North Star 27500 User manual

Proven Performance
MODEL 27500 PTOG
ITEM # 165937
Power Take-Off Generator
M165937D
OWNER’S MANUAL
AnyQuestions, 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

1
Thankyoufor purchasing a NorthStar Power Take-Off Generator. Your machine is designed
for long life, dependability, and the top performance you demand. Please take the time now to
read throughthismanualso you canbetterunderstandthemachine’soperation,maintenance and
safety precautions. Everyone whooperatesthisgenerator must read and understand this manual.
The time you take now will prolong your generator’s life and prepare you forits safe operation.
Enjoy the exceptional performanceof your NorthStarPTO Generator.
IMPORTANT
If thismachineisused by anyone whoisnotthe owner orisloanedor rented, make certain the
operator:
- Isinstructedin safe andproper operationof thismachine.
- Readsand understandsthemanualspertaining to thismachine.
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 1
Specifications 2
ANSI safety definitions 2
Machine componentidentification 3
Generator features 4
Introduction 4
Rules forsafe operation 4-5
Installation 5-6
Load application 6-7
Pre-startup preparations 7-8
Generator care 8
Troubleshooting 9
SPECIFICATIONS
Item Number #165937

2
Maximum Output 27500 Watts (W)
Continuous Output 24000 W
Voltage 120 /240 Volt(V)
Phase Single phase (4-wire)
Frequency 59.0-63.0 Hertz(Hz)
Power Factor 1.0
Minimum PTOHP 48 HP at540 RPM
Input Shaft 1 3/8” Diameter,6spline
120VReceptacle (2) 20 Amp (A) duplex(NEMA 5-20R)
30ATwistlock (NEMAL5-30R)
120/240VReceptacle 60AStraightblade (NEMA14-60R)
100APin andsleeve (4100R12W)
CircuitBreaker (2) 20Athermal, push to reset style
30Athermal, push to reset style
60Athermalmagnetic
100Athermal magnetic
Gear Box
Gear Ratio 1:7
Gear Oil SAE 80W-90
Oil Capacity .53 Qt. (.5 L)
Dimensions
Length 36.95” (93.9 cm)
Width 16.85” (42.8 cm)
Height 20.79” (52.8 cm)
Gross Weight 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.
WARNINGindicatesa potentiallyhazardoussituationwhich, if not avoided, could
resultina death or serious injury.
CAUTION indicatesa potentiallyhazardoussituation, whichif notavoided,may
resultinminor or moderateinjury. Itmayalso be used to alert against unsafe
practices.
MACHINE COMPONENT IDENTIFICATION

3
Ref. Description Ref. Description
1Voltmeter 11 30A CircuitBreaker
2 Lifting Eye 12 120/240V60A Receptacle
3Breather/Oil Fill Plug 13 Gear Box
4 1 3/8”, 6Spline Input Shaft 14 Warning Decals
5SightGlass 15 Grounding Clamp
6 Fan Vents 16 100A Circuit Breaker
7Mounting Holes 17 120/240V100APin and Sleeve
8 120V 30ATwistlockReceptacle 18 60A CircuitBreaker
9120V 20A Duplex Receptacles 19 Shield
10 20A CircuitBreakers
GENERATOR FEATURES References 1 - Voltmeter. Voltmeter needle
should be in green area during all generator load
conditions. The black line in the centeron the green
00410
Figure 1 (Ref. 1-12)
Figure 2 (Ref. 13-19)
00411

4
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
90gearoil. Maintain the correct oil level. Over filling
can cause the oil to over heat and damage seals and
bearings.
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
isinthe middleofthe glass.
Reference 6 - Fan Vents. Never block the vent
slots or insert objects through the slots. The closest
objectshouldbeatleast 3 feetawayfrom 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
section ).
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). NEMAnumberis5-20R.
Reference 10 - Circuit Breaker. Two 20A push-
to-reset thermal circuitbreakers.
Reference 11 - Circuit Breaker. One 30A push-
to-reset thermal circuitbreaker.
Reference 12 - 120/240V Receptacle. This
straight blade receptacle is 120/240V 60A. This
receptacle acceptsa NEMA plug number 14-60P.
ALWAYS use grounded male plugs. The neutral
line of the generatoris 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,toa copper pipe or
rod thatisdriven intomoist soil.
Reference 16 - 100A Circuit Breaker. One 100A
thermal magnetic breaker.
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)
canbe ordered from NorthStar at1-800-270-0810.
Reference 18 60A Circuit Breaker. One 60A
thermal magnetic breaker.
References 11 - Shield. Plastic implement
shield. NEVER operate generator without shield in
place.
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 specificationsoutlined 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 andassumesliability 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 clamp, 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
cordscan cause electric shock.
ALWAYS use a ground fault circuit interrupter
(GFCI) in damp or highly electrical conductive areas
andon construction job sitestopreventelectric shock.
ALWAYS remove PTO driveline before working
on thegenerator.
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
horizontallyand vertically.

5
NEVER operate thegenerator 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 shockmay result.
NEVER operate the generator under the following
conditions:
A. Excessive changein engine speed, slow or
fast.B. Overheating inload connecting devices.
C. Sparking orarcsfrom generator.
D. Lossof electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
H. Enclosed compartments, orconfined areas.
I. Flameor smoke.
J. Rain, snow or wet conditions.
K. Operator non-attendance.
L. Withoutproper guarding inplace.
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 fumesare
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
engineand generator.
INSTALLATION
Choose a location where the generator will not be
exposed to rain, snow or direct sunlight. Common
placesformounting your PTO generator are toa trailer
or a cement slab. However you choose to mount the
generator, make sure it canget asclose 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.
Design the application tominimize the angleof 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 totip over. The
constant vibration of the generator can cause metal
fatigueof the trailer base if the steel used is not thick
enough.
DANGER Trailermay tip over and cause
seriousinjuryor death. Never standnear an operating
PTOgenerator.
Use four, grade 5, 5/8” bolts to mount
generator.
After the generatoris firmly mounted , attach the
PTOdriveline to the generator then the tractor. Use a
synchronizedPTO driveline rated at48 HPminimum.
DANGER Never attach PTO driveline
whiletractorisrunning.
DANGER Always have proper guarding
of rotating parts. Failure to guard the power
transmission mechanisms may result in serious injury
or death.
While seatedon the tractor and the engine at idle,
engage thePTO. Slowlyincrease 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 stay clear of
the rotating PTO driveline. From the tractor seat re-
adjust the speed until the needle on the generator
voltmeterisclose to theblacklinein thegreenarea. 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 withpossible problems.
Before eachuse checkthe gear boxoil level. Use
80W-90SAE syntheticgearoil and fill to the middle of
the oil level sight plug.
LOAD APPLICATION
Itisimportanttodetermine the total electrical load
beforeitisconnected to thegenerator. Thetwomajor
factorsin determining the lifeof 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
00506

6
become excessively hot and cause the insulation to
break down, reducing its ability to resist corrosive
contaminants. Over time the effectiveness of the
insulationiseliminatedanda 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
multiplying nameplate voltage by nameplate
amperage.
VOLTS X AMPS = WATTS
Example: 120V X 5A = 600W
When connecting a resistive load such as
incandescentlights, heatersor common electric power
tools, a capacity of up to the generator full rated
wattage outputcanbe 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’sfull rated output canbe used.
Always allow the generator to reach operating
speed before a load isapplied.
STARTING ELECTRICMOTORS
Electric motors require much more current (amps)
to start than to run. Some motors, particularlylow cost
split-phasemotors, are very hard to start and require 5
to 7timesmore currentto start than to run. Capacitor
motors are easier to start and usually require 2 to 4
timesasmuch current to start than to run. Repulsion
Induction motors are the easiest to start and require
1.5to2.5timesasmuchto start thantorun.
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 variousconditions.
120V,60 HzMotors Starting Amps
Hp motor Running
Watts RI type Cap type SP type
1/6 525 7-11 9-18 16-22
1/4 700 9-15 12-23 22-32
1/3 875 11-18 14-29 26-35
1/2 1175 15-25 20-40 NA
11925 24-40 32-64 NA
1 1/2 2400 30-50 40-80 NA
22900 36-60 48-96 NA
3 4075 51-85 68-136 NA
56750 84-140 112-224 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
themotor.
Generators respond to severe overloading
differently thanthe power line. When overloaded, the
engineisnotable tosupply enough powerto 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
theengine. If allowed to operate at very low speeds,
the electric motor starter winding will burn out in a
short time. The generator head windingmightalso be
damaged.
Running thegenerator underthese conditionsmay
resultindamage 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
allowfor distance in length and amperage so that the
voltage dropbetween the set and point of use is held
to a minimum.
Current/Power Maximum Extension Cord Length
Amps
at
240V
Load
(watts) #10 Ga.
Cord
#12
Ga.
Cord
#14
Ga.
Cord
#16
Ga.
Cord
10 2400 250’ 150’ 100’ 75’
20 4800 125’ 75’ 50’ 25’
30 7200 60’ 35’ 25’ 10’
40 9600 30’ 15’ 10’ *
50 12000 15’ ***
*Not recommended
CAUTION: Equipment damage can resultfrom 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

7
Device Running Watts
Air Conditioner (12,000 Btu) 1700 (a)
Battery Charger (20 Amp) 500
Belt Sander (3”) 1000
Chain Saw 1200
Circular Saw (6-1/2”) 900
Coffee Maker 1000
Compressor (1 HP) 2000 (a)
Compressor (3/4 HP) 1800 (a)
Compressor (1/2 HP) 1400 (a)
CurlingIron 700
Dishwasher 1200
Edge Trimmer 500
Electric Nail Gun 1200
Electric Range (one element) 1500
ElectricSkillet 1250
Freezer 800(b)
Furnace Fan (1/3 HP) 1200 (a)
Hair Dryer 1200
Hand Drill (1”) 1100
Hand Drill (1/2”) 875
Hand Drill (3/8”) 500
Hand Drill (1/4”) 250
HedgeTrimmer 450
HomeComputer 150
Impact Wrench 500
Jet Pump 800 (a)
LawnMower 1200
LightBulb 100
MicrowaveOven 700
MilkCooler 1100 (a)
Oil Burneron Furnace 300
Oil FiredSpace Htr(140,000 Btu) 400
Oil Fired Space Htr (85,000 Btu) 225
Oil Fired Space Htr (30,000 Btu) 150
Oven 4500
Paint Sprayer, Airless (1/3 HP) 600 (a)
PaintSprayer, Airless(handheld) 150
Radio 200
Refrigerator 600(b)
Slow Cooker 200
Submersible Pump (1-1/2 HP) 2800 (a)
SubmersiblePump (1 HP) 2000 (a)
Submersible Pump (1/2 HP) 1500 (a)
Sump Pump 600 (a)
TableSaw (10”) 2000 (a)
Television 500
Toaster 1000
Vacuum cleaner 250
VCR 70
Water Heater 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 themaximum wattage.
PRE-START UP PREPARATIONS
Yourgenerator hasbeen thoroughly testedpriorto
shipment from the factory. However, damage can
occur during shipping, so be sure to check for
damagedparts,loose ormissing nutsandbolts. If the
these problemsoccur, call CustomerService at 1-800-
270-0810.
GROUNDING - All units must be grounded. Drive
a 3/4” or 1” copper pipeor rod intothe ground close to
the generator. The pipe/rod must penetrate moist
earth. Connect an approvedground 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
groundused bya 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 engineshave atendency to slow down when a
load isapplied. 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 whenthegeneratorisloaded to itsfull capacity
than when it is running with no load. The slight
variationhas no appreciable effect in the operation of
motors, lights and most appliances. Electronic
equipmentand clockswill be effected if correct RPM is
notmaintained. See Load vs. Output chart
Load Output
Percent of
Generator
Output
Speed
(RPM) Frequency (Hz) Generator voltage at 120V
Receptacle
0 % 3780 63.0 125V
50 % 3600 60.0 122V
100% 3480 58.0 118V
Output voltage should be checked periodically to
ensure continued proper operation of the generating
plantandappliances, it can be checked withaportable
meter. Frequency canbe checkedby usinganelectric
clock with a sweep second hand. Timed against a
wrist watch ora stop watch the clockshouldbe correct
within +/- 2 seconds per minute. All speed setting
adjustmentsshould bedoneby a qualified technician.

8
GENERATOR CARE
The generator head isa two pole, 3600 RPM, 60
Hz, brushless, revolving field and synchronous type
withtwo sealed radial bearings.
Proper care and maintenance are necessary to
ensure along 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. Thiswill dry out anymoisture that
hasaccumulated in the windings. If left, this moisture
can cause corrosion in the winding. Frequent
operation ofthe generatorwill also ensure that the set
is operating properly should it be needed in an
emergency.
Generator Maintenance - The generator head is
brushlessand maintenance free. Anymajor generator
service including the installation or replacement of
partsshould be performedonlyby aqualifiedelectrical
service technician. USE ONLY NorthStarAPPROVED
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 nomaintenance 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 destructiveto 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 Departmentsmust be
consulted concerning proper and safe handling
procedures for gasoline. NEVER connect any
generator toanyexisting electrical system without an
isolating, UL approved transfer switch, installed by a
licensedelectrician.

9
TROUBLESHOOTING
Problem Possible Causes Possible Remedies
Voltagetoolow. a) Engine speed too slow.
b) Generatorisoverloaded.
a) Increase tractor RPMs.
b) Reduce the load.(See Load
Application section ofthismanual.)
Circuit breaker trips. a) Defectiveload connected to generator.
b) Defectivereceptacle.
c) Generator overloaded.
d) Defective circuitbreaker.
a) Disconnectload.
b) Replacereceptacle.
c) Reduce theload.(SeeLoad
Application section ofthismanual.)
d) Contact Customer Servicefor the
nearest service center.
Voltage toohigh. a) Engine speed too high. a) Contact Customer Servicefor the
nearest service center.
Generatoroverheating. a) Generatorisoverloaded.
b) Insufficient ventilation.
a) Reduce the load.(See Load
Application section ofthismanual.)
b) Make sure there isatleast 3 feetof
clearance on all sides of generator.
No output voltage. a) Defectiveload connected to generator.
b) Broken orloose wire.
c) Defective receptacle.
d) Defectivestator.
e) Defective rotor.
f) Defective capacitor.
g) Defective circuit breaker.
h) Engine speed too slow.
I) PTOnot engaged.
j) Gearboxismalfunctioning.
a) Disconnectload.
b) Replacewire.
c) Replacereceptacle.
d) Contact Customer Servicefor the
nearest service center.
e) Contact Customer Servicefor the
nearest service center.
f) Contact Customer Service for the
nearest service center.
g) Contact Customer Servicefor the
nearest service center.
h) Increase tractor RPMs.
I) Engage PTO.
j) Contact Customer Service for the
nearest service center.
Excessive gear box
noise. a) Defective bearing.
b) Defective gear.
c) No orlowgear oil.
d) PTOdrivelineisoperating at an angleof
greater than 15°.
e) UnsynchronizedPTO driveline.
a) Contact Customer Servicefor the
nearest service center.
b) Contact Customer Servicefor the
nearest service center.
c) Fill gear box to oil level sight.
d) Reposition the tractor orgenerator so
theangleisreduced tolessthan15°both
verticallyand horizontally.
e) Disassemble PTOdriveline and
reassemblewith CVjointssynchronized.