Northern Industrial Tools 15000 PPG User Manual
M165925U
ITEM NUMBER: 165925
®
Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
SERIAL NUMBER: _____________
13,500 Watt Continuous (15,000 Watt Surge) Capacity
Can be used to power individual appliances plugged directly into the generator’s outlets, or as a
back-up connection to a building’s power supply (via a professionally installed UL-approved
transfer switch.
WARNING
READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up, operate,
and maintain this generator could result in serious injury or death from carbon monoxide poisoning, electri c shock,
fire/explosion, or burns. In particular, be aware of the following hazards:
Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
• ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or
semi-enclosed spaces, including homes, basements, garages, sheds , boxes , RVs, boats or pick-up truck beds. These
spaces can trap poisonous gases, EVEN if you run a fan or open windows.
• Install carbon monoxide alarms inside nearby structures/buildin gs (bat t er y -o perat ed , or plug-in with battery backup).
Electric shock / Electrocution
• High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly
grounded. Use only UL-listed, outdoor-rated grounded extension cords of proper size.
• 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 a UL-approved transfer switch installed by a licensed
electrician. Otherwise, back feed from the generator into the power grid could kill utility workers.
• DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so
engine does not overheat. Exhaust can be extremely hot. Keep muffler at least 7’ from all combustible objects.
• All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station – use
approved container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
• ALWAYS keep a fire extinguisher rated “ABC” nearby.
CO Poisoning
Fire / Explosion
STOP!
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power load Planning & Management” section
of this manual to determine your power load requirements and then compare to the generator’s rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking
& Delivery Inspection” section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to
your building’s electrical system. See the “Installation/Initial Set-Up” section for more information about this
requirement.
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
Hazard Signal Word Definitions
2
Table of Contents
Hazard Signal Word Definitions .................................................................................................2
About Your Generator .................................................................................................................4
Specifications .................................................................................................................................6
Safety Label Locations..................................................................................................................7
Machine Component Identification.............................................................................................8
Power Load Planning & Management........................................................................................10
Installation / Initial Set-Up:
1. Unpacking & Delivery Inspection..........................................................................................12
2. Planning the Power Load........................................................................................................12
3. Set-up as a PORTABLE or BUILDING BACK-UP Power Source ......................................13
4. Selecting a Suitable Site.........................................................................................................16
5. Grounding the Generator........................................................................................................18
6. Battery Installation .................................................................................................................19
Operation:
1. General Safety Rules for Operation .......................................................................................20
2. Preparing for Operation..........................................................................................................23
3. Starting the Engine.................................................................................................................27
4. Checking Generator Output....................................................................................................28
5. Connecting Loads...................................................................................................................29
6. Stopping the Engine ...............................................................................................................29
7. Storage & Exercise.................................................................................................................30
Maintenance & Repair..................................................................................................................32
Troubleshooting.............................................................................................................................34
Summary of Important Safety Information for Operation.......................................................35
Generator Exploded View............................................................................................................39
Wiring Diagram.............................................................................................................................41
Generator Head Exploded View..................................................................................................43
Limited Warranty.........................................................................................................................45
3
About Your Generator
This engine-driven, portable generator is designed to provide up to 15,000 Watts of
electrical power (13,500 watts continuous, 15,000 watts surge).
It can supply power:
1. As a portable power source. You can plug appliances directly into the generator’s
2. As a back up, standby power source for a building. A licensed electrician can connect
You must select a generator adequately sized for your power needs. You need to
determine the power needs of all the appliances/tools you wish to power at the same time and
choose a generator rated to provide at least that power level. See the “Power Load Planning &
Management” section of this manual to determine your specific power load requirements and
then compare them to this generator’s rated capacity. You must not overload the generator.
Overloading will cause damage to the generator and attached electrical devices, and may also
result in fire.
Be sure to read about site selection and grounding requirements for running this
generator. More detailed information can be found in the “Installation & Initial Set-up, Steps
5 & 6” of this manual.
This generator is too heavy for one person to lift without mechanical assistance. An
optional wheel kit is available from NorthStar and is recommended if you will be moving the
generator unassisted. Other optional accessories available from NorthStar include a vinyl
cover for storage, UL-approved transfer switches, and extension cords.
Contact NorthStar Product Support at 1-800-270-0810 with questions about optional
accessories or to order.
Thank you for purchasing your NorthStar portable generator!
About Your Generator
electrical outlets.
the generator to your building’s electrical system via the installation of an UL-approved
transfer switch. (See the “Installation & Initial Set-up” section of this manual to learn
more about specific requirements and precautions relating to wiring the generator to your
building’s electrical system.)
Read this Manual
Improper use or maintenance of this generator can result in serious injury or death from
carbon monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.
Read this manual completely before using the generator and follow all instructions and
safety rules.
You must follow all instructions and safety precautions presented throughout this manual. A
summary of important safety information can be found at the end of the manual. Keep this
manual for reference and review.
Proper preparation, operation, and maintenance will result in operator safety, as well as best
performance and long life of the generator. For detailed engine operation and maintenance
information, always refer to the engine Owner’s Manual furnished with the generator.
4
WARNING
About Your Generator (cont’d)
NorthStar is constantly improving its products. The specifications outlined herein are subject
to change without prior notice or obligation. The purchaser and/or user shall assume liability
for any modification and/or alterations of 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.
Contact NorthStar Product Support at 1-800-270-0810 for any questions about the
appropriate use of this generator.
Warranty Registration
Please fill out and submit the warranty registration card so that we have your contact
information for any future product literature or replacement parts you may need.
ATTENTION:
All Rental Companies and Private Owners who loan this
equipment to others!
All persons to whom you rent/loan this generator must have access to and read this manual.
Keep this owner’s manual with the generator at all times and advise all persons who will
operate the machine to read it. You must also provide personal instruction on how to safely
operate the generator and remain available to answer any questions a renter/borrower might
have.
5
Specifications
SPECIFICATIONS
Item Number #165925
Maximum Output 15000 Watts (W)
Continuous Output 13500 Watts (W)
Voltage 120/240 Volt (V)
Phase Single phase (4-wire)
Frequency 56.5 - 63.3 Hertz (Hz)
Power Factor 1.0 p.f.
Total Harmonic Distortion less than 8%
Engine 25 HP Kohler Command
Engine Speed 3390 - 3798 RPM
Fuel Type Unleaded gasoline
Fuel Capacity 10 gallons (38.0 L)
Oil Capacity 2.1 US quarts with filter
Starting Method Electric start
120V Receptacles 2 - 20 Amp (A) duplex (NEMA 5-20R)
30 Amp (A) locking device (NEMA L5-30R)
120/240V Receptacles 30 Amp (A) locking device (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) thermal, push to reset
Battery (not included) 12 Volt, Group size U1
330 CCA, 30 amp-hr
Dimensions
Length 35.75” (90.8 cm)
Width 24.25” (61.6 cm)
Height 26.25” (66.7 cm)
Dry Weight 425 lb (193 kg)
Gross Weight 495 lb (225 kg)
6
Safety Label Locations
BATTERIES:
1) contain caustic acid, 2) emit explosive gases, 3) can cause ele ctric shock
ALWAYS use eye protection. Caus tic acid and explosive gases can cause blindness or severe burns.
NO smoking, sparks, or flames.
NEVER touch both battery terminals at the same time with you r hand or any non-insulated tools.
FLUSH immediately with water if battery acid co ntacts eyes, skin, o r clothing.
CONNECT cables in correct sequence: FIRST RED to POSITIV E terminal, then BLACK to NEGATIVE
terminal. When disconnecting, DISCONNECT BLACK cable first, then RED.
NEVER charge a visibly damaged or frozen battery. ALWAYS read and follow charger instructions.
IF GENERATOR IS TO BE STORED LONGER THAN 2 MONTHS,
charge battery with a trickle charger that is rated for 3 amps maximum.
©2007 NT+E 1-800-270-0810
Always make sure safety labels are in place and in good condition. If a safety label
is missing or not legible, order new labels or unsafe operation could result.
To order replacement safety labels, call NorthStar Product Support at 1-800-270-
0810.
WARNING - BATTERY HAZARDS
ATTENTION
A changed battery ensures reliable engine starting.
PN 779396
On-Product Warning Labels
Part numbers Description
779400 Warning
779396 Battery Warning
7
Machine Component Identification - Item #165925U
Figure 1 (Ref. 1-10)
Ref. Description Ref. Description
1 Air Cleaner 11 10.0 Gallon Gas Tank
2 Circuit Breakers 12 Engine Key Switch
3 120/240V, 60A Receptacle 13 Choke Lever
4 120/240V, 30A Locking Receptacle 14 Muffler & Spark Arrestor
5 120V, 30A Locking Receptacle 15 Oil Filter
6 120V, 20A Duplex Receptacle 16 Battery Box
7 Oil Drain Valve 17 Gas Line Valve
8 Vibration Isolation Mount 18 Generator Head
9 Optional Wheel Kit (#165919) 19 Gas Cap with Gauge
10 Oil Filler Cap (not shown)
Figure 2 (Ref. 11-19)
8
Machine Component Identification - Item #165925U
REFERENCE GUIDE
Reference 1 – Air Cleaner
Reference 2 – Circuit Breakers
Reference 3 – 120/240V, 60A
Receptacle
Reference 4 – 120/240V, 30A
Locking Receptacle
Reference 5 – 120V, 30A Locking
Receptacle
Reference 6 – 120V, 20A Duplex
Receptacle
Reference 7 – Oil Drain Valve
Reference 8 – Vibration Isolation
Mount
Reference 9 – Optional Wheel Kit
Reference 10 – Oil Filler Cap
Reference 11 – 10.0 Gallon Gas
Tank
Reference 12 – Engine Key Switch
Reference 13 – Choke Lever
Reference 14 – Muffler and Spark
Arrestor
Reference 15 – Oil Filter
Reference 16 – Battery Box
Reference 17 – Fuel Line Valve
Reference 18 – Generator Head
Reference 19 – Gas Cap with Gauge
Refer to your Kohler engine manual for air cleaner care.
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.
This receptacle is a 120/240V 60A NEMA 14-60R
receptacle. This receptacle accepts a NEMA plug number
14-60P. Use this receptacle if installing a transfer switch.
This locking device is a 120/240V 30A NEMA L14-30R
receptacle. This receptacle accepts a NEMA plug number
L14-30P.
This locking device is a 120V 30A NEMA L5-30R
receptacle. This receptacle accepts a NEMA plug number
L5-30P.
The generator has a control panel with two duplex (two
receptacles in a common housing) receptacles. Each
duplex is a 120-volt (V) 20 amp (A) straight blade
receptacle, National Electrical Manufacturer’s Association
(NEMA) number 5-20R. This receptacle accepts NEMA
plug numbers 5-15P and 5-20P. Each duplex is capable of
drawing 20A at 120V.
To drain oil, rotate valve. Refer to your Kohler engine
manual for oil change recommendations.
The engine and generator head is 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.
Optional heavy-duty wheel kit (Item # 165919).
Refer to your Kohler engine manual.
Large tank allows for extended run capabilities. Always
allow room for gasoline expansion by not filling the gas
tank completely full.
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.
Used during cold starts. Refer to the starting/stopping
instructions and the Kohler engine manual for usage.
Refer to your Kohler engine manual for maintenance.
Kohler oil filter number 12-050-01 or equivalent.
The battery box provides protection for the battery, and will
accept the standard lawn tractor size battery (Group U1-7).
The engine requires a 12 volt battery. See battery section
for sizing.
The generator tank has an ON-OFF valve mounted
underneath the tank. Always keep this valve closed when
the generator is not in use.
The electricity producing part of the generator.
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.
9
Power Load Planning & Management
NEVER exceed the rated wattage capacity of your generator.
WARNING
OVERLOADING may cause SERIOUS DAMAGE to the generator and
attached electrical devices, and may result in fire.
Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge)
wattage of the devices you will be powering. Before using your generator, determine the running
and starting wattage requirements of all the electrical devices you will be powering simultaneously.
The sum of the running and starting wattages of the devices being powered must not exceed the
continuous output rating of your generator. (The continuous output rating of your generator is listed
in the “Specifications” section of this manual.) Note that:
• Devices without electric motors such as light bulbs, radios, and televisions have the same
running and starting wattage.
• Devices with electric motors such as refrigerators, compressors, and hand tools typically
require a starting wattage that is 3 to 5 times greater than the running wattage.
The running and starting wattage requirements are often listed on a device’s nameplate. If wattage
is not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate
voltage by nameplate amperage, Watts = Volts X Amps.
Example conversion to watts:
120 Volts X 5 Amps = 600 Watts
If only the running voltage is given on the nameplate for a device with an electric motor, the starting
wattage can be approximated to be three to five times the running wattage.
Estimates for the running wattage requirements for common devices are listed in Table 1 below.
Guidance for starting wattages is provided in the table’s footnotes.
Table 1
Device
Air conditioner (12.000 BTU) 1700 (a,b) Jet pump 800 (a)
Battery charger (20 Amp) 500 Lawn mower 1200
Belt sander (3”) 1000 Light bulb (100 Watt) 100
Chain saw 1200 Microwave oven 700
Circular saw (6½”) 2000 (a,b) Milk cooler 1100 (a)
Coffee maker 1800 (a,b) Oil burner on furnace 300
Compressor (1 HP) 1400 (a,b) Oil-fired space heater (140,000 Btu) 400
Compressor (3/4 HP) 1800 (a) Oil-fired space heater (85,000 Btu) 225
Compressor (1/2 HP) 1400 (a) Oil-fired space heater (30,000 Btu) 150
Curling iron 700 Oven 4500
Dishwasher 1200 Paint sprayer, Airless (1/3 HP) 600 (a)
Edge trimmer 500 Paint sprayer, Airless (handheld) 150
Electric nail gun 1200 Radio 200
Running
Watts Device
Running
Watts
10
Power Load Planning & Management (cont’d)
Device
Electric range (1 element) 1500 Refrigerator 600 (b)
Electric skillet 1250 Slow cooker 200
Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a)
Freezer 800 (b) Submersible pump (1 HP) 2000 (a)
Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a)
Hand drill (1”) 1100 Sump pump 600 (a)
Hand drill (1/2”) 875 Table saw 2000 (a)
Hand drill (3/8”) 500 Television 500
Hand drill (1/4”) 250 Toaster 1000
Hedge trimmer 450 Vacuum cleaner 250
Home computer 150 VCR 70
Impact wrench 500 Water Heater 3000
Weed trimmer 500
(a) Hard-starting motors require 3-5 times the rated running watts
(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to
determine maximum wattage
Running
Watts Device
Running
Watts
To calculate the running and starting wattage requirements for the devices you will be
powering, follow these steps:
1. Make a list of all electrical devices you will be powering at the same time with the generator.
2. List the greater of
the running or starting wattage next to each device as obtained from the
devices’ nameplate or Table 1. If only the running wattage for a device with an electric
motor is known, the starting wattage can be estimated to be at least 3 times the running
wattage.
3. Add the wattages for all devices on your list. This total must be lower than the continuous
output rating of your generator.
Example:
Device to be Powered
Starting/Running Wattage
Greater of
Light Bulb 75 W
Refrigerator – 18 Cu. Ft. 1600 W
Microwave 700 W
Window AC 1800 W
Sump pump (1/3 hp) 2100 W
Total 6275W
In this example, the generator must have a continuous output of at least 6275 W in order to
power all of the devices simultaneously.
STAGGERING LOADS
You can increase the number of devices your generator can power by staggering the load on the
generator. For example, you could alternately power your refrigerator and air conditioner for
limited periods of time -- powering only one of the devices at a time and never powering both at the
same time.
11
Installation / Initial Set-Up
There are a number of important steps required to set up your generator for initial use. These
steps are:
Each of these steps is discussed in detail below:
You should inspect the generator immediately after you receive delivery.
• If you have missing components, contact Product Support at 1-800-270-0810.
• If you have damaged components, contact the freight company that delivered the unit and file
Plan your power load so that you do not exceed the generator’s rated capacity.
See the “Power Load Planning & Management” section of this manual to review how to plan and
manage power loads for the generator.
Steps for Installation / Initial Set-Up
1. Unpacking & delivery inspection.
2. Planning the power load to stay within the generator’s rated
capacity.
3. Setting up generator for the type of power generation you need:
a. portable power source, or
b. connected to a building as a back-up power source.
4. Selecting a site for using the generator.
5. Grounding.
6. Battery installation (electric start models only).
1. Unpacking & Delivery Inspection
See the “Machine Component Identification” section of this manual for a
diagram of the generator and its components.
a claim.
2. Planning the Power Load
12
Installation / Initial Set-Up
3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source
This generator is designed to provide up to 15,000W of electrical power. It can supply electricity in
two ways:
1. As a back-up, standby power source for a building. For this application, you must arrange
for a licensed electrician to connect the generator to your building’s electrical system via the
installation of an UL-approved transfer switch. The transfer switch must be installed in
accordance with building electrical code and guidelines supplied by your power company.
2. As a portable power source. You can plug appliances or tools directly into the generator’s
electrical outlets.
Specific requirements for each are given below.
Note: Regardless of whether you use your generator as a back-up power source connected to a building
or as a portable power source, you must not overload the generator. Overloading may cause serious
damage to the generator and attached electrical devices.
Using as a
Back-up Power
Source for a
Building
Contact a licensed electrician to install a UL-approved transfer switch if
you want to use your generator as a back-up power source for a building.
What does a transfer switch do? It:
a) Safely connects the generator to your building’s electrical system by
isolating your generator from your utility company’s power lines,
AND
b) Connects your generator to a critical subset of your building’s circuits
that are needed for emergency power needs.
If your generator will be connected to your building’s electrical system, it
MUST ALWAYS be isolated from the utility power grid with a UL-approved
transfer switch installed by a licensed electrician in compliance with all
applicable building and electrical codes, and in accordance with guidelines
supplied by your power company.
DANGER:
A transfer switch must be installed in order to isolate your
generator from the utility power grid. If your generator is NOT
properly isolated from the utility system, serious hazards will
arise:
♦ When your generator is running, it’s output will back feed into
the utility power line and transformer that are normally used to
provide you with power. The transformer will step up the
current to the normal line voltage. An unsuspecting utility line
worker working on what he thinks is a deactivated line could
be electrocuted.
♦ If your generator is connected (running or not) when utility
power is restored, your generator will be destroyed. It could
also explode or cause fire.
In addition to isolating your generator from the utility system, the transfer
switch connects your generator to a limited set of circuits in your building
that have been chosen as critical to operate during a power outage.
13
Using as a
R
R
R
R
Portable Power
Source
Installation / Initial Set-Up
The generator cannot power your entire home -- you must work with the
installing electrician to determine which devices/appliances you wish to
power during an outage. The electrician can help you determine which
circuits and devices can be powered simultaneously without overloading the
generator.
(See the previous section of this manual entitled “Power Load Planning &
Management” for more information on load application and selection.)
When using the generator as a portable power source, you can plug
electric devices and appliances directly into the generator’s electrical
outlets.
There are four different kinds of electrical outlets on the generator:
1. One 120/240 Volt, 60 Amp straight-blade receptacle (NEMA 14-60R
receptacle compatible with NEMA 14-60P mating plug)
2. One 120/240 Volt, 30 Amp locking receptacle (NEMA L14-30R
locking receptacle compatible with L14-30P mating plug)
3. One 120 Volt, 30 Amp locking receptacle (NEMA L5-30R receptacle
compatible with NEMA L5-30P mating plug)
4. Two 120 Volt, 20 Amp duplex straight-blade receptacles (NEMA 520R duplex receptacles compatible with NEMA 5-20P or 5-15P
mating plugs).
120V
15000 PPG
120V
PRO SERIES
GENERATOR
120V
(2)
NEMA
5-20
Duplex
120V-20A
120V-30A
Please read your owner's manual before operating, if you do not have a manual or have questions, call customer service at 1-800-270-0810
NEMA
L5-30
NEMA
L14-30
(See more technical detail about these receptacles and their associated circuit
breakers in the “Machine Component Identification” section of this manual.)
CIRCUIT BREAKERS
120/240V-30A
20A
20A
30A
120/240V-30A
120/240V-60A
120/240V-60A
NEMA
14-60
14
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