North Star M165951C User's Manual
Contents
1. NOR THE M165951C Proven Performance m OWNER S MANUAL 7800 PTOG 7800 Watt Power Take Off Generator Serial Number e A WARNING n gt Read this manual Serious injury or death can result if safety instructions are not followed Fire hazard Do not operate in an enclosure or building Fire or explosion will result Never place this product near combustible materials SS aaa A DANGER POISONOUS GAS The tractor used to power this product gives off carbon monoxide a ss poisonous gas that can kill you d ONLY use outdoors and away from air intakes NEVER use inside homes garages or sheds EVEN IF you run a fan or open doors and windows See product manual for more details Any Questions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 Hazard Signal Word Definitions This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER red indicates an imminently A DAN G E R hazardous situation which if not avoided will result in death or serious injury WARNING orange indicates a potentially AWARN N G hazardous situation which if not avoided could result in death or serious injury CAUTION yellow indicates a potentially A CAU TIO N hazardous situa2. 2 Push to reset style thermal breakers protect against overcurrents 120 240V Locking Receptacle 30A receptacle NEMA L14 30R Gearbox 1 7 gear ratio Filler Breather Plug Fill oil here use SAE 80W 90 gear oil Implement shield Never operate generator without shield in place 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 12 Mounting Holes Use these locations to mount the generator in place with 5 8 grade 5 bolts 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 14 1 3 8 Diameter 6 Spline Input Shaft Requires 14 HP or greater at 540 RPM 15 Oil Fill Sight Glass When oil is even with the red dot the oil level is correct Check oil level daily 16 Oil Drain Plug Remove to drain oil from gearbox A 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 Make sure it is 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 abr
3. L14 30R 2 20 Amp A thermal push to reset style 1 30 Amp A thermal magnetic 1E SAE 80W 90 0 75 Qt 82 L ZOO 12 50 17 25 110 Ibs ACCESSORIES PTO Driveline 165936 The manufacturer 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 ltem 165951 7800 PTOG Generator Parts Explosion Revision C 14 FIGO2034 Item Part Description Qty Item Part Description Qty 1 39138 Control box top 1 28 780143 Rotor securing stud 1 2 38541 NorthStar decal 1 29 307479 Diode 2 3 31727 _ Voltmeter 1 30 307481 Varistor 2 4 779781 Warning decal 1 31 780229 Rotor A 5 82070 1 4 20 x 5 Serrated flange bolt 8 32 780142 Stator 1 6 82005 8 32 Keps nut 8 33 38270 _ Enclosing band 1 7 306422 120 240V 30A receptacle 1 34 38269 Drive end bracket 1 8 39137 Control box 1 35 779557 _ Fan 1 9 82004 8 32 Button head cap screw 8 36 82102 3 8 16 x 75 Serrated flange bolt 4 10 39074 Control panel decal 1 37 779556 Fan bolt 2 11 305587 Isolation mount 4 38 780228 _ Mount plate 1 12 82158 _ M5 8 x 14mm Pan Phillips screw 2 39 38890 Gearbox 1 13 82243 M5 8 Hex nut 2 40 82014 5 16 18 x 5 Serrated flange bolt 4 14 82161 _ Grounding screw 1 41 39136 _ Control
4. box mount plate 1 15 38280 Bracket securing stud 4 42 82069 10 Split lock washer 4 17 38271 _ End cover plug 1 43 82244 10 32 x 5 Pan Phillips screw type F 2 18 777304 __ End cover 1 44 306459 Ground wire 1 19 779562 Capacitor 1 45 31763 120V 20A Duplex receptacle 1 20 82091 5 16 18 x 1 Hex head cap screw 1 46 30643 Circuit breaker 125V 20A 2 21 39140 Base 1 47 777130 Circuit breaker mounting clip 4 22 82019 5 16 18 Serrated flange nut 5 48 31005 Thermal breaker 125 250V 30A 1 23 82049 _ M10 Rib washer 16 49 39053 Implement shield 1 24 82241 M10 1 5 x 20mm screw 8 50 779770 PTO Warning decal 1 25 38278 _ Non drive end bracket 1 51 82201 M10 Flat washer 4 27 38276 _ Bearing 1 52 82137 _ M10 1 5 x 16mm Hex head cap screw 4 Item 38890 Gearbox Parts Explosion Revision C Note Gearbox exploded view is shown upside down when compared to its orientation on the generator 39287 Nut M8 co sy cS Item Part Description Qt Item Part Description Qty 1 39275 Housin 14 39288 Pin 8x20mm 2 39276 Shaft 15 39289 Cap 3 39277 Gear 16 39290 Breather plug 3 8 4 39278 Flange 17 31762 Oil plug 3 8 5 39279 Shaft 18 39292 Drain plug 3 8 6 39280 _ Housing 19 39293 Cap 7 31766 Circli 20 39294 Cap 8 39282 Oil seal 25x52x10mm 21 39295 _ Sight glass 9 39283 Oil seal 35x52x10mm 22 3
5. effect in the operation of motors lights and most appliances Electronic equipment and clocks will be affected if correct RPM is not maintained See Load vs Output chart Output voltage should be checked periodically to ensure continued proper operation of the generator Load Output and appliances It can be checked with a portable Rd he B Vac are ae meter Frequency can be checked by using an electric Output Receptacle clock with a sweep second hand Timed against a 0 3780 63 0 125V wristwatch or a stopwatch the clock should be correct 50 3600 60 0 122V within 2 seconds per minute All speed setting 100 3480 58 0 118V adjustments should be done by a qualified technician A Operation Instructions 4 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 120V 60 Hz Motors Starting Amps current to start than to run Capacitor motors HP Motor Running Ri Type Cap Type SP Type are easier to start and usually require 2 to 4 Watts times as much current to start than to run 1 6 525 7 11 9 18 16 22 Repulsion Induction motors are the easiest to 4 700 9 15 12 23 22 32 start and require 1 5 to 2 5 times as much to 1 3 875 11 18 14 29 26 35 start than to run Va 1175 15 25 20 40 NA Most fractional mo
6. 9296 Screw M8 x 20mm 10 39284 Key 10x8x25mm 23 39297 Screw M8 x 40mm 11 39285 _ Bearing 24 39298 Screw M8 x 110mm 12 31760 Bearing 25 39299 Sleeve Any Questions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 15 POPPI OD PO PO A A A A Po
7. ance and Storage The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with two sealed ball bearings Proper care and maintenance are required to ensure a long trouble free life Generator Maintenance The generator head is brushless and maintenance free Any major generator service including the installation or replacement of parts should be performed by a qualified electrical service technician USE ONLY NorthStar APPROVED REPAIR PARTS AVAILABLE AT 1 800 270 0810 1 Bearing The bearings used in this generator are a heavy duty sealed ball bearing type They require no maintenance or lubrication 2 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 Exercising the Generator The generator should be operated every four weeks This is accomplished by running the generator 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 ensure that the generator is operating properly should it be needed in an emergency Storage Keep the generator covered and away from any moisture Troubleshooting Problem olta SOLUTION ABO OLUTION A B SOLUTION F Excessive gearbox
8. asive 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 shorting out of the generating system 1 Mounting the PTO generator to a trailer Use four 4 5 8 grade 5 bolts to secure the PTO generator to the trailer Important 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 A PTO trailer is available from Northern ltem 165959 Call 1 800 556 7885 to order WARNING DANGER PTO trailer or generator may tip over and cause serious injury or death Never stand near an operating PTO generator Always bolt PTO base to a secure foundation or mounting slab A 2 Mounting the PTO generator to concrete Use four 4 5 8 grade 5 anchor bolts when mounting the generator on a cement slab 3 Connecting the PTO generator to a tractor After the generator is firmly mounted attach the PTO driveline to the generator then the tractor Use a synchronized PTO driveline rated at 14 HP minimum A PTO driveline is available from Northern Item 165936 Call 1 800 556 7885 to order Important The angle o
9. cessively 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 Apply the load 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 overloaded or there is a problem Use the troubleshooting guide at the end of the manual for assistance with possible problems 3 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
10. erator 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 5 Extension Cords When electric power is to be provided to i i Current Power Maximum Extension Cord Length various loads at some distance from the Ange Eoad WOGa 44S Ga Aa HG Ga generator extension cords can be used at Watts Cord Cord Cord Cord These cords should be sized to allow for 240V distance in length and amperage so that the 10 2400 250 150 100 75 voltage drop between the generator and point 20 4800 125 75 50 25 of use is held to a minimum 30 7200 60 35 25 10 40 9600 30 15 10 ii CAUTION Equipment damage can result from 50 12000 15 x x the low voltage caused by using an extension cord with a small wire size Nlinat Rarnmmandad A WARNING Keep a fire extinguisher close by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type 10 A Operation Instructions Use to Approximate Generator Load Requirements Device Running Watts Device Running Watts Air Conditioner 12 000 Btu 1700 a Lawn Mower 1200 Ba
11. f the driveline shall not exceed 15 in either the horizontal or vertical plane WARNING Always properly guard rotating parts Failure to guard the power transmission mechanisms may result in serious injury or death Top View Driveline 02021 Side View 4 Grounding This unit must be grounded Drive a 3 4 or 1 copper pipe or rod into the ground near the generator It must penetrate moist earth Connect an approved ground clamp to the pipe Run an 8 gauge copper wire from the clamp to the generator ground screw Do not connect to a water pipe or a ground used by a radio system WARNING Always ground the generator Electrical shock can kill 5 Standby Use 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 WARNING Never connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician 8 A Operation Instructions 1 Engaging the PTO 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 2 Applying a Load It is important to determine the total electrica
12. his generator is equipped with a grounding screw located on the generator frame Always complete the grounding path from the generator to a copper pipe rod that is driven into moist earth to prevent electric shock 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 Electric shock could result Always use electrical cords in good condition Worn bare frayed or 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 E 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 8 Always wear ear protection while operating generator 9 Never operate the generator under the following conditions A Overheating in load connecting devices Sparking or arcs from generator Loss of electrical output Damaged receptacles Loose broken or missing parts Excessive vibration Enclosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance or without proper guarding in place MAINTENANCE AND STORAGE AWARNING Refer to the Maintenance and Storage section of this manual for proper procedures Always remove PTO driveline bef
13. l load before it is connected to the generator 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 X5A 600W Also a chart of estimated load requirements for some appliances and tools is shown on page 11 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 Important 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 become ex
14. ning may occur engine ALWAYS clean up fuel spills and NEVER operate generator move generator away from the without proper guarding spill before starting engine Call 1 800 270 0810 to order new labels Warning General Rules Part No 777131 Danger Rotating Driveline Part No 31696 Warning Electric Shock Part No 305545 Unpacking Closely inspect all contents in the shipping carton If you have damaged components Contact the freight company that delivered the unit and file a claim If you have missing components Contact Product Support at 1 800 270 0810 Assembly The gearbox is shipped with oil Remove the shipping plug and install the filler oreather plug Make sure that the gear oil level is in the middle of the sight glass add SAE 80W 90 gear oil as required Filler Breather plug Shipping plug Sight glass Machine Component Identification Alternator Also called generator head Grounding Screw Use to ground the generator to a copper pipe or rod that is driven into moist soil lsomounts Reduces vibrations transmitted to the control box 30A Circuit Breaker Thermal magnetic breaker protects against overcurrents and short circuits 120V Receptacles One 120V 20A straight blade receptacle duplex two receptacles in a common housing National Electrical Manufacturer s Association NEMA number 5 20R 20A Circuit Breaker Qty
15. noise Cause A Tractor throttle set too low Increase tractor RPMs Reduce the load See load application section of this manual C Defective load connected to generator for the nearest service center Contact Product Support for the nearest service center F Make sure that there is at least 3 feet of clearance on all sides of the generator Support for the nearest service center center center K gt center center O Defective gear Contact Product Support for the nearest service center Fill gear box to middle of oil level sight glass Q PTO driveline is operating at an angle of Reposition the tractor or generator so the angle greater than 15 is reduced to less than 15 both vertically and horizontally R Unsynchronized PTO driveline Disassemble PTO driveline and reassemble with CV joints synchronized Defective capacitor Contact Product Support for the nearest service center Specifications and Accessories SPECIFICATIONS Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Minimum PTO HP Input Shaft 120V Receptacle 120 240V Receptacle Circuit Breaker Gear Box Gear Ratio Gear Oil Oil Capacity Dimensions Length Width Height Gross Weight 165951 7800 Watts W 7200 Watts W 120 240 Volt V Single phase 4 wire 60 0 Hertz Hz 100 p f 1 0 14 HP at 540 RPM 1 3 8 Diameter 6 spline 2 20 Amp A NEMA 5 20R 1 30 Amp A locking device NEMA
16. ore working on the generator Clear debris from moving parts when the tractor is shut off This will ensure the generator is in safe working condition Check that all nuts and bolts are tight to assure the generator is in safe working condition Make sure all guards and shields are replaced after maintenance is complete If apart needs replacement only use parts that meet the manufacturer s specifications Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator Never modify the generator in any way modifications may create a safety hazard and result in serious injury 4 NOANA STTrgon moan oO W OahWNM N Warning Label Locations ROTATING DRIVELINE CONTACT CAN CAUSE DEATH NEVER OPERATE WITHOUT All driveline guards tractor and generator shields in place Drivelines securely attached at both ends e Driveline guards that turn freely on driveline A WARNING ELECTRICAL SHOCK CAN KILL 309949 ALWAYS ground generator NEVER connect generator to another electrical system without an isolation transfer switch installed by a licensed electrician A WARNING NEVER operate generator in an NEVER operate generator with enclosed area Exhaust gases loose broken or missing parts contain carbon monoxide an NEVER operate generator under odorless and deadly poison wet conditions electric shock NEVER refuel a hot or run
17. s Operator s Manual 5 Never operate in an enclosure or building Fire or explosion will result 6 Keep a fire extinguisher close by your generator and be familiar with how to use it Consult your local fire department for correct extinguisher type 7 Always keep the generator and the area around the generator clean 8 Never mount to a trailer that is not wide enough to handle operating torque Trailer may tip and cause injury or death 9 Never connect generator to another electrical system without a licensed electrician installed isolation transfer switch OPERATION AWARNING 1 Before starting this generator review the Operation Instructions section of this manual Failure to follow these rules may result in serious injury to the operator or bystanders 2 Always provide adequate ventilation Do not operate generator in any enclosed or narrow space Tractors consume oxygen and give off deadly carbon monoxide a poisonous gas that can kill you Never operate the generator without proper guarding including driveline guards and tractor and generator shields Always securely attach the driveline at both ends and keep the driveline guard from rotating freely on the driveline Never operate the generator when the PTO driveline is at an angle greater than 15 either horizontally or vertically Never operate the generator while wearing loose fitting clothing such as neckties scarves or untucked shirts ELECTRIC SHOCK HAZARD A T
18. tion which if not avoided may result in minor or moderate injury CAUTION yellow used without the safety CAUTIO N alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage fig01453 Table of Contents A Important Safety Rules cccecseeeeeeseee eens 4 A Warning Label Locations ccccccceseee eens 25 UD CIA ates saeco ce eects R A 6 PASS CMD IY sucece rie eat ate 6 Machine Component Identification 07 A stal ATOM eienen o e 8 Operation INStrUctionS ccccceeesseeeeeeesee eens 9 11 Maintenance and Storage scseeccccceeeeeeeeeeeee Td TOUDIESIOOUING eieae Sted core E edad 12 Specifications and ACCESSOTLIES ccccccssseee eens 13 PAMSEXDIOSION sacraire ens ae acetates aes 14 15 A Important Safety Rules TRAINING AND INSTALLATION AWARNING 1 Read the Operator s Manual completely before attempting to use the generator Serious injury or death can result if safety instructions are not followed 2 Do not allow anyone to operate the generator who has not read the Operator s Manual or has not been instructed on the safe use of the generator 3 Never allow anyone under 16 years old or untrained adults operate the generator Children 16 years and older must be trained and supervised by a trained adult 4 Read and follow all safety rules in the tractor
19. tors take about the same 1 1925 24 40 32 64 NA amount of current to run whether they are of 1 2400 30 50 40 80 NA Repulsion Induction RI Capacitor Cap or 2 1900 36 60 48 96 NA Split Phase SP type The chart shows the 3 4075 91 85 68 136 NA approximate current required to start and run 5 6750 84 140 112 124 NA various types and sizes of 120 volt 60 cycle electric motors under various conditions 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 power lines 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 gen
20. ttery Charger 20 Amp 500 Light Bulb 100 Belt Sander 3 1000 Microwave Oven 700 Chain Saw 1200 Milk Cooler 1100 a Circular Saw 6 1 2 900 Oil Burner on Furnace 300 Coffee Maker 1000 Oil Fired Space Htr 140 000 Btu 400 Compressor 1 HP 2000 a Oil Fired Space Htr 85 000 Btu 225 Compressor 3 4 HP 1800 a Oil Fired Space Htr 30 000 Btu 150 Compressor 1 2 HP 1400 a Oven 4500 Curling Iron 700 Paint Sprayer Airless 1 3 HP 600 a Dishwasher 1200 Paint Sprayer Airless handheld 150 Edge Trimmer 500 Radio 200 Electric Nail Gun 1200 Refrigerator 600 b Electric Range one element 1500 Slow Cooker 200 Electric Skillet 1250 Submersible Pump 1 1 2 HP 2800 a Freezer 800 b Submersible Pump 1 HP 2000 a Furnace Fan 1 3 HP 1200 a Submersible Pump 1 2 HP 1500 a Hair Dryer 1200 Sump Pump 600 a Hand Drill 1 1100 Table Saw 10 2000 a Hand Drill 1 2 875 Television 500 Hand Drill 3 8 500 Toaster 1000 Hand Drill 1 4 250 Vacuum cleaner 250 Hedge Trimmer 450 VCR 70 Home Computer 150 Water Heater 3000 Impact Wrench 500 Weed Trimmer 500 Jet Pump 800 a 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 Mainten
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