Northern Industrial Tools 157494 User's Manual
Contents
1. 1 25 4045 JjFulCap 1 1 26 777319 FuelTank 4Galon 27 2263 HoseClamp 1 2 1 1 4 NPT x 1 4 Hose Barb 3 29 171410 HoseClamp1 4 31 31976 1 4 FuelTankFitng 1 32 306401 Rubber Seal Fuel Tank CT Large Grommet 34 82125 5 8 11HexNut 2 35 82126 58 I1HexJjJamnNut __ 2 1 18 5 48 305208 t 2 Tee PlatedSteel _ 1 49 779228 jHeaingCol 1 50 38398 InsulaionCap 1 52 35331 Lid HeatExchanger 1 53 305410 Decal Caution Hot 1 Tri 3 WI CI I NI _ 43 _ se al 9 40 43 46 47 19 gi cile p405 JSMOd NYO ng ma 91IV ONIMIM TOYXLNOO 20 BURNER MOTOR CORD ORN ORANGE NEUTRAL 120 VOLT GROUND SREEN 03 WHITE P 1 FLOW THERMO SWITCH STAT 2 3 BLUE HEAT SWITCH IGNITOR fig013882. 12 13 15 16 Long Term Storage Machine Component Identification Troubleshooting Guide Installation Instructions 6 9 Parts Breakdowns 18 19 Operation Instructions 10 11 Wiring Diagrams 20 21 Important Safety Instructions WARNING Risk of Injection or Injury to Persons Do not direct discharge stream at persons Do not use a hose if exterior damage is evident Risk of explosion Do not spray flammable liquids Do not operate in a flammable environment CAUTION Risk of Asphyxiation Exhaust fumes are deadly For outdoor use only Avoid inhaling exhaust fumes Risk of fire Do not add fuel when the product is operating or hot Gun kicks back Hold with both hands To reduce the risk of injury read operating instructions carefully before use WARNING When using this product basic precautions should always be followed including the following 1 Read all the instructions before using the product wa 2 Make sure that your existing hose gun and all accessories are rated for high temperatures and the appropriate pressure 3 To reduce the risk of injury close supervision is necessary when the product is used near children Do not allow irresponsible use by children Always stop the product and bleed pressures before leaving unattended disconnecting hoses or servicing 4 Know how to stop the product and bleed pressures quickly Be thoroughly familiar with the controls 5 Stay alert watch what y
3. 4 Turn the air band half way back to the black smoke position previously noted Tighten the locking Screw 5 Fine tune the burner air by loosening the shutter lock screw and turning the shutter until the exhaust is cleanest Tighten the shutter lock screw Shutter q E UU 9 CN shutter gt 9 e j Lock Screw CAUTION If white smoke appears from the burner exhaust vent during start up or operation discontinue use and readjust air bands NOTE If a flue is installed have a professional serviceman adjust your burner for a 1 or 2 smoke spot on the Bacharach scale Existing Gun Operating Instructions Follow these instructions every time you use the water heater 1 Pre Operation M A Position the machine for easy access to all controls MI B Position the machine on a solid surface with less than a three degree slope and so it is protected from external damage MI Position the machine so that ambient lighting is sufficient for the surface you are cleaning to be seen with ease Use artificial light if needed M D Check hoses fittings and fuel connections for signs of wear cracks and looseness and replace as required E Read entire manual especially the important safety instructions listed on page 2 Il Check Your Water Supply A Make sure the water supply is clea
4. under Maintenance Instructions Safety Relief Valve Sprays Water Causes Solutions Pressure Washer Burner Control Problem Call Customer Service Poor Or No Detergent Suppl Soap control knob set too low Adjust soap control knob Inadequate detergent supply Refill detergent container Make sure chemical strainer is fully submerged High pressure hose too long Use less hose Move machine closer to the work Chemical strainer or injector clogged Clean the strainer and injector Always start with a clean detergent container Run clean water through the injector after each use Any Questions Comments Problems or Parts Orders In the United States In the United Kingdom NorthStar Customer Service Call 02392639752 Call 1 800 270 0810 Northern Tool and Equipment Co UK Ltd Hours Monday Friday 7 00 AM to 5 30 PM Unit 2 Keel Close Saturday 7 30 AM 11 30 AM Central Time Portsmouth Hants PO3 5QD England 17 157494H 157494 Parts Breakdown 18 157494H QTY 1 7 10 11 12 14 3826 j DecalShet 1 1 15 35894 BurnerCord _ 1 1 1 16 38482 HeatShield j 1 17 305180 Switch 120VLamp 1 18 305422 Adjustable Thermostat 19 37525 JjRightHande 1 20 30747 Handle Grip j 2 21 37532 Decal ControlPanel 1 22 23 30754 jLleatherWasher _ C 4 24 37524 LeftHande _
5. FF 16 NEVER attempt to immediately run or re light the burner if it doesn t ignite the first time Unburned oil or gas may have accumulated causing potential explosion or fire hazard 17 Always make sure all switches and controls are in the OFF position prior to plugging in the electrical cord Do no stand in water while plugging and unplugging electrical cord 18 This product is provided with a ground fault circuit interrupter built into the power cord plug II replacement of the plug or cord is needed use only identical replacement parts Failure to do so will void all warranties SAVE THESE INSTRUCTIONS Grounding Instructions This product must be grounded If it should malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the risk of electrical shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances DANGER Improper connection of the equipment grounding conductor can result in a risk of electrocution Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded Do not modify the plug provided with the product If it will not fit the outlet have a proper outlet installed by a qualified electrician Do not use any type adapter with this pro
6. M157494H ITEM NUMBER 1574994 SERIAL NUMBER Volts Amp Ph PSI GPM Max Discharge Temperature Si 24 e Proven Performance 2 K BAR ci iii MN 55021 Installation Operation and Maintenance Manual INDUSTRIAL WATER HEATER Upgrades cold water pressure washers into hot water steam cleaners To the Owner Thank you for purchasing a NorthStar water heater Your machine is designed for long life dependability and the top performance you demand Take time now to read through this manual so you better understand the machine s operation maintenance and safety precautions Everyone who operates this machine must read and understand this manual The time you take now will prolong your machine s life and prepare you for its safe operation Enjoy the exceptional performance of your NorthStar water heater the industry leader The manufacturer reserves the right to make improvements in design and or changes in specifications at any time without incurring any obligation to install them on units previously sold Read and understand all manuals before operatin Any Questions Comments Problems or Parts Orders In the United States In the United Kingdom NorthStar Customer Service Call 02392639752 Call 1 800 270 0810 Northern Tool and Equipment Co UK Ltd Hours Monday Friday 7 00 AM to 5 30 PM Unit 2 Keel Close Saturday 7 30 AM 11 30 AM Central Time Portsmouth Hants PO3 5QD England
7. NorthStar pressure washer chemicals or chemicals specifically form ulated for pressure washers and make sure that the coil is flushed completely with clean water after chemical use 3 Spray detergent onto the surface and allow it to soak Chemicals need time dwell time to work properly Follow the chemical manufacturer s recommendations for dwell time Hold the lance with two hands Have a sturdy stance Point lance at dirty surface and squeeze trigger Wash from the bottom to the top using side to side motions This washes away heavy dirt and allows the detergent to soak as you work toward the top 7 Use the width of the spray pattern to wash in a wide path Overlap spray paths for complete coverage 8 The nozzle should be 12 to 24 from the work closer for tough areas oof Caution Be careful on painted or delicate surfaces The pressure may damage the surface if the nozzle is too close 9 Small parts should be washed in a basket so the pressure does not push them away Larger light weight parts should be clamped down VIII To Stop 1 If detergents were used draw clear water through the detergent inlet line to purge detergent Failure to do so may clog the chemical injector 2 If the burner was used turn off the Heat switch and pump cold water through the coil for 3 minutes Insufficient cool down period of high pressure hose will cause excessive wear and eventual rupturing of hose Turn the pre
8. ay need to initially adjust your burner for peak performance See the Oil Burner section under INSTALLATION 4 When the trigger is released or the temp setting is reached the burner will automatically turn off IMPORTANT Do not run the machine in hot mode without any fuel in the fuel tank The fuel pump will be damaged if it is run dry VII To Clean WARNING Wear eye ear hand foot and skin protection at all times while operating this water heater DANGER Do not point the spray wand at yourself or at any person Bodily injury may result from hot water or water under high pressure CAUTION Be careful on painted or delicate surfaces The pressure may damage the surface if the nozzle is too close WARNING Only use NorthStar pressure washer chemicals or chemicals specifically formulated for pressure washers Follow the chemical manufacturer s recommendations Understand all safety precautions and first aid for all chemicals 1 If your pressure washer is equipped with a quick connect chemical injector it can be snapped onto the high pressure water outlet Then snap the high pressure hose to the injector and submerge the suction strainer into the chemical solution High Pressure Hose Adjustment Knob Water Outlet Chemical Injector Diluted Chemical Strainer 0555 2 If your chemical injector cannot be moved to the water heater s outlet it is acceptable to run chemicals through the heating coil Only use
9. ck couplers you can order them at 1 800 270 0810 3b If you do not want quick connect fittings the quick connect nipple on the water heaters outlet can be removed leaving a male 3 8 NPT fitting 4 Fill the burner fuel tank The tank s capacity is four gallons We recommend kerosene because it burns cleanest 1 grade home heating oil 1 or 2 diesel can also be used DO NOT USE GASOLINE OR CRANKCASE OIL DRAINING 5 If detergents will be used use only detergents intended for pressure washers Follow instructions on the detergent container WARNING Make sure that your existing hose gun and all accessories are rated for high temperatures and the appropriate pressure Pressure 10 Garden Hose IV To Start DANGER Do not point the spray wand at yourself or at any person Bodily injury may result from hot water or water under high pressure WARNING Wear eye ear hand foot and skin protection at all times while operating this water heater 1 Turn water supply ON 2 Squeeze the trigger to allow air to purge from the system This step goes faster with the pressure nozzle removed V Turn Your Pressure Washer ON 1 Follow your pressure washer s manual for its start up procedure VI Turn The Water Heater ON 1 Make sure there is fuel in the fuel tank 2 Turn the heat switch ON and adjust the thermostat to the desired temperature 3 The burner will fire when the trigger is squeezed You m
10. decrease the water temperature rise and may eventually clog the heating coil 1 Mix scale remover in a 5 gallon bucket and elevate the bucket so it is higher than the pump on your pressure washer 2 Attach water heaters inlet hose to the high pressure outlet of your pressure washer 3 Attach high pressure hose to the outlet of the water heater but do not hook up the spray gun 4 Place the other end of the high pressure hose in the 5 gallon bucket 5 Attach a short length of hose to the garden hose inlet on your pressure washer 6 Prime the pump by filling the short length of hose with water then place the end of the hose in the 5 gallon bucket Connect to Connect to Pressure Water Heater Outlet Connect Pressure Washer Outlet to Water Heater Inlet 7 Run the pressure washer in cold mode for 1 to 3 hours recirculating the cleaning solution Warning Do not run the burner 8 Dispose of the cleaning solution where it is not harmful to animals or the environment 9 Flush with fresh water and clean the inlet strainer when finished x Washer Inlet VIII Coil Desooting Poor grades of fuel oil or inadequate combustion air will cause heavy soot build up on the outside surface of the heating coil These deposits will insulate the coil This will restrict the air flow through the coil further aggravating the soot build up Most coils will never require desooting However to desoot a coil 1 Wear
11. duct GROUND FAULT CIRCUIT INTERRUPTER PROTECTION This water heater is provided with a ground fault circuit interrupter GFCI built into the plug of the power supply cord This device provides additional protection from the risk of electric shock Should replacement of the plug or cord become necessary use only identical replacement parts that include GFCI protection Extension Cords Use only 3 wire extension cords that have 3 prong grounding type plugs and 3 pole cord connectors that accept the plug from the product Use only extension cords that are intended for outdoor use These extension cords are identified by a marking Acceptable for use with outdoor appliances store indoors while not in use Use only extension cords having an electrical rating not less than the rating of the product Do not abuse extension cord and do not yank on any cord to disconnect Keep cord away from heat and sharp edges Always disconnect the extension cord from the receptacle before disconnecting the product from the extension cord Warning To reduce the risk of electrocution keep all connections dry and off the ground Do not touch plug with wet hands SAVE THESE INSTRUCTIONS Specifications 157494 Temperature Rise 190 F 2GPM 190 F O 3GPM 140 F 4GPM Kerosene Fuel Oil 5 15R 115V 60Hz single Dimensions Ship Weight Machine Component Identification 157494 ZA Cle Descr
12. e funnel 4 Turn your pressure washer on Do not turn on the water heater 5 Let your pressure washer run until antifreeze comes out of the high pressure outlet of the water heater 6 It will take about 1 5 gallons of antifreeze to fill your pump and the heating coil 7 Disconnect the water heater s inlet hose from the pressure washer and reconnect it to the outlet of the water heater 8 The water heater is now prepared for long term N Water Inlet RV Antifreeze storage 16 Troubleshooting Guide Water Heater Will Not Run No Power Machine not plugged in GFCI tripped Machine turned OFF Line circuit breaker tripped GFCI Trips During Operation Solutions Voltage too low Check the voltage Extension Cord Make sure connections are dry and off of the ground Check extension cord section on page 3 for more guidelines Burner Will Not Fire Causes Solutions Electrodes corroded or improperly spaced Clean electrodes and reset spacing See Electrode section on page 15 Damaged flow switch Replace flow switch Call Customer Service Smoke From Heat Exchan Air band not adjusted properly due to Adjust the air band until the burner burns cleanly See Oil Burner under different elevation Installation Instructions Poor quality fuel Use Kerosene for the cleanest burn Water Not Heating Solutions Scale build up in coil See Coil Descaling under Maintenance Instructions Coil is full of soot See Coil Desooting
13. g all preventative maintenance procedures as outlined in the provided manuals 2 Keep a stock of recommended service parts for maintenance and minor repairs 1 Recommended Service Parts List V Burner Fuel Filter Following is a list of the service parts we recommend Drain water that has accumulated in the fuel filter bowl stocking and replace the filter as needed Description Part Number Il Maintenance Mode Before performing any maintenance on the water heater it must be placed in maintenance mode A Turn off water supply B Bleed water from system C Turn off and unplug power cord VI Checking the Hoses h WARNING Do not use a finger or skin to check for III Maintenance Schedule leaks Escaping fluid under pressure has sufficient force to penetrate the skin causing serious injury What to Check When To What to Do Do not operate the pressure washer if the hose is A Check all hoses for leaks Check for Wear B Check all hoses for worn areas Bolts Each Use Check for Loose 1 I Bun IV Checking the Tire Air Pressure Good A Remove air fill cap B Fill tire to 20psi 1 4bar C Replace air fill cap m b 68 Bad lt Air Fill Stem El Bad 00426 Air Fill Cap 00425 13 VII Coil Descaling In hard water areas scale build up within the heating coil will occur Scale deposits will
14. ged 3 Let the burner fall away from the heat exchanger Tip the burner towards you until you can see the electrodes and fuel nozzle 15 Moving and Handling Instructions I Maneuvering Your Water Heater ll Lifting Your Water Heater 1 Lift handles with both hands until the wheels come in 1 To reduce risk of injury it is recommended to use a contact with the ground and the frame is lifted off of hoist to lift this water heater the ground 2 Lift from four lifting points 2 Push the water heater forward if it is being moved on 3 If the water heater is to be moved a short distance the solid smooth ground concrete hard packed dirt hoist can be positioned on the front lifting points and 3 Pull the water heater backward if it is being moved on the back lifting points can be hand lifted rough uneven ground grass gravel Back Lifting Points Front Lifting Points Long Term Storage During cold weather store the water heater indoors and move it outdoors before starting Follow these instructions to prevent the heat exchanger coil from freezing during storage Winter Storage Items needed 12 piece of garden hose or equivalent funnel and RV antifreeze approximately 2 gallons 1 Attach the water heater s inlet hose to the high pressure outlet of your pressure washer 2 Attach the garden hose with funnel to your pressure washer s pump inlet see illustration 3 Pour RV antifreeze into th
15. iption _ Ref Description Ret Description Water Outlet 6 FuelTank Safety Relief Valve Burner Heating Coil 8 FuelFilter Water Inlet pressure washer 9 Exhaust Vent Power Cord w GFCI Flow Switch HEB Installation Instructions k NN Hardware Bag 01348 7 N Zn EN 7 esi YS 2 S IL Owner s Manual 4X 5 16 X 75 Flange Bolt 4X 5 16 Flange Nut 2X 5 8 X 3 5 Hex Bolt 2X 5 8 Hex Nut 2X 5 8 Jam Nut N II Assembly Instructions To attach handles use 5 16 X 75 Flange Bolts 4x 5 16 Flange Nuts 4x To attach wheels 1 Slide 5 8 X 3 5 bolt through hub of wheel 2 Spin 5 8 Jam Nut onto bolt Do not tighten against wheel 3 Slide bolt through hole in frame secure with 5 8 Hex Nut Attach handles see above Attach wheels see above Remove water heater from the pallet It is recommended that a hoist is used or that two people lift the unit off of the pallet If a hoist is used use the attachment points shown in the Moving and Handling section on page 16 Do not try to lift the unit by the hook on the heating coil inside the heat exchanger The heating coil is not secured to the frame lll Getting Started IMPORTANT Proper initial installation of equipment will assure more satisfactory performance longer service life and lo
16. n Debris can reduce performance Do not pump flammable liquids or liquids containing incompatible chemicals or solvents lll Connect Your Pressure Washer WARNING Make sure all switches and controls are in the OFF position prior to plugging in the cord DO NOT stand in water while plugging or unplugging electrical cord WARNING Use a UL recognized receptacle protected by a ground fault interrupter and extension cord of proper voltage and amperage at all times WARNING Check hoses fittings fuel connections daily for signs of wear cracks and looseness replace as required and Hose Inlet Hose 1 Connect electrical cord to NEMA receptacle 5 15R 2 Connect outlet of your pressure washer to inlet of the water heater Your NorthStar Water Heater is equip ped with quick connect fittings as are all NorthStar pressure washers Slide the collar back on the inlet hose and push it over the outlet nipple of the pressure washer Pull on hose to assure a good connection 2a If your pressure washer does not have quick connect fittings you can order them at 1 800 270 0810 2b lf you do not want quick connect fittings the quick connect coupler on the inlet hose can be removed The inlet hose can then be threaded directly into any female 3 8 NPT port 3 Connect your existing high pressure hose and gun to the water heater outlet using quick connect fittings 3a lf your high pressure hose does not have qui
17. ou are doing 6 Do not operate the product when fatigued or under the influence of alcohol or drugs Never smoke while operating or fueling this machine 7 Keep operating area clear of all persons 8 Do not overreach or stand on unstable support Keep good footing and balance at all times Wear footwear capable of maintaining a good grip on wet surfaces Do not place the machine on soft or unstable ground 9 Follow the maintenance instructions specified in all manuals 10 Wear safety glasses gloves face protection and appropriate clothing when operating the machine 11 Do not operate this machine with broken or missing parts Never alter the manufacturer s original design or deactivate any safety device on the machine 12 Risk of exposure to dangerous chemicals Wear protective gloves when handling and cleaning with chemicals Follow the chemical manufacturer s directions Understand all safety hazards and first aid for all chemicals being used Do not pump highly abrasive fluids or use with incompatible chemicals or solvents 13 Know the pressure and temperature limits of your machine Be sure all high pressure accessories meet or exceed your machine s limits Do not set the pressure relief valve above the machine s limit 14 Do not move this machine by pulling on the hose Do not attempt to use this machine as a prop 15 Do not clean this machine with its own spray Cleaning should be done with a damp sponge with the machine O
18. protective clothing goggles and gloves 2 Remove the flow switch from the inlet of the heating coil and remove the thermostat from the outlet of the heating coil 3 Remove the lid and insulation cap from the heating chamber and hoist the coil out Be careful the coil is very heavy Important Be careful not to damage the threads on the coil inlet and outlet If the threads get damaged it will be hard to reconnect and seal the fittings on the coil inlet and outlet Lid Insulation Cap Heating Coil Heating Chamber 4 Clean the coil 5 Reassemble the coil to the machine Make sure the white insulation remains in place Reattach the flow switch and thermostat using thread sealant Make sure all fittings are tight before using the machine 14 IX Electrodes On a yearly basis the electrodes should be 4 Clean off carbon deposits that may have inspected and any necessary adjustments made accumulated on the tips of the electrodes 1 Block up the front of the water heater 6 inches 5 Reset the spacing as shown below LET Electrodes 2 Remove the 4 nuts that attach the burner to the heating chamber You do not have to disconnect the fuel lines or the electric cords but be careful not to subject them to excessive strain Also make sure the fuel filter does not get dama
19. ssure washer OFF Turn OFF the water supply Squeeze the trigger to relieve the system pressure oR OW 11 Safety Features l Safety Relief ll High Temperature Limit The safety relief valve is a backup safety feature If the The high temperature limit or thermostat keeps the system s pressure exceeds its limits the safety relief outlet water temperature below 250 F valve will open and relieve system pressure ERIT WOOT OPI 01724 WARNING If the safety relief valve ever discharges water turn the unit off and do not use the machine See a dealer or call Customer Service at 1 800 270 0810 12 Maintenance Instructions WARNING Unauthorized machine modification or use of non approved replacement parts may cause personal injury and or property damage and will void the manufacturer warranty All mechanical equipment no matter how well designed will need repairs A NorthStar water heater is no exception At times a NorthStar water heater may be inoperable because repairs are required NorthStar Customer Service will assist in these repairs as needed but if an inoperable water heater creates a major expense to your business then we strongly recommend the following 1 Have someone on staff who is trained in the operation of the water heater and is capable of making minor repairs and performin
20. ustion can only be obtained when there is a sufficient supply of oxygen available for the amount of fuel being burned If it is necessary to install a unit in a poorly ventilated area outside fresh air may have to be piped to the burner and a fan installed to bring sufficient air into the unit Locate the water heater in such a manner that the flue will be as straight as possible and protrude through the roof at a proper height and location to provide adequate draft This oil fired unit must have a draft controller installed in the flue Part 18007 call 1 800 270 0810 to order A draft controller will permit proper upward airflow of exhaust flue gases Arrow V Oil Burner Burner Air Adjustment The oil burner is preset and performance tested at the factory elevation 1100 feet A one time initial correction of the burner for your location will pay off in economy performance and extended service life Air Band White RS Locking P i Burner Screw 1 Turn the pump and heat switches on Refer to Operation for details Have someone operate the spray gun so the burner fires 2 Loosen the locking screw and close the air band until black smoke appears from the burner exhaust vent Note the position of the white arrow on the air band 3 Slowly open the air band until white smoke just starts to appear
21. wer maintenance cost Make sure the water heater is on a level surface and ina protected area where it is not readily influenced by outside forces such as freezing temperatures strong winds rain etc Locate the water heater for easy access to fill fluids and make adjustments It is recommended that a partition is made between the wash area and the water heater to prevent direct nozzle spray from coming in contact with the water heater Excessive moisture will reduce the water heater s service life ae IV Venting DANGER Do not run machine indoors or in an enclosed area without adequate ventilation or in areas where flammable vapors gasoline solvents etc may be present Do not vent exhaust gases into a wall a ceiling or a concealed space CAUTION All venting must be in accordance with applicable federal and state laws and local ordinances Consult local heating contractors 01356 If the water heater is to be used in an enclosed area a flue must be installed to vent burner exhaust to the outside atmosphere Be sure the flue is the same size as the burner exhaust vent on the water heater lid Poor draft will cause the water heater to soot and not operate properly When selecting the location for installation beware of poorly ventilated locations or areas where exhaust fans may cause an insufficient supply of oxygen Proper comb
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