MODEL 15000 PPG, ITEM #165925
Professional Portable Generator
M165925A
P r o v e n P e r f o r m a n c e
OWNER’S MANUAL
00211
Shown with Wheel Kit (Item # 165919)
Any Questions, Comments, or Problems?
Call Customer Service at 1-800-270-0810
Hours: Monday - Friday 7:30 AM to 5:30 PM CST
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SPECIFICATIONS
Item Number
Maximum Output
Continuous Output
Voltage
#165925
15000 Watts (W)
13500 Watts (W)
120/240 Volt (V)
Phase
Frequency
Single phase (4-wire)
60.0-62.5 Hertz (Hz)
Power Factor
Total Harmonic Distortion
Engine
1.0 p.f.
less than 8%
25 HP Kohler Command
3600-3750 RPM
Engine Speed
Fuel Type
Fuel Capacity
Oil Capacity
Unleaded gasoline
10 gallons (38.0 L)
2.1 US quarts with filter
Starting Method
Electric start
120V Receptacles
2 - 20 Amp (A) duplex (NEMA 5-20R)
30 Amp (A) twistlock (NEMA L5-30R)
30 Amp (A) twistlock (NEMA L14-30R)
60 Amp (A) straight blade (NEMA 14-60R)
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
12V DC 380 cca, shipped dry, add electrolyte to fill
line on each cell.
120/240V Receptacles
Circuit Breakers
Battery
Dimensions
Length
Width
Height
Dry Weight
Gross Weight
35.75” (90.8 cm)
24.25” (61.6 cm)
26.25” (66.7 cm)
425 lb (193 kg)
495 lb (225 kg)
2
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MACHINE COMPONENT IDENTIFICATION
Figure 1 (Ref. 1-10)
00212
Ref. Description
Ref. Description
1
2
Air Cleaner
Circuit Breakers
11
12
13
14
15
16
17
18
19
20
10.0 Gallon Gas Tank
Engine Key
Choke
Muffler & Spark Arrestor
3
4
5
6
120/240V, 60A Receptacle
120/240V, 30A Twistlock Rec.
120V, 30A Twistlock Rec.
120V, 20A Duplex Rec.
Oil Drain Valve
Oil Filter
Battery Box & Battery
Gas Line Valve
Generator Head
Gas Drain Valve
Gas Cap with Gauge
7
8
9
10
Vibration Isolation Mount
Starting/Stopping Instructions
Wheel Kit (#165919)
Figure 2 (Ref. 11-20)
00213
3
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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 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).
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.
WARNING Sulfuric acid is a corrosive
Reference 3 - 120/240V Receptacle.
This
poison. Avoid contact with skin, eyes or clothing.
Reference 17 - Gas Line Valve. The generator
tank has an ON-OFF valve mounted underneath the
receptacle is a 120/240V 60A NEMA 14-60R
receptacle. This receptacle accepts a NEMA plug
number 14-60P, which is supplied with the generator.
Use this receptacle if installing a transfer switch.
Compatible with Gentran transfer switch, item
#164117.
tank.
Always keep this valve closed when the
generator is not in use.
Reference 18 - Generator Head. The electricity
producing part of the generator.
Reference 4 - 120/240V Twistlock Receptacle.
This twistlock is a 120/240V 30A NEMA L14-30R
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 Cap with 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.
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 receptacle.
This receptacle accepts a NEMA plug number L5-30P,
which is supplied with the generator.
Reference 6 - 120V Receptacle. 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.
Low Oil Shutdown.
The Kohler engine is
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.
protected against damage resulting from low oil level.
As the oil falls below the safe level, the engine
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.
WARNINGContact a licensed electrician
to wire electrical plugs and/or cordsets. Improper
wiring could result in a fire or electrical shock.
INTRODUCTION
Reference 7 - Oil Drain Valve. Refer to your
Kohler
recommendations.
engine
manual
for
oil
change
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 will result in operator
safety, best performance 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.
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).
North Star is constantly improving its products.
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.
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.
4
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NEVER touch hot muffler, hot exhaust manifold or
engine cooling fins.
ANSI SAFETY DEFINITIONS
ALWAYS remove all oil or gasoline deposits and
accumulated dirt from generator and immediate area.
Keep generator head and engine clean.
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.
NEVER operate the generator under the following
conditions:
A. Excessive change in engine speed, slow or
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in a
death or seri ous i nj ury.
fast.
B. Overheating in load connecting devices.
C. Sparking or arcs from generator.
D. Loss of electrical output.
E. Damaged receptacles.
F. Engine misfire.
G. Excessive vibration.
CAUTION indicates a potentially hazardous
situation, which if not avoided, may result in minor or
moderate injury. It may also be used to alert against
unsafe practices.
H. Enclosed compartments or confined areas.
I. Flame or smoke.
J. Rain, snow or wet conditions.
K. Operator non-attendance.
RULES FOR SAFE OPERATIONS
Safety precautions are essential when operating
this generator. Respectful and cautious operation will
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:
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 close
by your generator and be familiar on how to use it.
Consult your local fire department for correct
extinguisher type.
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.
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 so it will not tip 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 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.
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 accidental starting.
ALWAYS provide adequate ventilation. Do not
operate generator in any enclosed 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.
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.
5
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Starting Amps
RI type Cap type SP type
120V, 60 Hz Motors
Hp motor Running
Watts
LOAD APPLICATION
It is important to determine the total electrical 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 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 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
1/6
1/4
1/3
1/2
1
1 1/2
2
525
700
875
1175
1925
2400
2900
4075
6750
7-11
9-15
9-18
12-23
14-29
20-40
32-64
40-80
48-96
68-136
112-224
16-22
22-32
26-35
NA
NA
NA
NA
NA
NA
11-18
15-25
24-40
30-50
36-60
51-85
84-140
3
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 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 will burn out in a
short time. The generator head winding might also be
damaged.
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 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.
Running the generator under these conditions may
result in damage to the generator stator as well as the
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.
Always allow the generator to reach operating
speed before a load is applied.
EXTENSION CORDS
STARTING ELECTRIC MOTORS
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
to a minimum.
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 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 run.
Current/Power Maximum Extension Cord Length
Amps
Load
#10
#12
#14
#16
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 run various
types and sizes of 120 volt 60 cycle electric motors
under various conditions.
at
240V
(watts)
Ga.
Cord
250’
125’
60’
Ga.
Cord
Ga.
Cord
Ga.
Cord
75’
25’
10’
*
10
20
30
40
50
2400
4800
7200
9600
12000
150’
75’
35’
15’
*
100’
50’
25’
10’
*
30’
15’
*
*Not recommended
CAUTION: Equipment damage can result from the
low voltage caused by using an extension cord with a
sm all wi re si ze.
6
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Use this chart to estimate the total load on your
generator.
NOTE: For extremely hard to start loads such as
air conditioners and air compressors, consult the
equipment dealer to determine the maximum wattage.
For Determining Generator Load Requirements
Device
Running Watts
1700 (a)
500
Air Conditioner (12,000 Btu)
Battery Charger (20 Amp)
Belt Sander (3”)
PRE-START PREPARATIONS
1000
Your generator has been thoroughly tested prior to
shipment from the factory. A factory test report has
been included with this manual. However, damage
can occur during shipping, so be sure to check for
damaged parts or loose or missing nuts and bolts. If
the aforementioned problems occur, call Customer
Service at 1-800-270-0810.
Chain Saw
Circular Saw (6-1/2”)
Coffee Maker
Compressor (1 HP)
Compressor (3/4 HP)
Compressor (1/2 HP)
Curling Iron
1200
900
1000
2000 (a)
1800 (a)
1400 (a)
700
Dishwasher
Edge Trimmer
Electric Nail Gun
Electric Range (one element)
Electric Skillet
Furnace Fan (1/3 HP)
Freezer
1200
500
1200
1500
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/rod must penetrate moist
earth. Connect an approved ground clamp to the pipe.
Run a no. 12 Ga. wire from the clamp 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.
1250
1200 (a)
800 (b)
1200
Hair Dryer
Hand Drill (1”)
1100
Hand Drill (1/2”)
Hand Drill (3/8”)
Hand Drill (1/4”)
Hedge Trimmer
Home Computer
Impact Wrench
Jet Pump
875
500
250
450
150
500
800
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
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
1200
100
700
1100 (a)
300
400
225
150
4500
600 (a)
150
200
600 (b)
200
2800 (a)
2000 (a)
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 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.
Refrigerator
Slow Cooker
Submersible Pump (1-1/2 HP)
Submersible Pump (1 HP)
Submersible Pump (1/2 HP)
Table Saw (10”)
Television
Toaster
Vacuum cleaner
VCR
1500 (a)
2000 (a)
500
1000
250
70
Water Heater
Weed Trimmer
3000
500
Load
Output
Frequency
Percent of
Generator
Output
0 %
50 %
100 %
Speed
(RPM)
Generator
Voltage at 120V
Receptacle
(Hz)
(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.
3750
3660
3600
62.5
61.0
60.0
120
120
120
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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. Warm 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.
Output voltage should be checked periodically to
ensure continued proper operation of the generating
plant 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 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.
Generator Maintenance - The generator head is
brushless and maintenance free. Any major generator
service including the installation or replacement of
parts should be performed only by a qualified electrical
BEFORE STARTING
1. Make sure the generator is positioned on firm
l evel 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.
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
is a 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.
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 warm engine, 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.
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 gasoline. NEVER connect any
generator to any existing electrical system without an
isolating, UL approved transfer switch, installed by a
licensed electrician.
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 Owner’s 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
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TROUBLESHOOTING
Problem
Possible Causes
Possible Remedies
Engine will not start.
a) Low oil level.
b) Fouled spark plug.
c) Out of fuel.
a) Fill crankcase to proper oil level.
b) Clean or replace spark plug.
c) Fill fuel tank.
d) Stop switch in OFF position.
e) Battery has lost its charge.
d) Place switch in ON position.
e) Battery has low electrolyte and/or
needs to be charged or replaced.
f) Replace fuse. 30A Buss type fuse,
located near starter motor.
f) Engine fuse is blown.
Voltage too low.
a) Engine speed too slow.
a) Bring generator to a qualified
technician for adjustment.
b) Generator is overloaded.
c) Voltage regulator out of adjustment.
b) Reduce the load. (See Load
Application section of this manual.)
c) Bring generator to a qualified
technician for adjustment.
Circuit breaker trips.
Voltage too high.
a) Defective load connected to generator.
b) Defective receptacle.
c) Generator overloaded.
a) Disconnect load.
b) Replace receptacle.
c) Reduce the load. (See Load
Application section of this manual.)
a) Bring generator to a qualified
technician for adjustment.
a) Engine speed too high.
b) Voltage regulator out of adjustment.
b) Bring generator to a qualified
technician for adjustment.
Generator overheating. a) Generator is overloaded.
b) Insufficient ventilation.
a) Reduce the load. (See Load
Application section of this manual.)
b) Make sure there is at least 3 feet of
clearance on all sides of generator.
a) Disconnect load.
No output voltage.
a) Defective load connected to generator.
b) Broken or loose wire.
b) Bring generator to a qualified
technician for repair.
c) Defective receptacle.
d) Defective stator.
c) Replace receptacle.
d) Bring generator to a qualified
technician for repair.
e) Bring generator to a qualified
technician for repair.
e) Defective rotor.
f) Defective capacitor.
f) Bring generator to a qualified
technician for repair.
g) Bring generator to a qualified
technician for repair.
a) Reduce the load. (See Load
Application section of this manual.)
b) Clean or replace air filter.
a) Fill fuel tank.
g) Voltage regulator fuse has blown.
a) Generator is overloaded.
Engine lacks power.
b) Dirty air filter.
a) Out of fuel.
b) Low oil level.
Engine shuts down
during operation.
b) Fill crankcase to proper oil level.
9
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