North Star 13000 PTOG User Manual

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MODEL 13000 PTOG ITEM # 165929
Proven Performance
O W NE R’S MA NUAL
Power T
ake-Off Generator
M165929A
00293
13000 PTOG
Any Questions, Comments, or Problems?
Call Cust omer Service at 1-800- 270- 0810
Hours: Monday - Friday 7:30 AM to 5:30 PM
Saturday 7:30 to 11:30 AM CST
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THANK YOU
Thank you for purchasing a NorthStar Power Take-Off Generator. Your machine is designed for l ong life, dependability, and the top performance you demand. Please take time now to read through this manual so you can better understand the machine’s operation, maintenance and safety precautions. Everyone who operates this generator must read and understand this manual. The time you take now will prolong your generator’s life and prepare you for its safe operation. Enjoy the exceptional performance of your NorthStar PT O Generator.
IM PORTANT
If this machine i s used by anyone who is not the owner or i s l oaned or rented, make certain the operator:
- Is instructed in safe and proper operati on of this machine.
- Reads and understands the manual s pertaining to this m achine.
NOTICE
K-BAR Industries Incorporated reserves the ri ght to m ake improvements in design and/or changes in specifications at any time without incurring any obli gati on to install them on uni ts previously sold.
TABLE OF CONTENT S
Thank you 1 Specifications 2 A NSI safety definitions 2 Machine component ident ificat ion 3 Gener ator features 4 Introduction 4 Rules f or safe oper ation 4-5 Installation 5-6 Load applicat ion 6-7 Pre- star t up prepar ations 7-8 Gener ator care 8 Troubles hooting 9
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SPECIFICATIONS
Item Number #165929 Ma ximum Outp ut 13000 Watts (W) Continuous Output 12000 Watts (W) Voltage 120 / 240 Volt ( V) Phase Single phase (4-wire) Frequency 59.0- 63.0 Hertz (Hz) Power Factor 100 % Mi nimum P TO HP 24 HP at 540 RP M Input Shaft 1 3/8” Diameter , 6 spline 120V Receptac le (2) 20 Amp (A) duplex (NEMA 5- 20R)
30 Amp (A) twistloc k ( NE MA L5-30R) 120/240V Receptacle 50 Amp (A) St r aight blade (NEMA 14-50R) Circuit Breaker (2) 20 Amp (A) thermal, push to reset style
30 Amp (A) ther mal, push to r eset style
(2) 40 Amp (A) t her mal, push to r eset style Gear B ox Gear Ratio 1:7 Gear Oil SAE 80W-90 Oil Capac ity .86 Qt. (.82 L) Dim ensions Length 28.38” ( 72.1 cm) Width 14.25” ( 36.2 cm) Height 12.50” (31.1 cm) Gr oss W eight 127 lb. ( 57.7kg)
ANSI SAFETY DEFINITIONS
DANG ER indicates an im minently hazardous situation which, if not avoi ded,
will result in death or serious injury. This signal word is to be limited to the most extreme si tuations.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in a death or serious injury.
CAUTION indi cates a potentially hazardous si tuation, which if not avoided,
may result in m i nor or moderate injury. It may also be used to alert agai nst unsafe practices.
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MA CHINE COMPO NENT IDENTIF ICATION
Figure 1 ( Ref. 1- 10)
Ref. Des cription Ref. Des cription
1 50A Ci rcuit Breakers 10 120/240V 50A Receptacle 2 30A Circui t Breaker 11 Shield 3 20A Ci rcuit Breakers 12 Gear Box 4 Warning Decal s 13 Grounding Screw 5 1 3/8”, 6 Spline Input Shaft 14 Mounting Holes 6 Oil Drai n Plug 15 Fan Vents 7 Voltmeter 16 Oil Level Sight 8 120V 20A Duplex
Receptacles
9 120V 30A Twistlock
Receptacle
17 Breather/Oil Fill Plug
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GENERATOR FEATURES
References 1-3 Circuit Breakers.
Reference 1 - two 50A push-to-reset circuit
breakers.
Reference 2 - one 30A push-to-reset circuit
breaker.
Reference 3 - two 20A push-to-reset circuit
breakers.
References 4 - Warning Decals. Read and
follow all warnings.
References 5 - 1 3/8” Diameter 6 Spline Input
Shaft. 540 RPM. PTO driveline i s availabl e from
Northern, Item #165936.
References 6 - Oil Drain Plug. Change oil after the first 50 hours of use, then after every 500 hours.
References 7 - Voltmeter. Voltmeter needle shoul d be in green area during all generator load conditions. The black line in the center on the green area indicates 120V. During no load conditions, the needle should be at or above the black l i ne.
References 8-9 120V Receptacles.
Reference 8 - 120V Receptacle. The generator has a control panel with two 120V 20A straight bl ade receptacl e duplexes (two receptacles in a common housing). National Electrical Manufacturer’s Association (NEMA) number is 5­20R.
Reference 9 - This twistlock receptacle is a 120V 30A receptacl e, NEMA number L5-30R. Thi s
Figure 2 (Ref. 10-16)
receptacle accepts NEMA plug number L5-30P, which i s suppli ed with the generator.
Reference 10 - 120/240V Receptacle. This straight blade receptacle is 120/240V 50A. This receptacle accepts a NEMA plug number 14-50P.
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.
References 11 - Shield. Plastic implement shield. NEVER operate generator without shiel d i n place.
Reference 12 - Gear Box. Cast iron fram e. 1:7 gear ratio.
Refe r ence 1 3 - Groundi ng Screw. Ground the generator via the ground screw, to a copper pi pe or rod that is driven into moist soi l .
Reference 14 - Mounting Holes. Use these three locations to mount the generator head in place with 7/16” grade 5 bolts. Mounting plates (i tem #165935) for mounting generator to a cement pad are available through Northern and the NorthStar parts catalog.
Reference 15 - Fan Vents. Never block the vent slots or insert objects through the slots. The closest object should be at least 3 feet away from the vents.
Reference 16 - Oil Level Sight. When oil is even with the red dot, the oil level is correct. Check oil level daily. Sight is m ounted on the gear box service panel. If panel is removed for whatever reason, reseal usi ng Dow Corning seal ant #732.
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Reference 17 - Breather/Oil Fill Plug. Use SAE 90 gear oil. Maintain the correct oil level. Over filling can cause the oil to over heat and damage seals and bearings. The gear box is shipped with temperary plastic plug, remove and repl ace with the metal breather plug that is in the manual bag.
INTRODUCTION
Before attempting to mount your generator, thoroughly study the i nstructions and cautions in this manual to assure you are full y acquainted with the operation of al l components of this generator. Proper preparation, operation and maintenance will result in operator safety, best perform ance and long l ife of the generator. NorthStar is constantly improving its products. The specifications outlined herein are subj ect to change wi thout prior notice or obl igation. The purchaser and/or user assumes liability of any modification and/or alterations on this equipment from original design and m anufacture. Before using, the user shall determine the suitability of this product for its intended use and assumes l iability therein.
RULES FOR SAFE OPERATIONS
Safety precautions are essential when operating this generator. Respectful and cautious operation will considerably lessen the possibilities of a personal i njury. Thi s manual will warn of specific personal injury potential, and these will be desi gnated by the symbol:
WARNING This generator is equipped
with a grounding screw, located on the generator frame for your protection. Always complete the grounding path from the generator to a copper pipe/rod that is driven into m oist earth, to prevent electrical shock.
ALWAYS use electrical cords that are in good condition. Worn, bare, frayed or otherwise damaged cords can cause electri c 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.
ALWAYS remove PT O dri vel ine before worki ng on the generator.
ALWAYS provide adequate ventilation. Do not operate generator in any encl osed or narrow space. Engines consume oxygen and give off deadly carbon monoxide, a poisonous gas. Improper ventilation will cause damage to generator and possible inj ury to people.
ALWAYS remove all oil or gasoline deposits
and accumulated dirt from generator and imm ediate area. Keep generator head and engi ne clean.
ALWAYS wear ear protection while operating
generator.
ALWAYS keep area around generator clean.
NEVER operate the generator without proper
guardi ng.
NEVER operate the generator continuously when PTO driveline is at angle greater than 15° both horizontally and vertically .
NEVER operate the generator while wearing loose fitting clothing such as neckties, scarves or untucked shi rts.
NEVER operate the generator, or handle any electrical equipment whi le standing i n water, while barefoot, whi l e hands are wet or while i n the rain or snow. Electric shock may result.
NEVER operate the generator under the following conditions:
A. Excessive change in engine speed, sl ow
or fast. B. Overheating in load connecti ng devices. C. Sparking or arcs from generator. D. Loss of electrical output. E. Damaged receptacles. F. Engine misfire. G. Excessive vib rat io n. H. Enclosed compartments, or confined areas. I. Flame or smoke. J. Rain, snow or wet conditions. K. Operator non-attendance. L. Without proper guarding in place.
WARNING Keep fire extinguisher close
by your generator and be familiar with how to use it. Consult your local fire department for correct extinguisher type.
DANG E R Remember, exhaust fumes are
deadly carbon monoxide, a poisonous gas and must be vented to the outside where there are no people. Cooling air of sufficient amounts must be brought in and exhausted out to ensure proper cooling of the engine and generator.
INSTALLATION
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Choose a location where the generator will not be exposed to rain, snow or direct sunlight. Common places for m ounti ng your PT O generator are to a trailer or a cement slab. However you choose to mount the generator, make sure it can get as close to the load as possibl e. T hi s 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 d u st, d irt, sand, l int, or abrasive materi als 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 grounding or shorting out of the generating system.
When trailer mounting the generator select a trail er that is wide enough to withstand the torque of start-up and l oading torque. Wheel s that are not spaced properly coul d cause the trail er to tip over. The constant vibration of the generator can cause metal fatigue of the trai ler base if the steel used i s not thick enough.
DANGER Trailer may tip over and cause
serious injury or death. Never stand near an operating PTO generator.
When mounti ng the generator on a cem ent slab use the optional mount kit (item #165935), available in the Northern catal og and the NorthStar parts catalog. The kit comes with two mounting plates and three grade 5, 7/16-14 bolts. Use grade 5 3/8” anchor bolts to mount plates to the concrete.
After the the generator is firmly mounted , attach the PT O driveline to the generator then the tractor. Use a synchronized PTO dri vel ine rated at 24 HP minimum.
DANGER Always have proper guarding
of rotating parts. Failure to guard the power transmission mechanisms may result in serious inj ury or death.
Whi le seated on the tractor and the engi ne at idl e, engage the PTO. Slowly i ncrease the throttle until the needle i n the generator voltmeter i s at or above the black line in the green area. A l oad can now be applied 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 i s close to the black l ine 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 probl em . Use the troubleshooting gui de at the end of the manual for assistance with possi ble probl em s.
Before each use check the gear box oil level. Use SAE gear oil and fill to the dot on the sight glass.
If the control box is not located on the correct side for your application, it can be rotated to the opposite side. First remove the fan vents, then remove the four drive end bracket bolts. Remove securing stud cap, loosen the securing stud nut. Rotate the dri ve end bracket 180°, re-torque bolts to 17 lbft. Re -torque securing stud nut to 88.5 lb•ft. Reinstall the fan vents. Remove the four screws at the base of control box, rotate the control box 180°. The voltmeter is now on the back of the machine instead of the front. See bel ow for terminology.
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LOAD APPLICATION
It is i mportant to determine the total el ectri cal load before it is connected to the generator. 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 el iminated and a dead short can result.
Always compare the generator nameplate data with that of the equipment to be used to ensure that watts, volts, amperage, and frequency requirements are suitabl e for operating equi pment. T he wattage listed on the equipment nameplate is its rated output. However, some equipment may require three to ten times more wattage than i ts rati ng on the nameplate, as the wattage i s 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
When connecting a resistive load such as incandescent lights, heaters or common electric power tools, a capacity of up to the generator ful l rated wattage output can be used.
When connecti ng a resi stive-i nductive load such as a fluorescent or mercury light, transformers or inductive coils, a capacity of up to 0.6 times the generator’s ful l rated output can be used.
Always allow the generator to reach operating speed before a load is appli ed.
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STARTIN G ELE C TR IC 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 requi re 5 to 7 times more current to start than to run. Capaci tor m otors are easier to start and usually require 2 to 4 times as much current to start than to run. Repulsion Induction motors are the easi est 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 them whether they are of Repulsion-Induction (RI), Capacitor (Cap), or Split­Phase (SP) type. The following chart shows the approximate current required to start and run various types and si zes of 120 volt 60 cycl e e le ctric motors under various conditions.
120V, 60 Hz Motors
Hp motor Running
Watts
1/6 525 7-11 9-18 16-22 1/4 700 9-15 12-23 22-32 1/3 875 11-18 14-29 26-35 1/2 1175 15-25 20-40 NA
1 1925 24-40 32-64 NA
1 1/2 2400 30-50 40-80 NA
2 2900 36-60 48-96 NA 3 4075 51-85 68-136 NA 5 6750 84-140 112-224 NA
The figures given above are for an average load such as a blower or fan. If the electric m otor i s connected to a hard starting load such as an air compressor, it will require more starti ng current. If it is connected to a light load or no load such as a power saw, it will requi re l ess starting current. The exact requirement will also vary with the brand or desi gn of the motor.
Generators respond to severe overloading differently than the power line. When overloaded, the engine is not able to suppl y enough power to bri ng the el ectric 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 windi ng m i ght al so be damaged.
Running the generator under these conditions may result in dam age to the generator stator as well
RI t y pe Cap
Starting Amps
type
SP
type
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as the electric motor windings. Because the heavy surge of current is requi red for only an instant, the generator will not be damaged if it can bring the motor up to speed in a few seconds. If difficul ti es i n starti ng a motor are experienced, turn off all other electrical l oads and if possi ble reduce the load on the electric motor.
EXTENSION CORDS
When el ectric 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 set and point of use i s hel d to a mi nimum.
Current/PowerM aximum E xtension Cord Length
Amps
at
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’ * * *
the low vol tage caused by using an extension cord with a small wire si z e.
generator.
Devic e Running Watts
Air Conditioner (12,000 Btu) 1700 (a) Battery Charger (20 Amp) 500 Belt Sander (3”) 1000 Chain Saw 1200 Circular S aw (6-1/2”) 900 Coffee Maker 1000 Co mpresso r (1 HP) 2000 (a) Compressor (3/4 HP) 1800 (a)
Co mpresso r (1/2 HP) 1400 (a) Curl ing Iron 700 Dis hwasher 1200 Edge Trimmer 500 Electric Nail Gun 1200 Electric Range (one element) 1500 Electric Skillet 1250
Load
(watts)
CAUT ION: Equipment damage can result from
Use this chart to esti mate the total l oad on your
For Determi ni ng Genera tor Load Requi r ements
Ge nerator Load Requireme nts Continued
#10
Ga.
Cord
#12 Ga.
Cord
#14 Ga.
Cord
*Not recommended
#16 Ga.
Cord
Freezer 800 (b) Furnace Fan (1/3 HP) 1200 (a) Hair Dryer 1200 Hand Drill (1”) 1100 Hand Drill (1/2”) 875 Hand Drill (3/8”) 500 Hand Drill (1/4”) 250 Hedge Trim m er 450 Home Computer 150 Impact Wrench 500 Jet Pum p 800 (a) Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 (a) Oil Burner on Furnace 300 Oil Fired Space Htr (140,000 Btu) 400 Oil Fired Space Htr (85,000 Btu) 225 Oil Fired Space Htr (30,000 Btu) 150 Oven 4500 Paint Sprayer, Airless (1/3 HP) 600 (a) Paint Sprayer, Airless (handheld) 150 Radio 200 Refrigerator 600 (b) Slow Cooker 200 Submersible Pum p (1-1/2 HP) 2800 (a) Submersible Pum p (1 HP) 2000 (a) Submersible Pum p (1/2 HP) 1500 (a) Sump Pump 600 (a) Tabl e Saw (10”) 2000 (a) Tel evision 500 Toaster 1000 Vacuum cl eaner 250 VCR 70 Water Heater 3000 Weed T rimmer 500
(a) Hard-starting motors require 3 to 5 ti mes the
rated running watts.
(b) These loads may requi re up to 15 minutes to restart due to its normal build up of compressor head pressure.
NOT E: For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to determine the maximum wattage.
PRE-START UP PREPARATI ONS
Your generator has been thoroughly tested prior to shipment from the factory. However, damage can occur during shi pping, so be sure to check for damaged parts, loose or missi ng nuts and bolts. If the these problems occur, call Customer Servi ce at 1-800-270-0810.
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GROUNDING - All units must be grounded. Dri ve a 3/4” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth. Connect an approved ground clamp to the pipe. Run a 8 gauge wire from the clamp to the generator ground screw. Do not connect to a water pipe or a ground used by a radi o system.
OPER A TIN G SPEED
The generator m ust 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 indi vidual.
All engines have a tendency to sl ow 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 i s loaded to its full capacity than when it is running with no l oad. T he sl i ght vari ation has no appreciabl e effect in the operation of motors, lights and most appliances. Electronic equipment and clocks will be effected if correct RPM is not maintai ned. See Load vs. Output chart
Load Output
Percent of
Generator
Output
0 % 3780 63.0 125V
50 % 3600 60.0 122V
100 % 3480 58.0 118V
Speed
(RPM)
Frequency
(Hz)
Generator voltage at
120V
Receptacle
GENERATOR CARE
The generator head i s a two pole, 3600 RPM, 60 Hz, brushless, revolving field and synchronous type with two sealed radi al beari ngs.
Proper care and maintenance are necessary to ensure a long troubl e free life.
Exercising The Generator - The generator should be operated ev ery four w eeks. This is
accompl ished by starting the engine and applying a load for 15 minutes. This will dry out any moisture that has accumul ated in the windi ngs. If left, this moisture can cause corrosion in the winding. Frequent operation of the generator will also ensure that the set is operati ng properly should it be needed in an em ergency.
Ge nera tor Ma intena nce - The generator head is brushless and maintenance free. Any major generator service including the installation or repl acement of parts shoul d be performed onl y by a quali fi ed electrical servi ce technician. USE ONLY NorthStar APPROVED REPAIR PART S AVAILABLE AT 1-800-270-0810.
A. Bearing - The beari ngs used in thi s generator are a heavy duty, sealed ball bearing type. They requi re no maintenance or lubrication.
B. Receptacl es - Quality receptacles have been utilized. If a receptacle shoul d become cracked or otherwise damaged, replace it. Using cracked or damaged receptacles can be both dangerous to the operator and destructive to the equipm ent.
WARNING, Stand-by Operation
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. Also, local Fire Departments must be consulted concerning proper and safe handling procedures for gasol ine. NEVER connect any generator to any existing electrical system without an isolating, UL approved transfer switch, install ed by a licensed electrician.
Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances, it can be checked with a portabl e meter. Frequency can be checked by using an electric clock with a sweep second hand. T imed against a wrist watch or a stop watch the clock should be correct wi thin +/- 2 seconds per minute. All speed setting adjustments should be done by a qualified technician.
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TROUBLESHOOTING
Proble m Possible Causes Possible Remedies
Voltage too low. a) Engine speed too slow.
b) Generator i s overloaded.
Circuit breaker trips. a) Defecti ve load connected to
generator. b) Defective receptacle. c) Generator overloaded.
d) Defective circuit breaker.
Voltage too high. a) Engine speed too high. a) Contact Customer Service for
Generator overheating.
No output voltage. a) Defective load connected to
Excessive gear box noise.
a) Generator i s overloaded.
b) Insufficient ventilation.
generator. b) Broken or l oose wire.
c) Defective receptacle. d) Defective stator.
e) Defective rotor.
f) Defective capacitor.
g) Defective circuit breaker.
h) Engi ne speed too slow. I) PTO not engaged. j) Gear box is mal functioning. a) Defective bearing.
b) Defective gear.
c) No or low gear oil. d) PT O driveline is operating at an angle of greater than 15°.
e) Unsynchronized PTO driveli ne.
a) Increase tractor RPMs. b) Reduce the load. (See Load Application section of this manual.)
a) Di sconnect l oad. b) Repl ace receptacle. c) Reduce the load. (See Load Application section of this manual.) d) Contact Customer Service for the nearest servi ce center.
the nearest servi ce center. a) Reduce the load. (See Load Application section of this manual.) b) Make sure there is at least 3 feet of clearance on al l si des of generator. a) Di sconnect l oad. b) Repl ace/tighten wi re. c) Replace receptacle. d) Contact Customer Service for the nearest servi ce center. e) Contact Customer Service for the nearest servi ce center. f) Contact Customer Service for the nearest service center. g) Contact Customer Service for the nearest servi ce center. h) Increase tractor RPMs. I) Engage PTO. j) Contact Customer Service for the nearest service center.
a) Contact Customer Service for the nearest servi ce center. b) Contact Customer Service for the nearest servi ce center. c) Fill gear box to oil level sight. d) Repostition the tractor or generator so the angle is reduced to less than 15° both vertically and horizontally. e) Disassembl e PTO driveli ne and reassembl e wi th CV j o ints synchronized.
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