driveline before working on the generator. Always discharge the capacitor before working on the generator head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on how to do this.) ...
  • Page 23 Operation (cont’d) generator OUTDOORS and away from air intakes. NEVER run tractor and generator inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.
  • Page 24: Connecting To The Tractor

    Operation (cont’d) 3. Connecting to the Tractor Follow the instructions in this section to connect the generator to the tractor’s PTO via a driveline shaft (purchased separately). Acquire a synchronized 1-3/8”, 6 spline PTO driveline rated at 24 HP Acquire PTO driveline shaft minimum.
  • Page 25: Starting The Generator

    Operation (cont’d) 2. Ensure that the tractor PTO is disengaged and the tractor is turned OFF. 3. Connect one end of the PTO driveline shaft to the generator’s input shaft. 4. Connect the other end to the tractor PTO stub. WARNING: Make sure PTO driveline shaft is securely locked at both ends.
  • Page 26: Connecting Loads

    Operation (cont’d) 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING:...
  • Page 27 Operation (cont’d) WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual. Note: All engines have a tendency to slow down when a load is applied.
  • Page 28: Stopping

    Operation (cont’d) 6. Stopping Stop the generator using the following steps: 1. Disconnect all loads to generator. (Never reduce throttle with electrical loads connected. Damage to generator and loads will occur.) 2. After all loads are disconnected, slowly reduce PTO speed to a minimum and then disengage PTO.
  • Page 29: Maintenance & Repair

    Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, remove PTO driveline and discharge the capacitor before cleaning, adjusting, or servicing the generator.
  • Page 30 If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replace- ment parts that do not meet specifications may result in a safety hazard or poor operation of the generator. Contact NorthStar Product Support at 1-800-270-0810 for any questions, problems, or parts orders.
  • Page 31: Troubleshooting

    Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Voltage too low a) Tractor throttle set too low a) Increase tractor RPMs. b) Generator is overloaded b) Reduce the load (See Power Load Planning & Mgt. section of this manual). Circuit breaker trips a) Defective load connected to a) Disconnect load.
  • Page 32: Summary Of Important Safety Information For Operation

    Summary of Important Safety Information for Operation This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator. WARNING Carefully read and make sure you understand the following safety information before using the generator.
  • Page 33 Summary of Important Safety Information for Operation (cont’d)  Isolate connection to building’s electrical circuit. Never plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST ISOLATE THE GENERATOR FROM UTILITY POWER via an UL-approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes.
  • Page 34 Summary of Important Safety Information for Operation (cont’d)  Protect sensitive electronics. Some electronic equipment, such as computers and audio/video equipment, can be damaged by small fluctuations in the flow of power. Use a surge suppressor for any voltage-sensitive electronic equipment you will be powering with the generator. ...
  • Page 35: Pto Generator Exploded View

    PTO Generator Exploded View Rev – G.2 Item Part# Description Item Part# Description 39138 Control box top 38276 Bearing 38541 NorthStar decal 780143 Rotor securing stud 31727 Voltmeter 307479 Diode 779781 Warning decal 307481 Varistor 1/4-20 x .5” Serrated flange bolt...
  • Page 36: Wiring Diagram

    Wiring Diagram Rev – G.2 Ref # Part # Description 31736 120V 20A Duplex Receptacle (NEMA 5-20R) 30643 20A Circuit Breaker 31005 Circuit Breaker, 30A 777130 Mounting Clip 306422 L14-30R Receptacle 39061 Lead Wire (V-) 39056 Wire Harness (B1, B4, G, G1, G2, W2, W3, W4, W5, W6) 39059 Lead Wire Assembly (B14, V+) 305608...
  • Page 37: Pto Gearbox Exploded View

    PTO Gearbox Exploded View Rev – G.2 Note: Gearbox exploded view is shown upside-down when compared to its orientation on the generator. Item Part# Description Item Part# Description BP2009168109 Housing BP8575378000 Pin, 8x20mm Order Gear Box BP8600103000 Cap #38890 BP8600142000 Breather plug, 3/8” 1 Order Gear Box #38890 BP8600144000 Oil plug, 3/8”...
  • Page 38 This page has intentionally been left blank.
  • Page 39: Limited Warranty

    Any misuse, abuse, alteration or improper installation or operations will void warranty. Determining whether a part is to be replaced or repaired is the sole decision of NorthStar. NOTE: Some services performed by parties other than NorthStar may void warranty.
  • Page 40 Manufactured by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...

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