North Star M157594I Pressure Washer User Manual
Contents
1. Check whether dangerous chemicals have been used and take any precautions that may have been recommended by the supplier of these chemicals when cleaning filters Do not pump highly abrasive fluids or use with incompatible chemicals or solvents 12 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 13 Do not move this machine by pulling on the hose Do not use the pump to support other items of equipment that impose unacceptable loads on the pump Do not attempt to use this machine as a prop 14 To reduce risk of injury do not secure the spray gun open Your spray gun is equipped with a built in trigger safety latch to guard against accidental trigger release and potentially dangerous high pressure spray Rotate the safety latch to the locked position when not spraying 15 Do not clean this machine with its own spray Cleaning should be done with a damp sponge with the engine OFF 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 starting the engine SAVE THESE INSTRUCTIONS Specifications 3 8 Specifications for Trailer Mounted Models Trailer GVWR 3500 Ibs2. 20 21 1 3 1 43 Av3Llve 20 2 3m8 oi NMOYS 038 104109 16 Trailer Assembly Instructions 157595 only Remove the top and four sides of the steel crate Remove a frame from trailer frame keep fasteners for step 7 3 Slide a frame into holders under trailer frame built into the front posts Install jack onto a frame with 3 8x1 bolts Class G lock nuts and washers provided Tighten to 37ft lbs Slide caster wheel onto jack and secure with pin Crank jack down until a frame becomes level Attach a frame to trailer frame with six 5 8 bolts and Class G nuts Tighten to 180ft Ibs Check trailer light wire routing though a frame make sure wires are not pinched stretched or pass any rough edges NO Crank jack down farther so frame goes up to take weight off front shipping posts Rear Shipping Posts 10 Remove front shipping posts one on each corner 11 Crank jack up as far as it will go so a frame goes down and weight is applied to wheels 12 Disconnect rear shipping posts from frame remove only the bolts at the top of the rear shipping posts 13 Roll trailer forward until it is free of the rear shipping posts Front Shipping 14 Attach coupler to a frame with two 1 2x4 bolts and Class lock nuts Tighten each bolt to 90ft Ibs 15 Attach safety cable
3. Hitch Ball Size Skid Dimensions 129 L X 75 75 W X 60 H Weight tank empty 960 Ib Weight tank full 2500 Ib Machine Component Identification Ref Description Description 9 Ball Valve feed tank Water Outlet Description Engine Key Switch Water Inlet city tap water trailer models use hose reel 6 GasolineTank 28 Water Inlet feed tank _____ re ee Installation Instructions Installing a Battery Warning Sulfuric acid is a corrosive poison Avoid contact with skin eyes or clothing Always wear safety glasses Always wear safety glasses when working on or near the battery The engine will not run and the burner will not fire without first installing a battery The battery box provides protection for the battery and will accept a standard automotive battery The inside dimensions are 11 1 8 L x 7 3 4 W x 10 1 8 H The battery must be 12VDC with a minimum rating of 18 Ah Amp hour When installing a battery always connect the red colored or cable first When disconnecting a battery always remove the black colored or cable first Location IMPORTANT Proper initial installation of equipment will assure more satisfactory performance longer service life and lower maintenance cost IMPORTANT The use of a back flow preventer Part 222815 call 1 800 270 0810 to order on the water supply hose
4. check all hoses for leaks and worn areas Discontinue use of any hose if leaks are noticed Discontinue use of the high pressure hose if the wire mesh is exposed Electrodes Inspect electrodes annually Clean off carbon deposits which may have accumulated on the tips of the electrodes Reset the spacing as shown below Electrodes Long Term Winter Storage During cold weather store the pressure washer indoors and move it outdoors before starting the engine Long Term Storage and Freeze Protection 1 Attach a feed tank or bucket to the water inlet feed tank See Installation section for Attaching a Water Feed Tank instructions Fill feed tank with 5 gallons of RV antifreeze 3 Run the pressure washer in cold mode until RV antifreeze comes out the water outlet Make sure excess antifreeze is disposed of safely RV antifreeze will save the components from freeze damage and keep them lubricated 4 Disconnect spark plug cable Make sure the engine start switch is OFF Disconnect the battery and store it indoors Short Term Freeze Protection 1 Drain water from feed tank 2 Drain water from the heat exchanger by extending the high pressure hose straight Place the end of the hose at a level that is below the pressure washer Remove the spray gun f
5. discharge hot water onto the ground The thermal relief valve is located on the unloader bypass port 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 See Engine manual for engine maintenance Maintenance Mode Before performing any maintenance on the pressure washer it must be placed in maintenance mode A Turn off water supply B Relieve pressure from system C Turn off engine and disconnect the spark plug cable Water Filter Check whether dangerous chemicals have been used and take precautions when handling filters Before each use remove filter screen and rinse with clear water Burner Fuel Filter Drain water from the fuel filter bowl and replace the filter as needed Changing The Pump Oil Change oil after first 40 hours then every months 500 hours 1 Open oil drain valve 2 Drain pump oil 3 Close oil drain valve 4 Fill pump middle of sight glass with Cat pump oil or 30 wt non detergent oil 5 Oil Capacity is 1802 Oil drain valve 10 Checking the Hoses WARNING Do not use a finger or skin to check for leaks Escaping fluid under pressure has sufficient force to penetrate the skin causing serious injury Do not operate the pressure washer if the hose is cracked worn or leaking Before each use
6. support 1 66 777838 1 4 13 67 305422 thermostat 1 68 777855 toggleswitch 11 69 31085 circuit breaker 20 _____ 1 70 777644 controlboxcover 71 777646 red LED 12700 2 72 777660 decal controlpanel 1 73 777643 controlboxpanel 1 74 36138 relay12VDC ______ 1 75 777645 1 2nptFx1 2hose 1 7 778946 221 0 degree 4 red 25309 221 15 degree 4 yellow 778948 221 25 degree 4 green 778947 221 45 degree 4 white 778949 221 chemical black QTY 1 2 1 lt 5 305410 36302 _ fiberglass 5 8 wo 5 38398 779228 1 5 2 24in 305278 shrink tube 30501 5 loom 305208 1 2npt FxFxF N 1 777915 couple nipple 3 8npt 1 1 1 48in 1 1 1 0 60 ajA 100 2210 3 25in 1 ojo N 779232 33387 as 36180 ojojo a Parts Breakdown 157595l REF PART DESCRIPTION QTY 3EF PART DESCRIPTION QT 1 779257 Hose Reel 2 19 5318 Nipple 34 NPT x Hose Barb 1 3 777903 Frame Skid 1 20 5370 Bulkhead 3 NPT Fe
7. NOR 1575941 ITEM NUMBER 157594 157595 SERIAL NUMBER Engine Model Pump Model Flow Pressure Proven Performance m Hose Lengthy Lance Lena Nozzle Size Installation Operation and Maintenance Manual HOT WATER PRESSURE WASHER Cleans dirty surfaces with high pressure hot water To the Owner Thank you for purchasing a NorthStar hot water pressure washer 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 machines 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 hot water pressure washer 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 Engine Oil Engine is shipped with out oil Fill before starting Use SAE 10W 30 motor oil Pump is shipped with oil Check pump oil level before starting Make sure your water is clean and particle free Do not allow water to freeze in the pump hose coil or spray gun Use any NorthStar brand or equivalent pressure washer chemicals Chemicals Adjust soap adjustment knob to regulate cleani
8. eed to use the low pressure black nozzle to spray chemicals onto the cleaning surface C The amount of chemical applied can be changed by turning the chemical adjustment knob located on the chemical injector D Squeeze the spray gun trigger The chemical injector will draw the chemical into the water stream E Apply chemicals evenly to the cleaning surface Allow the chemicals to react with the dirt then clean at high pressure with green nozzle F Never use more chemical than is necessary to clean the surface G If you do not intend on using chemicals we suggest removing the chemical injector to obtain maximum cleaning pressure IX Start Engine See the engine manual to start your engine IMPORTANT The water must be turned on or water feed tank filled before starting Running the pump dry will cause damage and void the warranty Make sure only one ball valve is open The ball valve that you are not using needs to be closed before starting the engine Pump cavitation can occur WARNING Do not inhale the exhaust from the engine Do not point the lance at anyone even if the engine has stopped because there could be a release of water under retained pressure if the spray gun trigger is actuated Operating Instructions X For Hot Water If HOT water is desired make sure there is fuel in the fuel tank turn the heat switch ON and adjust the thermostat to the desired temperature The burner will fire w
9. hen the trigger is squeezed You may need to initially adjust your burner for peak performance See the Oil Burner section under INSTALLATION When the trigger is released a pressure switch automatically turns the burner off Also when the temperature setting is reached the thermostat automatically turns the burner 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 Warning It is important that the burner stops firing when the trigger is released the burner remains firing discontinue use until the pressure washer is serviced Extremely high temperatures can result in serious injury and equipment damage Cleaning WARNING Wear eye ear hand foot and skin protection at all times while operating this pressure washer DANGER Do not point the spray wand at yourself or at any person Bodily injury may result from water under high pressure CAUTION Be careful on painted or delicate surfaces The pressure may damage the surface if the nozzle is too close IMPORTANT Your spray gun is equipped with a built in trigger safety latch to guard against accidental trigger actuation potentially dangerous high pressure spray Rotate the safety latch to the locked position when not spraying Safety Latch 00417 A Hold the lance with two hands have a sturdy stance B The pressure washer is set and locked to the maximum rated pre
10. is recommended and may be required by local code Place the pressure washer a solid level surface a protected area where it is not readily influenced by outside forces such strong winds freezing temperatures rain etc Locate the pressure washer for easy access for filling fluids adjustments controls and maintenance 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 qq Make a partition between the wash area and the pressure washer to prevent direct nozzle spray from coming in contact with the pressure washer Moisture reaching the equipment will reduce the pressure washer s service life Attaching a Water Feed Tank 157594 only Caution Make sure to follow these instructions Inadequate plumbing between a feed tank and the pressure washer can cause damage to the pump from cavitation Cavitation will not occur if you select large fittings and hose to connect the feed tank to the pressure washer Also place the pressure washer right next to the feed tank so the connection hose will be as short as possible Open Connect this ball feed line Close here this ball SOL 1402229 1 Use connection hose no longer than 6ft long 2 Make sure the connection hose does not kink 3 Make sure all fittings are 32
11. let city tap water Open this ball valve Close this ball valve 902230 1 Make sure the water supply is clean Debris cause excess pump wear and reduce performance 2 An insufficient water supply will damage your pump Make sure the water supply is steady and is 20 over the rated flow of your pump Use a stopwatch to time how long it takes to fill a 5 gallon bucket with your garden hose It should take less than 62 seconds 3 The water supply garden hose must have an inside diameter of at least 5 8 If the hose is more than 100 ft long the diameter must be at least 3 4 4 Always use a flexible rubber hose for your water supply Do not use rigid piping lll Attach High Pressure Hose Attach the high pressure hose to the water outlet See Machine Component Identification section for location of the water outlet Your pressure washer hose is equipped with quick couplers Simply pull the collar back and push the coupler onto the nipple Make sure the collar slides over the ball bearings Once the connection is made pull on the hose to assure a positive connection w Collar High Pressure Output H His CORRECT INCORRECT Operating Instructions V Turn Water Supply ON city water tap only Make sure the hose is not kinked A kinked hose will provide insufficien
12. male 3 4 30198 200 Gal Tank 1 21 50NBR12 v2 Hose Barb 34 NPT Elbow 1 5 777707 Tank Strap 2 22 17141 Hose Clamp 34 1 6 82080 Eye Bolt 4 4 23 30289 Clear PVC Hose 7 780200 15 Wheel 2 24 50CSC128 3 4 1 2 Reducer 1 8 777771 Trailer Frame 1 25 30048 1 2 3 8 Reducer 1 9 127432 Trailer Light Kit rear front wires __ 1 26 777338 3 8 1 4 Reducer 1 10 38485 Pin 1 27 777340 NPT x 4 Hose Barb 1 11 128480 Jack 1 28 17141 1 4 Hose Clamp 2 12 12736 Wheel for Jack 1 29 777165 1 4 Clear PVC Hose 12 13 777775 Coupler 1 30 777779 150 3 8 5400PSI Hose 1 14 777698 A frame Towbar 1 31 779801 Truck Chest 1 15 779542 Safety Cables 2 32 777914 QC 3 8 Female Coupling 1 16 39166 Axle 1 33 777410 3 8 Street Elbow 1 17 779782 Hose Reel Mount 2 34 777378 18 3 8 5400 PSI Gray Hose 1 18 35442 Ball Valve 1 35 777839 Flair nipple gt melX3 8MPT 1 4 iring 000913 1109 pow voz Les on Juve N ALINNILNOD HOLIMS 3NION3 GRAY GRAY BLK ANIONS y8 TT AVEO ineno ouei UBISILOIY THM THK 33938 THM THM THM 4 HOLIMS
13. ng power Maintenance Engine Oil change after first 20 hours then annually or every 100 hours Schedule Spark Plug clean every 100 hours replace annually or every 300 hours Air Filter clean every 100 hours replace annually or every 300 hours Oil change after first 40 hours then every 3 months or 500 hours Read and understand all manuals before operating Any Questions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 Table of Contents Important Safety Instructions Maintenance Instructions 3 __ Long Term Winter Storage pai Identification Parts Breakdowns 13 15 Electrical Schematic 16 Safety Features _______ 9 Trailer Assembly Instructions 157595 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 and understand 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 p
14. nt container Run clean water through the injector after each use Any Questions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 12 Parts Breakdown 1575941 YY fl Wi freely Why yyy yy S Krol 7X18 1 AW JEN 27 e fE 154141516 Component List 1575941 REF PART DESCRIPTION QTY 32842 muffler kit HONDA 2 30511 1 2nptplug 1 _3 777837 3 8nptplug 1 4 38198 CAT pump 1 5 777347 3 8npttee CE 2 6 777378 18 5400psi 2 _7 777682 pressure guage 6000psi 1 4 1 8 777338 3 8nptx 1 4npt MxF ___ 3 9 777410 elbow 3 8n pt MxF 22 777119 clamp 1 2 __ 6_ 6 6 30 777834 hoseclamp1 4hose _____ 8 33 777337 1 2 x 3 8nptMxM_ 3 35 777656 pressureswitth 11 36 777411 tee 3 8 FxFxF_ 2 37 777667 batterycable red 1 41 35743 warninglabel 1 7 1 1 14 49 777422 quick coupler 3 8nptM_ 1 50 777396 50 5400 includes 51 52 1 51 777722 quick coupler 3 8nptF 54 777488 heatshield tanks 1 14 REF PART DESCRIPTION 60 777489 battery strap 65 777484 tank
15. o 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 Lock Screw CAUTION If white smoke appears from the burner exhaust vent during start up 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 Operating Instructions Read and understand the entire manual before operating the pressure washer Follow these instructions every time you use the pressure washer 1 Pre Operation Read entire manual especially the important safety instructions 1 Check hoses fittings wand trigger gun and fuel connections for signs of wear cracks and looseness and replace as required Check and clean the nozzle orifice 3 Check and clean the water inlet screen and filter see Maintenance section 4 Check and maintain proper oil levels in the pump and engine see Maintenance section ll Connecting City Water Tap Follow these instructions when supplying water from a pressurized source such as a garden hose instead of a water feed tank Attach a garden hose to the water inlet city tap water See Machine Component Identification for location of the water in
16. or larger 4 Do not use 90 elbow fittings unless absolutely necessary 5 Make sure bottom of the tank is level or higher than the bottom of the skid frame 6 Do not pump flammable liquids or liquids containing incompatible chemicals or solvents 7 Reroute the easy start valve so it discharges back to the feed tank This will aid pump priming on initial start up The easy start valve is located below the unloader See Machine Component Identification for location of unloader Unloader ee Plug this port Reroute hose to water feed tank Installation Instructions 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 place CAUTION All venting must be in accordance with applicable state and federal laws local ordinances Consult local heating contractors If the pressure washer 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 pressure washer lid Poor draft will cause the pressure washer to soot and not operate properly When selecting the location for installation beware of poorly ventilated locations or areas where exhaust fans may cause insufficient supply of oxygen Prope
17. r combustion 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 pressure washer 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 air flow of exhaust flue gases Burner Burner Air Adjustment The oil burner is preset and performance tested at the factory elevation 1100 feet Different altitudes may require a one time initial burner correction Air Band White ae Arrow we Locking Screw Burner 1 Turn the engine 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 4 Turn the air band half way back t
18. roduct 2 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 the pump 3 Know how to stop the product and bleed pressures quickly Be thoroughly familiar with the controls 4 Stay alert watch what you are doing 5 Do not operate the product when fatigued or under the influence of alcohol or drugs Never smoke while operating or fueling this machine 6 Keep operating area clear of all persons 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 8 Follow the maintenance instructions specified in all manuals Do not run machine without sufficient lubrication or sufficient water to cool the pump Wear safety glasses gloves face protection and appropriate clothing when operating the machine 10 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 11 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
19. rom the hose Disconnect the plumbing that connects to the heat exchanger inlet The water will flow out of the heating coil This will protect the coil from freeze damage 3 Open both water inlet ball valves and remove the cap from the water filter This will drain the pump and water inlet plumbing 11 Troubleshooting Guide Engine Will Not Start Attach spark plug wire to spark plug Pressure Washer Runs But Burner Doesn t Fire Pressure Washer Runs But No Pressure Pressure Washer Surges Or Cycles While In Bypass Leak between unloader and gun Check all connections between unloader and gun for leaks Tighten loose components and replace damaged components Gun leaking internall Replace spray gun Smoke From Heat Exchanger Causes Solutions Air band not adjusted properly Adjust the air band until the burner burns cleanly See Installation Instructions Poor quality fuel Use kerosene for the cleanest burn Water Not Heating Sufficient Causes Solutions Scale build up in coil Call Product Support Coil is full of soot Call Product Support Poor Or No Detergent Suppl Causes 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 deterge
20. s to the a frame with 5 bolt and Class G lock nut Place a flat washer next to the head of the bolt slide the bolt through the cable and the a frame Then slide the other cable onto the bolt followed by another washer then the lock nut Tighten to 37ft lbs 16 Attach truck chest to a frame with four 5 16x1 bolts lock nuts and washers Insert bolts down though holes in truck chest and a frame Place washers under wall of a frame and fasten with lock nuts Tighten each bolt to 20 65
21. ssure when it leaves the factory WARNING Do not alter the unloader valve s maximum pressure Excess pressures could cause serious injury and or pump damage Any alteration other than turning the adjustment knob will void your warranty XII Shut Down Instructions WARNING Do not leave an operating machine unattended Always shut the machine OFF and relieve the pressure before leaving the machine Never disconnect the high pressure hose from the pump or spray gun while the system is pressurized Relieve pressure by squeezing the spray gun trigger after the engine is turned OFF A Turn heat switch OFF and run cold water through the coil for 3 minutes Turn engine OFF Turn water supply OFF Actuate spray gun trigger to relieve system pressure Remove garden hose Remove pressure hose VOW AM Safety Features Safety Relief Valve The safety relief valve is a backup safety feature If the system over pressurizes the safety relief valve will open and relieve system pressure The safety relief valve is located in the high pressure line between the unloader and the heat exchanger WARNING If the safety relief valve ever discharges water turn the engine off and do not use the machine until it is serviced Thermal Relief Valve The thermal relief valve allows the pump to remain in bypass without risk of overheating the pump If high temperatures are developed during bypass the thermal relief valve will open and
22. t water supply to the pump and will reduce its life Make sure the hose remains unkinked after moving the pressure washer VI Attach Nozzle Color of Nozzle Spray Angle For Highest Impact Tough Stains Stripping Light Cleaning Your pressure washer is equipped with four high pressure nozzles To install a nozzle pull the collar back and push the nozzle into the coupler Once the connection is made pull on the nozzle to assure a tight connection Lance Coupler ee ollar CORRECT INCORRECT WARNING Make sure the nozzle is correctly inserted The nozzle may become a projectile if not inserted correctly Do not attempt to use different types of nozzles that may not fit the coupler VIII Applying Chemicals 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 NOTE Your pressure washer is equipped with a low pressure chemical injector The proper chemical used for the proper application can speed up cleaning jobs tremendously A Snap the quick couple chemical injector onto the high pressure outlet and high pressure hose and submerge the suction strainer into the chemical solution Adjustment Knob High Pressure High Pressure Hose Diluted Chemical Chemical Injector 00322 B You n
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