Northern Industrial Tools 15000 PPG User's Manual
Contents
1. Frequency 60 0 62 5 Hertz Hz 13500 Watts W 120 240 Volt V Single phase 4 wire Power Factor 1 0 p f Total Harmonic Distortion less than 8 Engine 25 HP Kohler Command Engine Speed 3600 3750 RPM Fuel Type Unleaded gasoline Fuel Capacity 10 gallons 38 0 L Oil Capacity 2 1 US quarts with filter 120V Receptacles 2 20 Amp A duplex NEMA 5 20R 30 Amp A twistlock NEMA L5 30R 120 240V Receptades 30 Amp A twistlock NEMA L14 30R 60 Amp A straight blade NEMA 14 60R Circuit Breakers 60 Amp A thermal magnetic 30 Amp A thermal magnetic 30 Amp A thermal push to reset 2 20 Amp A themal push to reset Battery 12V DC 380 cca shipped dry add electrolyte to fill Starting Method Electric start line on each cell Dimensions Length 35 75 90 8 an Width 24 25 61 6 an Height 26 25 66 7 an Dry Weight 425 lb 193 kg Gross Weight 495 lb 225 kg MACHINE COMPONENT IDENTIFICATION 7 dl NY PRO Figure 1 Ref 1 10 00212 Ref Air Cleaner 11 10 0 Gallon Gas Tank Circuit Breakers 12 Engine Key 120 240V 60A Receptacle 13 Choke 2 E 4 120 240V 30A Twistlock Rec 14 Muffler amp Spark Arrestor 5 120V 30A Twistlock Rec 6 E s 9 15 Oil Filter 120V 20A Duplex Rec 16 Battery Box amp Battery Oil Drain Valve 17 Gas Line Valve Vibration Isolation Mount 18 Generator Head Starting Stoppi2. MODEL 15000 PPG ITEM 165925 Professional Portable Generator M165925A 00211 THANK YOU Thank you for purchasing a North Star Pro Series Generator Your machine is designed for long 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 perfomance of your North Star Pro Series Generator IMPORTANT Make certain the operator Reads and understands the manuals pertaining to this machine Is instructed in safe and proper operation of this machine NOTICE K BAR Industries Incorporated reserves the right to make improvements in design and or changes in spedfications at any time without incurring any obligation to install them on units previously sold TABLE OF CONTENTS Thank you 1 Speafications 2 Machine component identification 3 Generator features 4 Introduction 4 5 ANSI safety definitions 5 Rules for safe operation 5 Installation 5 6 Load application 6 7 Pre start up preparation 7 8 Starting 8 Stopping 8 Engine care 8 Generator care 8 Troubleshooting SPECIFICATIONS Item Number 165925 Maximum Output Continuous Output Voltage Phase 15000 Watts W
3. deteriorate and result in grounding or shorting out the generating system Foreign matters such as dust dirt sand lint or abrasive materials can cause damage to the generator head and engine if allowed into its cooling system NEVER install your generator inside confined areas Inside installation can cause health hazards or death DANGER Remember exhaust fumes are deadly carbon monoxide gas and must be vented to the outside where there are no people Cooling air of sufficient amounts must be allowed to flow in and exhausted out to ensure proper cooling of the engine and generator head LOAD APPLICATION Itis important to determine the total electrical load before itis 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 witing insulation If the generator is overloaded the wres become excessively hot and cause the insulation to break down reduang its ability to resist corrosive contaminants Over time the effectiveness of the insulation is eliminated 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 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 wat
4. muffler hot exhaust manifold or engine cooling fins ALWAYS remove all oil or gasoline deposits and accumulated dirt from generator and immediate area Keep generatorhead and engine clean NEVER operate the generator under the following conditions Excessive change in engine speed slow or fast Overheating inload connecting devices Sparking orarcs from generator Loss of electrical output Damaged receptacles Engine misfire Excessive vibration Enclosed compartments or confined areas Flame or smoke Rain snow or wet conditions Operator non attendance gt ACTIONMOOUW A WARNING Check fuel system on a regular basis Look for signs of leaks deterioration chafed or spongy fuel hose loose or missing fuel hose clamps damaged fuel tank or a defective fuel shut off valve Correct any defects before operation WARNING Keep fire extinguisher dose by your generator and be familiar on how to use it Consult your local fire department for correct extinguisher type INSTALLATION OUTDOORS Choose a location where the generator will not be exposed to rain snow or direct sunlight Position the generator on secure level ground soit wil nottip or slide down a hill Place the generator so that the exhaust fumes will not be directed towards people The installation site must be free from water moisture or dust All electrical components should be protected from excessive moisture or the insulation system will
5. number 5 20R This receptade accepts NEMA plug numbers 5 15P and 5 20P Each duplex is capable of drawing 20A at 120V 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 WARNING Contact a licensed electrician to wire electrical plugs and or cordsets Improper wiring could resultin a fire or electrical shock Reference 7 Oil Drain Valve Refer to your Kohler engine manual for oil change recommendations Reference 8 Vibration Isolation Mounts The engine and generator head are mounted on rubber cylinders that absorb most of the engine vibration This feature eliminates the tendency of the machine to walk which is common in engine powered equipment Reference 9 Starting Stopping Instructions Reference 10 Wheel Kit Heavy duty wheel kit Item 165919 Reference 11 10 0 Gallon Gas Tank Large tank allows for extended run capabilities Always allow room for gasoline expansion by not filling the gas tank completely full Reference 12 Engine Key The engine key switch is located on the front of the engine Always locate this switch and be familiar with its location before operating the generator Reference 13 Choke Lever Used during cold starts Refer to the starting stopping instructions and the Kohler Command 25 engine manual for usage Reference 14 Muffler and Spark Arrestor Reference 15 Oil Filter Kohler
6. 1 3 HP 1200 a Freezer 800 b Hair Dryer 1200 Hand Drill 1 1100 Hand Diill 1 2 875 Hand Diill 3 8 500 Hand Dill 1 4 250 Hedge Trimmer 450 Home Computer 150 Impact Wrench 500 Jet Pump 800 Lawn Mower 1200 Light Bulb 100 Microwave Oven 700 Milk Cooler 1100 a Oil Burneron Furnace 300 Oil Fred Space Htr 140 000 Btu 400 Oil Fired Space Htr 85 000 Btu 225 Oil Fred 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 Pump 1 1 2 HP 2800 a Submersible Pump 1 HP 2000 a Submersible Pump 1 2 HP 1500 a Table Saw 10 2000 a Television 500 Toaster 1000 Vacuum cleaner 250 VCR 70 Water Heater 3000 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 their 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 PRE START PREPARATIONS Your generator has been thoroughly tested priorto shipment from the factory A factory test report has been included wth this manual However damage can occur during shipping so be sure to check for damaged parts or loose or missing nuts and b
7. also be used to alert against unsafe practices RULES FOR SAFE OPERATIONS Safety precautions are essential when operating this generator Respectful and cautious operation wil considerably lessen the possibilities of a personal injury This manual will warn of specific personal injury potential and these will be designated by the symbol A WARNING This generator is equipped with a grounding screw located on the generator head for your protection Always complete the grounding path from the generator to a copper pipe rod that is driven into moist earth to prevent electrical shock ALWAYS use electrical cords that are in good condition Worn bare frayed or otherwise damaged cords can cause electric shock 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 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 the spark plug or spark plug wire before working on the engine or generator to prevent acadental starting ALWAYS provide adequate ventilation Do not operate generator in any endosed or narrow space Engines consume oxygen and give off deadly carbon monoxide poisonous gas Improper ventilation will cause damage to generator and possible injury to people NEVER touch hot
8. ant the generator will not be damaged ifit 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 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 set and point of use is held FETE aminimum Current Power Maximum Extension Cord Length T Load A ca 14 16 watts Ga Ga SN E rd ae Cord Cord 10 2400 250 150 100 75 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 i 50 12000 15 d i af Not recommended CAUTION Equipment damage can result from the low voltage caused by using an extension cord wth a small wire size Use this chart to estimate the total load on your generator For Determining Generator Load Requirements Device Running Watts Air Conditioner 12 000 Btu 1700 a Battery Charger 20 Amp 500 Belt Sander 3 1000 Chain Saw 1200 Circular Saw 6 1 2 900 Coffee Maker 1000 Compressor 1 HP 2000 a Compressor 3 4 HP 1800 a Compressor 1 2 HP 1400 a Curling Iron 700 Dishwasher 1200 Edge Trimmer 500 Electric Nail Gun 1200 Electric Range one element 1500 Electric Skillet 1250 Furnace Fan
9. e automatically shuts off the engine stop switch remains in the on position The engine will not start until the oil is refilled to above the safe level INTRODUCTION Before starting your generator thoroughly study the instructions and cautions in this manual to assure you are fully acquainted with the operation of all components of this generator Proper preparation operation and maintenance wil result in operator safety best perfomance and long life of the generator For detailed engine operation and maintenance always refer to the Kohler engine owner s manual furnished with the generator North Star is constantly improving its products The specifications outlined herein are subject to change without prior notice or obligation The purchaser and or user assumes liability of any modification and or alterations on this equipment from original design and manufacture Before using the user shall determine the suitability of this product for its intended use and assumes liability therein ANSI SAFETY DEFINITIONS DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations WARNING indicates a potentially hazardous situation which if not avoided could result in a death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may resultin minor or moderate injury It may
10. ine move choke lever to half choke or to RUN position 4 Turn engine key switch located on engine to start position 5 When engine starts let key return to the ON position Move choke lever to RUN position 6 Loads may now be connected to generator STOPPING 1 Disconnect all loads to generator 2 Turn engine key switch to OFF position 3 Turn gas line valve to OFF position ENGINE CARE Refer to your Kohler Owners Manual for proper care and maintenance NOTE When changing the oil on a hot engine the oil might overshoot the oil drain hole on the generator base Use a deflector piece of cardboard or paper to direct the oil down the hole GENERATOR CARE The generator head is a two pole 3600 RPM 60 Hz brushless revolving field and synchronous type with one sealed radial roller bearing The rotor of the generator head is directly connected to the engine crank shaft and the stator is rigidly coupled to the engine casting via the generator head casting Exercising The Generator The generator should be operated every four weeks Wam the unit up by starting the engine and letting it run for 10 to 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 engine generator will also ensure that the set is operating properly should it be needed in an emergency Generator Maintenance The generator head is brush
11. less and maintenance free Any major generator service including the installation or replacement of parts should be performed only by a qualified electrical service technician USE ONLY FACTORY APPROVED REPAIR PARTS Obtain factory parts from Customer Service at 1 800 270 0810 A Bearing The bearing used in these generators isa heavy duty sealed roller bearing They require no maintenance or lubrication B 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 A 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 Fre Departments must be consulted concerning proper and safe handling procedures for gasoline NEVER connect any generator to any existing electrical system without an isolating UL approved transfer switch installed by a licensed electrician TROUBLESHOOTING Problem Engine wil not start Voltage too low Circuit breaker trips Voltage too high Generator overheating No output voltage Engine lacks power Engine shuts down during operation Possible Causes 229 TH 9 Low oil level Fouled spark p
12. lug Out of fuel Stop switch in OFF position Battery has lost its charge f Engine fuse is blown Engine speed too slow Generator is overoaded Voltage regulator out of adjustment Defective load connected to generator Defective receptade Generator overloaded Engine speed too high Voltage regulator out of adjustment Generator is overloaded Insufficient ventilation Defective load connected to generator Broken orloose wire Defective receptade Defective stator Defective rotor Defective capacitor Voltage regulator fuse has blown Generator is overloaded Dirty air filter Out of fuel Low oil level Possible Remedies a Fill crankcase to proper oil level b Clean or replace spark plug c Fill fuel tank d Place switch in ON position e Battery has low electrolyte and or needsto be charged or replaced f Replace fuse 30A Buss type fuse located near starter motor a Bring generatorto a qualified technician for adjustment b Reduce the load See Load Application section ofthis manual c Bring generator to a qualified technician for adjustment a Disconnectload b Replace receptacle c Reduce the load See Load Application section of this manual a Bring generatorto a qualified technican for adjustment b Bring generator to a qualified technican for adjustment a Reduce the load See Load Application section of this manual b Make sure there is atleas
13. ly lower voltage when the generator is loaded to its full capacity than when it is running wth 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 Load Percent of Speed Frequency Generator Generator RPM Voltage at 120V pupui Receptade 0 3750 50 3660 100 3600 625 61 0 60 0 120 120 120 Output voltage should be checked periodically to ensure continued proper operation of the generating plant and appliances lt can be checked with a portable meter Frequency can be checked by using an electric clock with a sweep second hand Timed against a wrist watch or a stop watch the clock should be correct within 2 seconds per minute All speed setting adjustments should be done by a qualified technician BEFORE STARTING 1 Make sure the generator is positioned on firm level surface 2 Check the crankcase for oil and maintain at a proper level 3 Check fuel level and fill tank 7 8 full with fresh unleaded automotive gasoline Never fill fuel tank completely to the top Always wipe up and remove any spilled gasoline 4 Make sure that the exhaust fumes are directed away from people STARTING 1 Disconnect all loads to generator 2 Turn gas line valve to ON position 3 For cold engine move choke lever to full choke position For wam eng
14. n various types and sizes of 120 volt 60 cycle electric motors under various conditions 120V 60 Hz Motors Starting Amps Hp motor Running RI type Cap type SP type 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 11 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 motor is connected to a hard starting load such as an air compressor it will require more starting current If itis connected to a lightload 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 overoading differently than the power line 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 starting winding wil bum out in a short time The generator head winding might also be damaged Running the generator underthese conditions may resultin damage to the generator stator as well as the motor windings Because the heavy surge of current is required for only an inst
15. ng Instructions 19 Gas Drain Valve 10 Wheel Kit 165919 20 Gas Cap with Gauge Figure 2 Ref 11 20 00213 3 GENERATOR FEATURES Reference 1 Air Cleaner Refer to your Kohler engine manual for air cleaner care Reference 2 Circuit Breakers This portable single phase generator has 1 60 amp A thermal magnetic 2 pole breaker 1 30 amp A thermal magnetic 2 pole breaker 1 30 amp A push to reset circuit breaker and 2 20 amp A push to reset circuit breakers Circuit breakers protect against electrical overloads Reference 3 120 240V Receptacle This receptacle is a 120 240V 60A NEMA 14 60R receptacle This receptacle accepts a NEMA plug number 14 60P which is supplied wth the generator Use this receptacle if installing a transfer switch Compatible with Gentran transfer switch item 164117 Reference 4 120 240V Twistlock Receptacle This twistlock is a 120 240V 30A NEMA L14 30R receptacle This receptacle accepts a NEMA plug number L14 30P which is supplied with the generator Reference 5 120V Twistlock Receptacle This twistlock is a 120V 30A NEMA L5 30R receptade This receptacle accepts a NEMA plug number L5 30P which is supplied with the generator Reference 6 120V Receptacle The generator hasa control panel with two duplex two receptacles in a common housing receptades Each duplexis a 120 volt V 20 amp A straight blade receptacle National Electrical Manufacturers Association NEMA
16. oil filter number 12 050 01 or equivalent Reference 16 Battery Box and Battery Battery is shipped without electrolyte Fill each battery cell to the fill line with locally purchased electrolyte sulfuric acid and water A WARNING Sulfuric acid is a corrosive poison Avoid contact with skin eyes or dothing Reference 17 Gas Line Valve The generator tank has an ON OFF valve mounted underneath the tank Always keep this valve closed when the generator is notin use Reference 18 Generator Head The electricity producing part of the generator Reference 19 Gas Drain Valve The generator is equipped with a unique feature A gas drain valve is installed to drain gasoline from the tank without disconnecting the gas line feeding the engine This valve is intended to be used to drain gas prior to extended periods of non use It is recommended that if the period of non use is longer than 30 days the gas should be drained and the engine run until all the gas is evacuated from the carburetor ALWAYS make sure this valve is closed prior to filling the gas tank Reference 20 Gas Capwith Gauge The gas cap is extra large creating a large hole for refilling and a comfortable grip You can always monitor the fuel level without removing the cap by using the fuel level indicator built into the gas cap Low Oil Shutdown The Kohler engine is protected against damage resulting from low oil level As the oil falls below the safe level the engin
17. olts If the aforementioned problems occur call Customer Service at 1 800 270 0810 GROUNDING All units must be grounded Drive a 3 4 or 1 copper pipe or rod into the ground close to the generator The pipe od must penetrate moist earth Connect an approved ground clamp to the pipe Run ano 12 Ga wire from the damp to the generator grounding screw located on the generator head Do not connect to a water pipe or a ground used by a radio system CAUTION The engine has been shipped without oil Fill the crankcase with oil before trying to start Low oil shut down prevents your generator from starting without sufficient oil OPERATING SPEED The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency The speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency The output voltage should be checked with a voltmeter to ensure the generator is working properly before 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 slight
18. t 3 feet of clearance on all sides of generator a Disconnectload b Bring generatorto a qualified technician for repair c Replace receptacle d Bring generator to a qualified technician for repair e Bring generatorto a qualified technician for repair f Bring generatorto a qualified technician for repair g Bring generatorto a qualified technician for repair a Reduce the load See Load Application section ofthis manual b Clean or replace air filter a Fill fuel tank b Fill crankcase to proper oil level
19. tage than its rating on the nameplate as the wattage is influenced by the equipment efficiency power factor and starting system NOTE If wattage is not given on equipment nameplate approximate wattage may be determined by multiplying nameplate voltage by nameplate amperage VOLTS X AMPS WATTS Example 120V X5A 600W 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 capadty 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 STARTING ELECTRIC MOTORS Electric motors require much more current amps to start than to run Some motors particularl y low cost splitphase motors are very hard to start and require 5 to 7 times more currentto start than to run Capacitor motors are easier to start and usually require 2 to 4 times as much current to start as to run Repulsion Induction motors are the easiest to start and require 1 5 to 2 5 times as much to start as to tun Most fractional motors take about the same amount of current to run them whether they are of Repulsion Induction RI Capacitor Cap or Split Phase SP type The following chart shows the approximate current required to start and ru
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