North Star Portable Generator M165951C User Manual

M165951C  
Item Number:  
165951  
Serial Number:  
TM  
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  
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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  
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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.  
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Warning Label Locations  
DANGER!  
ROTATING DRIVELINE−CONTACT CAN CAUSE DEATH.  
NEVER OPERATE WITHOUT:  
WARNING!  
305545  
ELECTRICAL SHOCK CAN KILL.  
ALWAYS ground generator.  
NEVER connect generator to another electrical system without  
an isolation transfer switch installed by a licensed electrician.  
WARNING!  
NEVER operate generator in an NEVER operate generator with  
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.  
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  
Danger: Rotating Driveline  
Warning: Electric Shock  
Part No. 777131  
Part No. 31696  
Part No. 305545  
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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
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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.  
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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.  
Max. 15°  
Max. 15°  
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  
15o in either the horizontal or vertical plane.  
Top View  
Driveline  
WARNING Always properly guard rotating parts.  
Failure to guard the power transmission mechanisms  
may result in serious injury or death.  
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.  
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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  
Load  
Output  
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.  
Percent of Speed Frequency  
Generator (RPM)  
Output  
Generator  
Voltage at 120V  
Receptacle  
125V  
(Hz)  
0%  
50%  
100%  
3780  
3600  
3480  
63.0  
60.0  
58.0  
122V  
118V  
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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  
Starting Amps  
HP Motor  
Running  
Watts  
525  
RI Type  
Cap Type  
SP Type  
1/6  
¼
7-11  
9-15  
9-18  
12-23  
14-29  
20-40  
32-64  
40-80  
48-96  
68-136  
112-124  
16-22  
22-32  
26-35  
NA  
NA  
NA  
NA  
NA  
NA  
700  
1/3  
½
1
1 ½  
2
3
875  
11-18  
15-25  
24-40  
30-50  
36-60  
51-85  
84-140  
1175  
1925  
2400  
1900  
4075  
6750  
5
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  
Current/Power  
Maximum Extension Cord Length  
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.  
Amps  
at  
Load  
(Watts)  
#10 Ga  
Cord  
#12 Ga  
Cord  
#14 Ga #16 Ga  
Cord  
Cord  
240V  
10  
20  
30  
40  
2400  
4800  
7200  
9600  
12000  
250’  
125’  
60’  
30’  
15’  
150’  
75’  
35’  
15’  
*
100’  
50’  
25’  
10’  
*
75’  
25’  
10’  
*
CAUTION: Equipment damage can result from  
the low voltage caused by using an extension  
cord with a small wire size.  
50  
*
*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.  
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Operation Instructions  
Use to Approximate Generator Load Requirements  
Device  
Running Watts  
1700 (a)  
500  
Device  
Lawn Mower  
Light Bulb  
Microwave Oven  
Milk Cooler  
Oil Burner on Furnace  
Oil Fired Space Htr (140,000 Btu)  
Oil Fired Space Htr (85,000 Btu)  
Oil Fired Space Htr (30,000 Btu)  
Oven  
Paint Sprayer, Airless (1/3 HP)  
Paint Sprayer, Airless (handheld)  
Radio  
Running Watts  
1200  
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  
100  
700  
1100 (a)  
300  
400  
225  
150  
4500  
1000  
1200  
900  
1000  
2000 (a)  
1800 (a)  
1400 (a)  
700  
1200  
500  
600 (a)  
150  
200  
Dishwasher  
Edge Trimmer  
Electric Nail Gun  
Electric Range (one element)  
Electric Skillet  
Freezer  
Furnace Fan (1/3 HP)  
Hair Dryer  
1200  
1500  
1250  
800 (b)  
1200 (a)  
1200  
1100  
875  
500  
250  
450  
150  
500  
800 (a)  
Refrigerator  
Slow Cooker  
600 (b)  
200  
Submersible Pump (1-1/2 HP)  
Submersible Pump (1 HP)  
Submersible Pump (1/2 HP)  
Sump Pump  
Table Saw (10”)  
Television  
Toaster  
Vacuum cleaner  
VCR  
2800 (a)  
2000 (a)  
1500 (a)  
600 (a)  
2000 (a)  
500  
1000  
250  
70  
3000  
Hand Drill (1”)  
Hand Drill (1/2”)  
Hand Drill (3/8”)  
Hand Drill (1/4”)  
Hedge Trimmer  
Home Computer  
Impact Wrench  
Jet Pump  
Water Heater  
Weed Trimmer  
500  
(a) Hard-starting motors require 3 to 5 times the rated running watts.  
(b) These loads may require up to 15 minutes to restart due to its normal build up of compressor head pressure.  
NOTE: For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer  
to determine 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  
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Troubleshooting  
Problem  
Voltage too low  
SOLUTION: A,B  
SOLUTION: C,D,B,E  
SOLUTION: F  
Circuit breaker trips  
Voltage too high  
Generator overheating  
No output voltage  
Excessive gearbox noise  
SOLUTION: B,G  
SOLUTION: C,H,D,I,J,K,E,A,L,M  
SOLUTION: N,O,P,Q,R  
Cause  
Solution  
Increase tractor RPMs  
A- Tractor throttle set too low  
Reduce the load (See load application section of  
this manual)  
B- Generator is overloaded  
Disconnect load  
C- Defective load connected to generator  
Replace receptacle – Contact Product Support  
for the nearest service center  
Contact Product Support for the nearest service  
center  
D- Defective receptacle  
E- Defective circuit breaker  
Decrease tractor RPMs  
F- Tractor throttle set too high  
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  
G- Insufficient ventilation  
H- Broken or loose wire  
I- Defective stator  
Contact Product Support for the nearest service  
center  
J- Defective rotor  
Contact Product Support for the nearest service  
center  
K- Defective capacitor  
Engage PTO  
L- PTO not engaged  
Contact Product Support for the nearest service  
center  
M- Gearbox is malfunctioning  
Contact Product Support for the nearest service  
center  
N- Defective bearing  
Contact Product Support for the nearest service  
center  
O- Defective gear  
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  
P- No or low gear oil  
Q- PTO driveline is operating at an angle of  
greater than 15o  
Disassemble PTO driveline and reassemble with  
CV joints synchronized  
R- Unsynchronized PTO driveline  
12  
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Specifications and Accessories  
SPECIFICATIONS  
Item Number  
165951  
7800 Watts (W)  
Maximum Output  
Continuous Output  
Voltage  
7200 Watts (W)  
120 / 240 Volt (V)  
Phase  
Frequency  
Single phase (4-wire)  
60.0 Hertz (Hz)  
Power Factor  
Minimum PTO HP  
Input Shaft  
120V Receptacle  
120/240V Receptacle  
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  
L14-30R)  
Circuit Breaker  
(2) 20 Amp (A) thermal,  
push to reset style  
(1) 30 Amp (A) thermal magnetic  
Gear Box  
Gear Ratio  
Gear Oil  
Oil Capacity  
Dimensions  
Length  
Width  
Height  
Gross Weight  
1:7  
SAE 80W-90  
0.75 Qt. (.82 L)  
25.25”  
12.50”  
17.25”  
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  
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Item# 165951  
7800 PTOG Generator  
Parts Explosion  
Revision C  
Item  
1
2
3
4
5
6
7
8
Part# Description  
Qty  
1
1
1
1
Item  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
Part# Description  
780143 Rotor securing stud  
307479 Diode  
307481 Varistor  
780229 Rotor  
Qty  
1
2
2
1
1
1
1
1
4
2
1
1
4
1
4
2
1
1
2
4
1
1
1
4
4
39138  
38541  
31727  
Control box top  
NorthStar decal  
Voltmeter  
779781 Warning decal  
82070  
1/4-20 x .5” Serrated flange bolt  
8
8
1
1
8
1
4
2
2
1
4
1
1
1
1
1
5
16  
8
1
1
780142 Stator  
82005  
#8-32 Keps nut  
38270  
38269  
Enclosing band  
Drive end bracket  
306422 120/240V, 30A receptacle  
39137  
82004  
39074  
Control box  
#8-32 Button head cap screw  
Control panel decal  
779557 Fan  
9
82102  
3/8-16 x .75” Serrated flange bolt  
10  
11  
12  
13  
14  
15  
17  
18  
19  
20  
21  
22  
23  
24  
25  
27  
779556 Fan bolt  
780228 Mount plate  
305587 Isolation mount  
82158  
82243  
82161  
38280  
38271  
M5-.8 x 14mm Pan Phillips screw  
M5-.8 Hex nut  
Grounding screw  
Bracket securing stud  
End cover plug  
38890  
82014  
39136  
82069  
82244  
Gearbox  
5/16-18 x .5” Serrated flange bolt  
Control box mount plate  
#10 Split lock washer  
#10-32 x .5” Pan Phillips screw, type F  
777304 End cover  
779562 Capacitor  
306459 Ground wire  
31763  
30643  
120V, 20A Duplex receptacle  
Circuit breaker, 125V-20A  
82091  
39140  
82019  
82049  
82241  
38278  
38276  
5/16-18 x 1” Hex head cap screw  
Base  
777130 Circuit breaker mounting clip  
5/16-18 Serrated flange nut  
M10 Rib washer  
M10-1.5 x 20mm screw  
Non drive end bracket  
Bearing  
31005  
39053  
Thermal breaker, 125/250V-30A  
Implement shield  
779770 PTO Warning decal  
82201  
82137  
M10 Flat washer  
M10-1.5 x 16mm Hex head cap screw  
14  
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Item# 38890  
Gearbox  
Parts Explosion  
Revision C  
Note: Gearbox exploded view  
is shown upside-down when  
compared to its orientation on  
the generator.  
Item  
1
2
3
4
5
6
7
8
Part# Description  
39275 Housing  
39276 Shaft  
39277 Gear  
39278 Flange  
39279 Shaft  
39280 Housing  
31766 Circlip  
39282 Oil seal, 25x52x10mm  
39283 Oil seal, 35x52x10mm  
39284 Key, 10x8x25mm  
39285 Bearing  
31760 Bearing  
39287 Nut, M8  
Qty  
1
1
1
1
1
1
1
1
1
1
3
1
Item  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
Part# Description  
39288 Pin, 8x20mm  
39289 Cap  
39290 Breather plug, 3/8”  
31762 Oil plug, 3/8”  
39292 Drain plug, 3/8”  
39293 Cap  
Qty  
2
3
1
1
1
1
2
1
2
6
2
2
39294 Cap  
39295 Sight glass  
39296 Screw, M8 x 20mm  
39297 Screw, M8 x 40mm  
39298 Screw, M8 x 110mm  
39299 Sleeve  
9
10  
11  
12  
13  
8
Any Questions, Comments, Problems or Parts Orders  
Call NorthStar Product Support 1-800-270-0810  
15  
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