Northern Tool M165951G.5 Owner’s Manual
M165951G.5
Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable Outdoor Use-Only, Power Take-Off (PTO) Generator
7,200 Watt Continuous (7,800 Watt Surge) Capacity
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).
WARNING
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:
CO Poisoning
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).
Electric shock / Electrocution
• 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.
Fire
• 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 manu al for
minimum safe clearance distance between hot tractor exhaust and nearby combustible materials and structures.
• ALWAYS keep a fire extinguisher rated “ABC” nearby.
Power Take-Off (PTO)
• 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.
•
STOP!
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.
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
ITEM NUMBER: 165951
SERIAL NUMBER: _____________
Hazard Signal Word Definitions
2
Table of Contents
3
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. Planning the Power Load ........................................................................................................ 13
3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ...................................... 13
4. Selecting a Suitable Site ......................................................................................................... 16
5. Mounting the Generator ......................................................................................................... 18
6. Grounding the Generator ........................................................................................................ 20
Operation:
1. General Safety Rules for Operation ....................................................................................... 21
2. Preparing for Operation .......................................................................................................... 22
3. Connecting to the Tractor ....................................................................................................... 24
4. Starting the Generator ............................................................................................................. 25
5. Connecting Loads ................................................................................................................... 26
6. Stopping .................................................................................................................................. 28
7. Storage & Exercise ................................................................................................................. 28
Maintenance & Repair .................................................................................................................. 29
Troubleshooting ............................................................................................................................. 31
Summary of Important Safety Information for Operation ....................................................... 32
PTO Generator Exploded View ................................................................................................... 35
Wiring Diagram ............................................................................................................................. 36
PTO Gearbox Exploded View ...................................................................................................... 37
Limited Warranty ......................................................................................................................... 39
California Proposition 65 Information ........................................................................................ 40
About Your Generator
4
Thank you for purchasing your NorthStar PTO generator!
About Your Generator
This PTO-driven, portable generator is designed to provide up to 7200 Watts of electrical
power (7200 watts continuous, 7800 watts Surge). Connected to your tractor’s power take-off
(PTO)*, the generator can supply power:
1. As a portable power source. You can plug appliances directly into the generator’s
electrical outlets.
2. As a back-up, standby power source for a building. A licensed electrician can connect
the generator to your building’s electrical system via the installation of an UL-approved
transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn
more about specific requirements and precautions relating to wiring the generator to your
building’s electrical system.)
* Your tractor’s PTO must produce a minimum of 14 HP at 540 RPM.
You must select a generator adequately sized for your power needs. You need to
determine the power needs of all the appliances/tools you wish to power at the same time and
choose a generator rated to provide at least that power level. See the “Power Load Planning &
Management” section of this manual to determine your specific power load requirements and
then compare them to this generator’s rated capacity. You must not overload the generator.
Overloading will cause damage to the generator and attached electrical devices, and may also
result in fire.
This generator must be mounted on a reinforced concrete slab or a PTO generator
trailer, so that the generator will not flip during use due to the rotational force of the PTO.
The slab or trailer must be of adequate size and strength to withstand operating torque without
flipping or structural failure. 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.
Be sure to read about site selection and grounding requirements for running this
generator. More detailed information can be found in the “Installation & Initial Set-up, Steps
5 & 6” of this manual.
Optional accessories available from NorthStar include PTO drivelines, UL-approved transfer
switches and extension cords. Contact NorthStar Product Support at 1-800-270-0810 with
questions about optional accessories or to order.
Read this Manual
WARNING
Improper use or maintenance of this generator can result in serious injury or death from
carbon monoxide poisoning, electric shock/electrocution, entanglement, flying objects,
fire, or burns. In addition, PTO shaft and generator can become airborne and cause
severe injury if improperly secured.
Read this manual completely before using the generator and follow all instructions and
safety rules.
About Your Generator (cont’d)
5
You must follow all instructions and safety precautions presented throughout this manual. A
summary of important safety information can be found at the end of the manual. Keep this
manual for reference and review.
Proper preparation, operation, and maintenance will result in operator safety as well as best
performance and long life of the generator. Failure to follow the instructions in this manual
for proper mounting, set-up, operation, and maintenance of the generator will void the
manufacturer’s warranty.
Before using, the user shall determine the suitability of this product for its intended use and
assumes liability therein. The purchaser and/or user shall assume liability for any modification
and/or alterations of this equipment from original design and manufacture, or for any nonstandard application, or for use as a subcomponent in another piece of equipment.
NorthStar is constantly improving its products. The specifications outlined herein are subject
to change without prior notice or obligation.
Contact NorthStar Product Support at 1-800-270-0810 for any questions about the
appropriate use of this generator.
Warranty Registration
Please fill out and submit the warranty registration card so that we have your contact
information for any future product literature or replacement parts you may need.
ATTENTION:
All Rental Companies and Private Owners who loan this
equipment to others!
All persons to whom you rent/loan this generator must have access to and read this manual.
Keep this owner’s manual with the generator at all times and advise all persons who will
operate the machine to read it. You must also provide personal instruction on how to safely
operate the generator and remain available to answer any questions a renter/borrower might
have.
Specifications – Item #165951
6
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
1.0
Minimum PTO HP
14 HP at 540 RPM
Minimum Operating Torque
101.7 pound-foot
Input Shaft
1-3/8” Diameter, 6 spline
120V Receptacle
(2) 20 Amp (A) (NEMA 5-20R)
120/240V Receptacle
(1) 30 Amp (A) locking device (NEMA L14-30R)
Circuit Breaker
(2) 20 Amp (A) thermal, push to reset style
(1) 30 Amp (A) thermal magnetic
Gear Box
Gear Ratio
1:7
Gear Oil
SAE 90W
Oil Capacity
0.75 Qt. (.82 L)
Dimensions
Length
25.25”
Width
12.50”
Height
17.25”
Gross Weight
110 lbs.
Safety Label Locations – Item #165951
7
DANGER!
Driveline guard, plus tractor and generator shields must be in place. Driveline
guard must turn freely and independently on driveline.
Accidental contact with rotating driveline will cause hair or clothing near
rotating shaft to become rapidly entangled.
Driveline must be securely locked at both ends.
An unlocked PTO shaft can whip or become dangerously airborne.
Generator must be properly mounted in accordance with instructions.
Improper mounting may cause generator to flip dangerously during use.
Contact with rotating driveline can cause death!
Rotating Driveline/PTO Hazard
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
Part numbers
Description
779781
General Warning
779770
PTO Warning
779407
Danger Carbon Monoxide
NEVER use inside a home
or garage. EVEN IF doors
and windows are open.
Generator exhaust contains carbon monoxide. This is
a poison you cannot see or smell.
Using a generator indoors CAN KILL YOU IN MINUTES.
DANGER
Only use OUTSIDE and
far away from windows,
doors, and vents.
DO NOT overload generator.
OPE RATE ONLY with adequate cooling
ventilation. Keep all objects at least
7 feet from generator vent openings.
Keep tractor exhause away from all
combustible objects.
ALWAYS keep a fire extinguisher
nearby.
A Fire Hazard can arise from:
Overloading the generator
Lack of cooling ventilation
Contact with hot tractor exhaust
WARNING
NEVER connect generator directly
into a wall outlet.
ANY connection to a building's
electrical system MUST ISOLATE
GENERATOR FROM UTILITY
POWER via a transfer switch.
Be sure generator is properly
grounded.
Use only outdoor-rated, grounded
GFCI extension cords of proper
size.
DO NOT operate in wet locations.
Electric Shock/Electrocution Hazard
High voltage from generator can kill.
Read Owner's Manual completely before using. Serious injury or death can result if safety directions are not followed.
ONLY run tractor & generator
OUTDOORS and AWAY from building
air intakes.
Never run inside homes, garages, or
sheds, EVEN if you run a fan or open
windows.
Install carbon monoxide alarms inside
nearby structures/buildings.
DANGER
Poisonous Gas Hazard
Tractor engines give off carbon
monoxide, an odorless gas that
can kill you
in minutes.
Machine Component Identification - Item #165951G.4
8
Figure 1 (Ref 1-12)
Ref.
Description
Ref.
Description
1
Alternator
9
Filler/Breather Plug
2
Grounding Screw
10
Implement Shield
3
Isomounts
11
Fan Vents
4
30A Circuit Breaker
12
Mounting Holes
5
120V Receptacle
13
Voltmeter
6
20A Circuit Breaker
14
1-3/8” Diameter 6 Spline Input Shaft
7
120/240V Locking Receptacle
15
Oil Fill Sight Glass
8
Gearbox
16
Oil Drain Plug
Figure 2 (Ref 13-16)
Machine Component Identification – Item #165951G.4 (cont’d)
9
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 – Isomounts
Reduces vibrations transmitted to the control
box.
Reference 4 – 30A Circuit Breaker
Thermal magnetic breaker protects against
over currents and short circuits.
Reference 5 – 120V Receptacles
One 120V 20A straight blade receptacle
duplex (two receptacles in a common
housing). National Electrical Manufacturer’s
Association (NEMA) number 5-20R.
Reference 6 – 20A Circuit Breaker
(Qty 2) Push to reset style thermal breakers
protect against over currents.
Reference 7 – 120/240V Locking
Receptacle
30A receptacle, NEMA L14-30R.
Reference 8 – Gearbox
1:7 gear ratio.
Reference 9 – Filler/Breather Plug
Fill oil here; use SAE 90W gear oil.
Reference 10 – Implement Shield
Never operate generator without shield in
place.
Reference 11 – 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 12 – Mounting Holes
Use these locations to mount the generator in
place with 5/8” grade 5 bolts.
Reference 13 – Voltmeter
Needle should be in green area during all
generator load conditions. The black line in
the center of the green area indicates 120V.
During no load conditions, the needle should
be at or above the black line.
Reference 14 – 1-3/8” Diameter 6
Spline Input Shaft
Requires 14 HP or greater at 540 RPM.
Reference 15 – Oil Fill Sight Glass
When oil is even with the red dot, the oil level
is correct. Check oil level daily.
Reference 16 – Oil Drain Plug
Remove to drain oil from gearbox.
Power Load Planning & Management
10
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. Before using your generator, determine the running
and starting wattage requirements of all the electrical devices you will be powering simultaneously.
The sum of the running and starting wattages of the devices being powered must not exceed the
continuous output rating of your generator. (The continuous output rating of your generator is listed
in the “Specifications” section of this manual.) Note that:
• Devices without electric motors such as light bulbs, radios, and televisions have the same
running and starting wattage.
• Devices with electric motors such as refrigerators, compressors, and hand tools typically
require a starting wattage that is 3 to 5 times greater than the running wattage.
The running and starting wattage requirements are often listed on a device’s nameplate. If wattage
is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate
voltage by nameplate amperage, Watts = Volts X Amps.
Example conversion to watts:
120 Volts X 5 Amps = 600 Watts
If only the running voltage is given on the nameplate for a device with an electric motor, the starting
wattage can be approximated to be three to five times the running wattage.
Estimates for the running wattage requirements for common devices are listed in Table 4 below.
Guidance for starting wattages is provided in the table’s footnotes.
Table 4
Device
Running
Watts
Device
Running
Watts
Air conditioner (12.000 BTU)
1700 (a,b)
Jet pump
800 (a)
Battery charger (20 Amp)
500
Lawn mower
1200
Belt sander (3”)
1000
Light bulb (100 Watt)
100
Chain saw
1200
Microwave oven
700
Circular saw (6½”)
2000 (a,b)
Milk cooler
1100 (a)
Coffee maker
1800 (a,b)
Oil burner on furnace
300
Compressor (1 HP)
1400 (a,b)
Oil-fired space heater (140,000 Btu)
400
Compressor (3/4 HP)
1800 (a)
Oil-fired space heater (85,000 Btu)
225
Compressor (1/2 HP)
1400 (a)
Oil-fired space heater (30,000 Btu)
150
Curling iron
700
Oven
4500
Dishwasher
1200
Paint sprayer, Airless (1/3 HP)
600 (a)
Edge trimmer
500
Paint sprayer, Airless (handheld)
150
Electric nail gun
1200
Radio
200
Electric range (1 element)
1500
Refrigerator
600 (b)
Electric skillet
1250
Slow cooker
200
Power Load Planning & Management (cont’d)
11
Device
Running
Watts
Device
Running
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
Sump pump
600 (a)
Hand drill (1/2”)
875
Table saw
2000 (a)
Hand drill (3/8”)
500
Television
500
Hand drill (1/4”)
250
Toaster
1000
Hedge trimmer
450
Vacuum cleaner
250
Home computer
150
VCR
70
Impact wrench
500
Water Heater
3000
Weed trimmer
500
(a) Hard-starting motors require 3-5 times the rated running watts
(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to
determine maximum wattage
To calculate the running and starting wattage requirements for the devices you will be
powering, follow these steps:
1. Make a list of all electrical devices you will be powering at the same time with the generator.
2. List the greater of the running or starting wattage next to each device as obtained from the
devices’ nameplate or Table 4. If only the running wattage for a device with an electric
motor is known, the starting wattage can be estimated to be at least 3 times the running
wattage.
3. Add the wattages for all devices on your list. This total must be lower than the continuous
output rating of your generator.
Example:
Device to be Powered
Greater of
Starting/Running Wattage
Light Bulb
75 W
Refrigerator – 18 Cu. Ft.
1600 W
Microwave
700 W
Window AC
1800 W
Sump pump (1/3 hp)
2100 W
Total
6275W
In this example, the generator must have a continuous output of at least 6275 W in order to
power all of the devices simultaneously.
You can increase the number of devices your generator can power by staggering the load on the
generator. For example, you could alternately power your refrigerator and air conditioner for
limited periods of time -- powering only one of the devices at a time and never powering both at the
same time.
STAGGERING LOADS
Installation / Initial Set-Up
12
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.
3. Setting up generator for the type of power generation you need:
a. portable power source, or
b. connected to a building as a back-up power source.
4. Selecting a site for using the generator.
5. Mounting the generator.
6. Grounding the generator.
Each of these steps is discussed in detail below:
1. Unpacking & Delivery Inspection
1. You should inspect the generator immediately after you receive delivery.
See the “Machine Component Identification” section of this manual for a
diagram of the generator and its components.
• If you have missing or damaged components, contact Product Support at 1-800-270-0810.
2. The gearbox is shipped with oil and a
temporary shipping plug.
a. Remove the temporary
shipping plug and replace
with the metal breather/oil fill
plug that is in the manual
bag.
b. Make sure that the gear oil
level is in the middle of the
sight glass, at the red dot.
Add SAE 90W gear oil as
required.
Filler/Breather plug
Shipping plug
Sight glass
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