Troubleshooting. NORTHSTAR PTO Generator, PTO Generator, 7800 Surge Watts, 7200 Rated Watts, 14 HP Required

Troubleshooting

Problem

Voltage too low

Circuit breaker trips a) Defective load connected to generator b) Defective receptacle c) Generator is overloaded d) Defective circuit breaker

Voltage too high a) Tractor throttle set too high

Generator overheating a) Generator is overloaded

No output voltage

Excessive gearbox noise

TROUBLESHOOTING

Possible Causes

a) Tractor throttle set too low b) Generator is overloaded a) Defective load connected to generator b) Broken or loose wire c) Defective receptacle d) Defective stator e) Defective rotor f) Defective capacitor g) Defective circuit breaker h) Tractor throttle set too low i) PTO not engaged j) Gearbox malfunctioning k) Circuit breaker tripped. a) Defective bearing b) Defective gear c) No or low gear oil d) PTO driveline is operating at an angle of greater than 15

 e) Unsynchronized PTO driveline

Possible Remedies

a) Increase tractor RPMs. b) Reduce the load (See Power Load Planning &

Mgt. section of this manual). a) Disconnect load. b) Replace receptacle – Contact Product Support for the nearest service center. c) Reduce the load (See Power Load Planning &

Mgt. section of this manual). d) Contact Product Support for nearest service center. a) Decrease tractor RPMs. a) Reduce the load (See Power Load Planning &

Mgt. section of this manual). a) Disconnect load. b) Replace or tighten wire – Contact Product for the nearest service center. c) Replace receptacle – Contact Product Support for the nearest service center. d) Contact Product Support for the nearest service center. e) Contact Product Support for the nearest service center. f) Contact Product Support for the nearest service center. g) Contact Product Support for the nearest service center. h) Increase tractor RPMs. i) Engage PTO. j) Contact Product Support for the nearest service center. k) Reset circuit breaker and reduce loads connected to the generator. a) Contact Product Support for the nearest service center. b) Contact Product Support for the nearest service center. c) Fill gearbox to middle of oil level sight glass. d) Reposition the tractor or generator so the angle is reduced to less than 15



both vertically and horizontally. e) Disassemble PTO driveline and reassemble with CV joints synchronized.

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Summary of Important Safety Information for Operation

This section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your generator.

WARNING

Carefully read and make sure you understand the following safety information before using the generator.

Improper use or maintenance of the generator can 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.

General

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Read manual.

Read this Owner’s Manual and the engine Owner’s Manual completely before attempting to set-up and use the generator . Serious injury or death can result if safety instructions are not followed.

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Instruct operators . The generator owner must instruct all operators in safe generator set-up and operation.

Do not allow anyone to operate the generator who has not read the Owner’s Manual and been instructed on its safe use.

•

Adults only.

Only trained adults should set up and operate the generator. Do not let children operate.

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Under the influence . Never operate, or let anyone else operate, the generator while under the influence of alcohol, drugs, or medication.

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Intended use . Carefully read about and understand the intended use of this generator. Do not use for other purposes, as unforeseen hazards or equipment damage may result.

Prohibition Against Modifications

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Modifications prohibited.

Never modify or alter the generator in any way. Modifications can create serious safety hazards and will also void the warranty.

•

Guards . Do not operate generator unless all guards and cover shields, which prevent access to moving parts and pinch points, are in place. Failure to guard the power transmission mechanisms may result in serious injury or death.

Safety – Installation & Set-up

•

Mount generator.

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.

•

The generator must be securely mounted to either a reinforced concrete slab or a trailer.

•

Slab or trailer must be of adequate size and strength to withstand operating torque without flipping or structural failure.

• See the “Installation / Initial Set-Up” section of this Owner’s Manual for mounting requirements and instructions.

•

Dry, level surface . Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Apply parking brake, and block trailer wheels if generator is trailer-mounted.

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Operate OUTSIDE only – dangerous carbon monoxide exhaust ! The running tractor gives off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from building air intakes. NEVER run generator inside homes, garages, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN if you run a fan or open windows

•

Cooling ventilation . The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head so it does not overheat and possibly cause fire. Situate so there is adequate clearance around generator to allow for cooling airflow. Do not allow debris to accumulate and block airflow.

Keep all objects at least 7 feet away from vent slots.

•

Grounding . Always ensure generator is properly grounded to prevent electrical shock. This generator is equipped with a grounding post. Always complete the grounding path from the generator to a copper pipe/rod driven into moist earth to a sufficient depth. Check with an electrician for local grounding requirements. If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a standby power system, grounding will be complete through the building’s grounding system.

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Summary of Important Safety Information for Operation (cont’d)

•

Isolate connection to building’s electrical circuit . Never plug the generator directly into a wall outlet.

ANY connection to a building’s electrical system MUST ISOLATE THE GENERATOR FROM UTILITY

POWER via an UL-approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes. If the generator is not isolated from the utility power system by such means, generator output will back feed into the utility power grid. This may result in injury or death to utility power workers or others who contact the lines during a power outage. It may also cause the generator to explode or cause fires when utility power is restored.

•

Wet conditions . Water conducts electricity. Do not operate generator where it is wet. Operate on a dry surface under an open, canopy-like structure.

•

CO alarms . Ensure that working, battery-operated or battery back-up carbon monoxide alarms are used in any dwelling/structure that is in close proximity to the running generator.

•

Hot tractor exhaust . Tractor exhaust can be extremely hot and cause fire. Refer to your tractor manual to determine safe clearance distance required between hot tractor exhaust and nearby combustible objects.

•

Fire extinguisher

. Keep a fire extinguisher rated “ABC” by the National Fire Protection Association nearby.

Keep it properly charged and be familiar with its use.

Safety – Before Use

Know how to operate

•

Review safety rules

. Before each use of this generator, review the “Rules for Safe Operation.” Failure to follow these rules may result in serious injury or death.

•

Know how to operate. Be thoroughly familiar with all controls and with the proper use of the equipment.

Know how to stop the generator quickly if needed.

Personal protective equipment

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Hearing protection . The use of earplugs or other hearing protection device is recommended for those in close proximity to the generator while it is operating.

•

No loose / dangling apparel . Loose or dangling apparel and long hair can become entangled in moving/rotating parts. Metal jewelry can conduct electricity. Never wear jewelry or loose-fitting clothing such as neckties, scarves, or long-sleeved or untucked shirts when operating the generator. Tie back hair and secure close to head.

Safety – During Use

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Safety equipment / controls . Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation.

•

Know how to stop . Be thoroughly familiar with proper use of the equipment and all generator controls, output receptacles, and connections. Know how to stop the generator quickly if needed.

•

Damaged . Do not operate the generator with damaged, missing, or broken parts.

•

Carbon monoxide exhaust . The running tractor engine gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it. If you start to feel sick, dizzy, or weak while using the generator, shut off the tractor and get to fresh air RIGHT AWAY. See a doctor. You may have carbon

•

Smoking/sparks . Never smoke near the running generator, and never operate near sources of sparks or flames.

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PTO shaft secured.

Make sure PTO driveline shaft is securely locked at both ends. An unlocked PTO shaft can whip or become dangerously airborne.

•

PTO guards.

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.

•

Driveline angle.

Never operate the generator continuously when the PTO driveline shaft is at an angle greater than 15° either horizontally or vertically.

•

Check output voltage . Check output voltage to ensure the generator is working properly before connecting loads to the generator. Failure to do so could result in damage to equipment powered by the generator and possible injury to the individual. Do not adjust output speed of engine to change voltage. If voltage is not within specified range, have generator repaired by factory-authorized personnel.

•

Stabilize before connecting loads. Start generator and let engine stabilize before connecting electrical loads.

•

Do not overload . Do not overload the generator. Make sure that combined starting and running loads do not exceed rated capacity of generator or damage will result.

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Summary of Important Safety Information for Operation (cont’d)

•

Protect sensitive electronics . Some electronic equipment, such as computers and audio/video equipment, can be damaged by small fluctuations in the flow of power. Use a surge suppressor for any voltage-sensitive electronic equipment you will be powering with the generator.

•

Electrical cords.

Use only UL-listed, outdoor-rated, three prong extension cords of the proper size. All extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise damaged.

Use of inadequate or damaged electric cords can cause electric shock or fire.

•

GFCI extension cords.

Always use ground fault circuit interrupter (GFCI)-equipped extension cords to prevent electrical shock in damp or highly electrical conductive areas and on construction jobsites.

•

Wet conditions.

Do not 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.

•

Avoid contact . Avoid contact with bare wires, terminals, connections, etc. while the unit is running.

•

Electric shock accident.

If an electric shock accident occurs, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. Avoid direct contact with victim. Use a nonconducting implement, such as a dry rope or board, to free the victim from the live conductor. Apply first aid and get immediate medical help.

•

Hot parts. Parts of the generator are extremely hot during and after operation and can burn you. Never touch hot gearbox, and do not touch any other part of the generator unless you have first determined if it is hot. Wait a sufficient time for parts to cool before touching any part of the generator.

•

Moving parts . Keep hands, feet, and apparel away from PTO connections, drive shaft, belts, fans, and other moving parts. Never attempt to remove drive shaft or any guard or shield while the unit is operating.

•

Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in tractor engine speed, slow or fast o

Overheating in load connecting devices o

Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Excessive vibration o Flame or smoke o Abnormal noise

•

Adjusting / repairing . Always turn off generator and remove PTO driveline before working on or cleaning the generator.

Safety – After use

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Driveline removed.

Always stop tractor engine and remove driveline after use.

•

Cool before storing. Let generator cool for at least five minutes before storing. Hot equipment can be a fire hazard near combustible materials.

•

Storage location.

Store the generator in a dry location.

•

Exercise regularly.

Exercise generator every four weeks to dry out moisture that accumulates in the windings. If generator cannot be exercised on a regular basis, prepare generator for long-term storage.

•

Periodic maintenance.

Perform periodic maintenance as directed in this manual to keep the generator in safe working condition.

Safety - Inspection/Maintenance

Inspect and maintain your generator on a regular basis and repair as needed to keep it in safe working condition:

•

Generator off & driveline detached . Always stop tractor engine and remove PTO driveline before working on or cleaning the generator.

•

Discharge capacitor. When the generator is shut down, the capacitor may maintain a charge. Always discharge the capacitor before working on the generator head to prevent electrical shock.

•

Clear debris/deposits.

Keep generator head and moving parts clean. This will ensure the generator is in safe working condition.

•

Replace guards / shields.

Make sure all guards and shields are replaced after servicing the generator.

•

Replacement parts.

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 and will void the warranty

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