TM

M165951C

Item Number: 165951

Serial Number:

OWNER’S MANUAL

7800 PTOG: 7800 Watt Power Take-Off Generator

WARNING

Read this manual.

Serious injury or death can result if safety instructions are not followed.

DANGER

DANGER

Any Questions, Comments, Problems or Parts Orders

Call NorthStar Product Support 1-800-270-0810

1

Hazard Signal Word Definitions

2

Table of Contents

Important Safety Rules ..............................……. 4

Warning Label Locations .............................…… 5

Unpacking ......................................................……. 6

Assembly ....................................................………. 6

Machine Component Identification...........…………. 7

Installation ................................................……... 8

Operation Instructions...................................…... 9-11

Maintenance and Storage.......................………….. 11

Troubleshooting ............................................…….. 12

Specifications and Accessories........................…… 13

Parts Explosion ..............................................……. 14-15

3

Important Safety Rules

TRAINING AND INSTALLATION

WARNING:

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’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

WARNING:

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.

3. Never operate the generator without proper guarding, including driveline guards and tractor and generator shields.

4. Always securely attach the driveline at both ends and keep the driveline guard from rotating freely on the driveline.

5. Never operate the generator when the PTO driveline is at an angle greater than 15

° either horizontally or vertically.

6. Never operate the generator while wearing loose fitting clothing such as neckties, scarves, or untucked shirts.

7. ELECTRIC SHOCK HAZARD:

A. This 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.

B. 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.

C. Always use electrical cords in good condition. Worn, bare, frayed or damaged cords can cause electric shock.

D. 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.

B. Sparking or arcs from generator.

C. Loss of electrical output.

D. Damaged receptacles.

E. Loose, broken, or missing parts.

F. Excessive vibration.

G. Enclosed compartments, or confined areas.

H. Flame or smoke.

I. Rain, snow, or wet conditions.

J. Operator non-attendance or without proper guarding in place.

MAINTENANCE AND STORAGE

WARNING:

1. Refer to the “Maintenance and Storage” section of this manual for proper procedures.

2. Always remove PTO driveline before working on the generator.

3. Clear debris from moving parts when the tractor is shut off. This will ensure the generator is in safe working condition.

4. Check that all nuts and bolts are tight to assure the generator is in safe working condition.

5. Make sure all guards and shields are replaced after maintenance is complete.

6. If a part 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.

7. Never modify the generator in any way, modifications may create a safety hazard and result in serious injury.

4

Warning Label Locations

DANGER!

ROTATING DRIVELINE−CONTACT CAN CAUSE DEATH.

NEVER OPERATE WITHOUT:

WARNING!

ELECTRICAL SHOCK CAN KILL.

ALWAYS ground generator.

305545

NEVER connect generator to another electrical system without an isolation transfer switch installed by a licensed electrician.

WARNING!

NEVER operate generator in an

enclosed area. (Exhaust gases

contain carbon monoxide, an

odorless and deadly poison.)

NEVER refuel a hot or running

engine.

NEVER operate generator

without proper guarding.

NEVER operate generator with

loose, broken or missing parts.

NEVER operate generator under

wet conditions, electric shock

may occur.

ALWAYS clean up fuel spills and

move generator away from the

spill before starting engine.

Call 1-800-270-0810 to order new labels.

Warning: General Rules Part No. 777131

Danger: Rotating Driveline

Warning: Electric Shock

Part No. 31696

Part No. 305545

5

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/breather 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

6

Machine Component Identification

1. Alternator. Also called generator head.

2. Grounding Screw. Use to ground the generator to a copper pipe or rod that is driven into moist soil.

3. Isomounts. Reduces vibrations transmitted to the control box

4. 30A Circuit Breaker. Thermal magnetic breaker protects against overcurrents and short circuits.

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.

6. 20A Circuit Breaker. (Qty 2) Push to reset style thermal breakers protect against overcurrents.

7. 120/240V Locking Receptacle. 30A receptacle, NEMA L14-30R.

8. Gearbox. 1:7 gear ratio.

9. Filler/Breather Plug. Fill oil here; use SAE 80W-90 gear oil.

10. Implement shield. Never operate generator without shield in place.

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.

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.

7

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 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 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,

Item# 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

Mounting holes (4)

PTO base to a secure foundation or mounting slab .

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 of the driveline shall not exceed

15 o

in either the horizontal or vertical plane.

Driveline

Top View

Max. 15°

Max. 15°

WARNING Always properly guard rotating parts.

Failure to guard the power transmission mechanisms may result in serious injury or death.

4. Grounding

Side View

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

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 electrical 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 X 5A = 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 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.

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 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 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 wristwatch or a stopwatch the clock should be correct within +/- 2 seconds per minute. All speed setting adjustments should be done by a qualified technician.

Load Output

Percent of

Generator

Speed

(RPM)

Frequency

(Hz)

Generator

Voltage at 120V

Output Receptacle

0% 3780 63.0 125V

50% 3600 60.0

100% 3480 58.0

122V

118V

9

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 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 whether they are of

Repulsion-Induction (RI), Capacitor (Cap), or

Split-Phase (SP) type. The chart shows the approximate current required to start and run various types and sizes of 120 volt 60 cycle electric motors under various conditions.

120V, 60 Hz Motors

HP Motor Running

Watts

Starting Amps

RI Type Cap Type SP Type

1/3 875 11-18 14-29 26-35

1 ½ 2400 30-50 40-80 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 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 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.

5. 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 generator and point of use is held to a minimum.

CAUTION: Equipment damage can result from the low voltage caused by using an extension cord with a small wire size.

Current/Power

Amps at

Load

(Watts)

Maximum Extension Cord Length

#10 Ga

Cord

#12 Ga

Cord

#14 Ga

Cord

#16 Ga

Cord

240V

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

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

Operation Instructions

Use to Approximate Generator Load Requirements

Air Conditioner (12,000 Btu)

Battery Charger (20 Amp)

Belt Sander (3”)

Chain Saw

Circular Saw (6-1/2”)

Coffee Maker

Compressor (1 HP)

Compressor (3/4 HP)

Compressor (1/2 HP)

Curling Iron

1700 (a)

500

1000

1200

900

1000

2000 (a)

1800 (a)

1400 (a)

700

Lawn Mower

Light Bulb

Microwave Oven

Milk Cooler

Oil Burner on Furnace

1200

100

700

1100 (a)

Oil Fired Space Htr (140,000 Btu)

Oil Fired Space Htr (85,000 Btu)

Oil Fired Space Htr (30,000 Btu)

300

400

225

150

Oven 4500

Paint Sprayer, Airless (1/3 HP) 600 (a)

150

Edge Trimmer

Electric Nail Gun

Electric Range (one element)

Electric Skillet

500

1200

1500

1250

Radio 200

Refrigerator 600

Slow Cooker

Submersible Pump (1-1/2 HP)

200

2800 (a)

Furnace Fan (1/3 HP)

Hair Dryer

Hand Drill (1”)

1200 (a)

1200

1100

Submersible Pump (1/2 HP)

Sump Pump

Table Saw (10”)

2000 (a)

1500 (a)

600 (a)

2000 (a)

Television 500 Hand Drill (1/2”)

Hand Drill (3/8”)

Hand Drill (1/4”)

Hedge Trimmer

875

500

250

450

Toaster 1000

Vacuum cleaner 250

VCR 70

Water Heater 3000 Home Computer 150

Impact Wrench

Jet Pump

500 Weed Trimmer 500

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.

Maintenance 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.

11

Troubleshooting

Problem

Voltage too low

Circuit breaker trips

Voltage too high

Generator overheating

No output voltage

Excessive gearbox noise

SOLUTION: A,B

SOLUTION: C,D,B,E

SOLUTION: F

SOLUTION: B,G

SOLUTION: C,H,D,I,J,K,E,A,L,M

SOLUTION: N,O,P,Q,R

I- Defective stator

J- Defective rotor

O- Defective gear

Cause Solution

A- Tractor throttle set too low

B- Generator is overloaded

C- Defective load connected to generator

D- Defective receptacle

E- Defective circuit breaker

F- Tractor throttle set too high

G- Insufficient ventilation

H- Broken or loose wire

K- Defective capacitor

L- PTO not engaged

M- Gearbox is malfunctioning

N- Defective bearing

P- No or low gear oil

Q- PTO driveline is operating at an angle of greater than 15 o

R- Unsynchronized PTO driveline

Increase tractor RPMs

Reduce the load (See load application section of this manual)

Disconnect load

Replace receptacle – Contact Product Support for the nearest service center

Contact Product Support for the nearest service center

Decrease tractor RPMs

Make sure that there is at least 3 feet of clearance on all sides of the generator

Replace or tighten wire – Contact Product

Support for the nearest service center

Contact Product Support for the nearest service center

Contact Product Support for the nearest service center

Contact Product Support for the nearest service center

Engage PTO

Contact Product Support for the nearest service center

Contact Product Support for the nearest service center

Contact Product Support for the nearest service center

Fill gear box to middle of oil level sight glass

Reposition the tractor or generator so the angle is reduced to less than 15

o

both vertically and horizontally

Disassemble PTO driveline and reassemble with

CV joints synchronized

12

Specifications and Accessories

SPECIFICATIONS

Item Number

Maximum Output

Continuous Output

Voltage

Phase

Frequency

Power Factor

Minimum PTO HP

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

Input Shaft

120V Receptacle

120/240V Receptacle

1-3/8” Diameter, 6 spline

(2) 20 Amp (A) (NEMA 5-20R)

(1) 30 Amp (A) locking device (NEMA

L14-30R)

(2) 20 Amp (A) thermal, Circuit Breaker push to reset style

(1) 30 Amp (A) thermal magnetic

Gear Box

Gear Ratio

Gear Oil

1:7

SAE 80W-90

Oil Capacity 0.75 Qt. (.82 L)

Dimensions

Length 25.25”

Width 12.50”

Height 17.25”

Gross Weight 110 lbs.

ACCESSORIES

PTO Driveline

PTO Trailer

165936

165959

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.

13

Item Part# Description

1 39138 Control box top

Item# 165951

7800 PTOG Generator

Parts Explosion

9

10

12

13

14

15

17

19

20

21

22

23

24

25

27

4 779781 Warning

5 82070 1/4-20 x .5” Serrated flange bolt

6

7

82005 #8-32 Keps nut

306422 120/240V, 30A receptacle

82004

39074

779562

82091

39140

82019

82049

82241

38278

38276

#8-32 Button head cap screw

Control panel decal

82158 M5-.8 x 14mm Pan Phillips screw

82243 M5-.8 Hex nut

82161 Grounding screw

38280 Bracket securing stud

38271 End cover plug

Capacitor

5/16-18 x 1” Hex head cap screw

Base

5/16-18 Serrated flange nut

M10 Rib washer

M10-1.5 x 20mm screw

Non drive end bracket

Bearing

Revision C

2

2

1

4

1

1

1

1

5

16

8

1

1

Qty Item Part# Description

1

1

1

28 780143 Rotor securing stud

1 31 780229 Rotor

8 32 780142 Stator

8

1

33

34

38270

38269

Enclosing band

Drive end bracket

1

8

1

36

37

82102

779556

3/8-16 x .75” Serrated flange bolt

Fan bolt

45

46

47

48

49

50

51

52

39

40

41

42

43

38890 Gearbox

82014 5/16-18 x .5” Serrated flange bolt

39136 Control box mount plate

82069 #10 Split lock washer

82244 #10-32 x .5” Pan Phillips screw, type F

31763 120V, 20A Duplex receptacle

30643 Circuit breaker, 125V-20A

777130 Circuit breaker mounting clip

31005 Thermal breaker, 125/250V-30A

39053 Implement shield

779770 PTO Warning decal

82201 M10 Flat washer

82137 M10-1.5 x 16mm Hex head cap screw

14

Qty

1

2

2

1

1

1

1

1

4

1

4

1

4

2

1

4

1

1

1

2

1

1

2

4

4

Item# 38890

Gearbox

Parts Explosion

Revision C

Note: Gearbox exploded view is shown upside-down when compared to its orientation on the generator.

Item Part# Description

1 39275 Housing

2 39276 Shaft

3 39277 Gear

4 39278 Flange

5 39279 Shaft

6 39280 Housing

7 31766 Circlip

8

9

10

11

39282 Oil seal, 25x52x10mm

39283 Oil seal, 35x52x10mm

39284 Key, 10x8x25mm

39285 Bearing

Qty

1

1

1

1

1

1

1

Item

14

15

16

17

18

Part# Description

39288 Pin,

39289 Cap

39290 Breather

31762 Oil

39292 Drain

19 39293 Cap

20 39294 Cap

3/8”

3/8”

3/8”

1

1

1

3

21

22

23

24

39295

39296

39297

39298

Sight glass

Screw, M8 x 20mm

Screw, M8 x 40mm

Screw, M8 x 110mm

1 25 39299

8

Any Questions, Comments, Problems or Parts Orders

Call NorthStar Product Support 1-800-270-0810

Qty

2

3

1

1

1

1

2

1

2

6

2

2

15