North Star M157594AF.1, 157594 Owner's Manual

M157594AF.1

WARNING – READ THIS MANUAL

READ and UNDERSTAND this Owner's Manual and the Engine Owner's Manual completely before attempting to set up and use the pressure washer! Failure to properly set up, operate, and

maintain this pressure washer could result in serious injury or death to operator or bystanders.

WARNING – SPECIAL HAZARDS

CO Poisoning

 Exhaust from both the engine and burner contains carbon monoxide, a

poisonous gas that can cause carbon monoxide poisoning and possible death if inhaled. OUTDOORS and at least 20 feet from the home, away from windows, vents and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT AWAY.

Skin/Eye Injury

 High-pressure spray can cause serious skin or eye injury, including injection injury

if fluid pierces the skin. Injection injury can result in blood poisoning and/or severe tissue damage.

Burns

 Hot spray can scald and burn skin.  Hot surfaces of wand, engine and burner, as well as hot exhaust from both

the engine and burner can cause burns.

Slips/Falls

 Spray discharge can cause puddles and slippery surfaces.  Spray-gun kickback can cause operator loss of balance and falls.

Flying Debris

 High-pressure spray can cause surface damage and flying debris.

Fire/ Explosion

 Engine and burner sparking can ignite fuel or other flammable liquids or

vapors in the vicinity.

 Hot exhaust from engine and burner can ignite combustible materials.

Chemical Exposure

 Cleaning chemical vapors or contact with skin may be hazardous.

Electric shock

 Spray contact with electrical sources can cause electric shock.

A summary of important safety information is provided at the end of the manual.

ITEM NUMBERS: 157594 SERIAL NUMBER: _____________

Owner's Manual

Instructions for Set-up, Operation, Maintenance & Storage

HOT WATER PRESSURE WASHER – 4000 PSI / 4 GPM

Portable Outdoor-Use Only

This pressure washer produces both cold and hot water high-pressure spray. Cleaning chemicals may be incorporated into the spray if desired. The pressure pump for this equipment is powered by a gasoline internal combustion engine and the water is heated by a kerosene/fuel-oil fired, open flame burner.

Any Questions, Comments, Problems, or Parts Orders

Call NorthStar Product Support 1-800-270-0810

Hazard Signal Word Definitions

Equipment Protection Quick Facts

Inspect Upon

Delivery

STOP! Closely inspect to make sure no components are missing or damaged. See the "Assembly and Initial Set-Up" section for instructions on whom to contact to report missing or damaged parts.

Fill with

Engine Oil

STOP! Engine is shipped without oil. DO NOT start pressure washer without adding oil to engine. Please refer to Engine Manual shipped with unit for acceptable grade motor oils.

Check Pump

Oil

Pump is shipped with oil. Remove shipping tape and black vent plug (if present) from oil fill cap. Check pump oil level before starting.

Battery

Required

A battery is not included. The engine will not run and the burner will not fire unless a battery is installed. Purchase a standard 12VDC, 18 Ah automotive battery (Group 75).

Water Flow

Requirements

Make sure your supply water flow rate is 20% higher than the pressure washer's flow rate (see "Specifications" section for detail), and that your water is clean and particle free.

Storage

Do not allow water to freeze in the pump, hose, coil, or spray gun(s).

Chemical

Spraying

Use only NorthStar brand or equivalent washer chemicals designed for high-pressure use. Use soap adjustment knob to regulate cleaning power.

Maintenance

Schedule

Engine:

 See Engine Owner's manual.

Pump:

 Change oil after first 40 hours, then every 3 months or 500 hours.

Burner fuel filter /water separator:

 Drain water as needed.  Change filter after every 500 hours of use.

Coil:

 Descale coil annually or more frequently as

conditions/performance require.

 Inspect coil for soot build-up annually and desoot if needed.

Electrodes:

 Inspect electrodes annually and clean/adjust as needed

Table of Contents

About Your Pressure Washer .................................................................................................... 4

Specifications ................................................................................................................................. 5

Component Identification ............................................................................................................ 6

Safety Labeling ............................................................................................................................. 8

Special Equipment Safety Features ............................................................................................ 9

Assembly and Initial Set-Up ....................................................................................................... 10

Step 1. Unpacking & Delivery Inspection .............................................................................. 10

Step 2. Attaching a Water Feed Tank (customer supplied) .................................................... 12

Step 3. Initial Pump & Engine Preparation ............................................................................. 14

Step 4. Battery Installation ...................................................................................................... 15

Moving and Handling .................................................................................................................. 16

Before Each Use ........................................................................................................................... 17

Step 1. Check Equipment ........................................................................................................ 17

Step 2. Add Fuel(s) ................................................................................................................. 18

Step 3. Select a Suitable Worksite .......................................................................................... 20

Operation ....................................................................................................................................... 22

Step 1. Connect Hose(s), Water Supply, and Spray Nozzle(s) ............................................... 22

Step 2. Set Up for Chemical Spray (if desired) ....................................................................... 26

Step 3. Spraying ...................................................................................................................... 28

Step 4. Stopping ...................................................................................................................... 34

Storage ........................................................................................................................................... 35

Burner Adjustment....................................................................................................................... 38

Maintenance and Repair ............................................................................................................. 40

Troubleshooting ............................................................................................................................ 47

Parts Explosion ............................................................................................................................. 48

Pump Explosion ............................................................................................................................ 50

Wiring Diagram ............................................................................................................................ 51

Summary of Important Safety Information ............................................................................... 52

Limited Warranty ........................................................................................................................ 56

About Your Pressure Washer

WARNING

Carefully read and follow all instructions and safety information for using this pressure washer.

Improper use or maintenance of the pressure washer can result in serious injury or death to the operator or bystanders from:

 Carbon monoxide poisoning

 Fire/explosion

 Chemical exposure

 Skin/eye injury from high

pressure spray

 Burns

 Slips/falls

 Electric shock

 Flying objects/debris

ATTENTION:

Rental Companies and Private Owners who loan this equipment to others!

All persons to whom you rent/loan this pressure washer must have access to and read this manual. Keep this owner's manual with the pressure washer 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 set-up and operate the pressure washer and remain available to answer any questions a renter/borrower might have.

Thank you for purchasing a NorthStar hot water pressure washer! Your machine is designed for long life, dependability, and the top performance you demand. This pressure washer is designed to:

1) Produce a high-pressure spray of heated or unheated water (up to 4 gallons per minute at 4000 psi).

2) Incorporate cleaning chemicals into a low-pressure water spray.

Water is supplied to the pressure washer via external water tank (the water tank must be supplied by the customer – a 200 gallon capacity tank or greater is recommended.) or via standard tap water through a garden hose. In either case, the water supply must have a flow rate of at least 4.8 gallons per minute. If using tap water, the use of a backflow preventer on the water supply hose is recommended, and may be required by local code. Any cleaning chemicals that are used must be specifically approved for use in pressure washers.

The pump is powered by a gasoline-fueled engine. The spray water is heated (when desired) by a kerosene/fueloil fired, spark-ignited, open flame burner. Normal operation of this equipment will require you to supply:

 Gasoline fuel and lubrication oil for the engine  Pump oil  Fuel for the burner (kerosene, diesel, or fuel oil)

See the "Specifications" section of this manual for more detail. Gasoline powered pressure washers are for OUTDOOR USE ONLY. Be sure to read about site selection

for running this pressure washer in the "Installation & Initial Set-up" section of this manual. The user should plan to acquire and wear safety apparel during operation of this pressure washer. Safety apparel

includes waterproof insulated gloves, safety glasses with side and top protection, and non-slip protective footwear. Some cleaning chemicals may require the use of a respirator mask (as instructed on chemical label).

Before using this washer, the user shall determine the suitability of this product for its intended use and assumes liability therein.

 A 12-volt standard automotive battery.

Read this Manual

Keep this manual for reference and review. A summary of important safety information can be found at the end of the manual.

Proper preparation, operation, and maintenance of this pressure washer will result in optimal performance and a long life for this equipment. For detailed Engine operation and maintenance information, always refer to the Engine Owner's Manual furnished with the pressure washer.

Specifications

MODEL

Model #

157594

FLOW OUTPUT

Pressure Rating

4000 psi

Flow Rate

4 gpm

Maximum Temperature

210 F

DIMENSIONS / COMPONENTS

Length

47"

Width

37.5"

Height

42"

Weight (dry)

500 lbs.

Pump Type

CAT 66DX

Engine Displacement

630cc

High Pressure Discharge Hose

3/8" x 50'

Chemical Injector

Maximum dilution ratio 13-to-1

SUPPLIES REQUIRED (not included)

Engine Fuel

Regular, Unleaded Gasoline

Engine Oil

See Engine Owner's Manual

Burner Fuel

#1 or #2 Diesel, B5 or lower Biodiesel, Kerosene,

or Fuel Oil

(Capacity: 4 Gal.)

Pump Oil

(shipped with oil, but refills required)

SAE 30 non-detergent oil

18 oz. capacity

Battery

12 Volt, minimum 18 Amp/Hr.

Automotive Battery (Group 75)

Input Water Supply

Tap: Standard tap water @ 20-75 psi

Water feed tank: 200 gallon tank recommended

(customer supplied).

Flow rate must be maintained at 4.8 gpm

Input Water Supply Hose

For Tap: Standard garden hose with inside

diameter at least 5/8" (at least 3/4" diameter if

hose longer than 100 ft.)

For Tank: 3/4" connection hose no longer than 6'

long and 3/4" or larger fittings

Component Identification

Ref #

Description

Ref #

Description

Ref #

Description

Unloader

Ball Valve (feed tank)

Engine Key Switch

Lifting Eye

Ball Valve (city tap water)

Circuit Breaker

Engine (see engine manual)

Water Filter

Heat Switch

Inlet Plumbing

Water Inlet (city tap water)

Thermostat

Diesel Tank

Control Panel

Indicator Light (pressure sw.)

Gasoline Tank

Battery Box (battery not included)

Indicator Light (thermostat)

Pump

Pressure Switch

Water Inlet (feed tank)

Water Outlet (high pressure)

Component Identification

REFERENCE GUIDE

1. Unloader

Valve that regulates pressure and directs flow into bypass when trigger is closed.

2. Lifting Eye

Used to lift the unit.

3. Engine

The air-cooled engine powers the pump.

4. Inlet Plumbing

Means of connecting garden hose to pump inlet.

5. Diesel Tank

Diesel fuel storage container.

6. Gasoline Tank

Gasoline fuel storage container.

7. Pump

A device that moves fluid through a combination of suction and displacement.

8. Water Inlet (feed tank)

Used to connect water from the feed tank to the inlet plumbing.

9. Ball Valve (feed tank)

Used to open or close the water line from feed tank.

10. Ball Valve (city tap water)

Used to open or close the water line from city tap.

11. Water Filter

Filters water prior to entering the pump.

12. Water Inlet (city tap water )

Used to connect city tap water to the inlet plumbing.

13. Control Panel

Flat surface for mounting switches.

14. Battery Box

Storage place to house the battery.

15. Pressure Switch

Controls burner.

16. Water Outlet

Connect high pressure hose here.

17. Engine Key Switch

Start engine by turning clockwise.

18. Circuit Breaker

Push to reset circuit breaker to protect against electrical overloads.

19. Heat Switch

On/off device for power to burner components.

20. Thermostat

Adjust the water temperature.

21. Indicator Light (pressure sw.)

Instrument used to monitor unit operation. Should not be illuminated when the gun is in use.

22. Indicator Light (thermostat)

Instrument used to monitor unit operation. Should be illuminated when the gun is in use and the burner is firing.

On-Product Warning Labels

Part #'s

Description

Part #'s

Description

782325

Danger & Warning

782397

Battery Hazard

305410

Caution Hot

777721

Operating Instructions

NEVER use inside any building, structure or

garage, EVEN IF doors and windows are open.

DANGER

WARNING

FOR OUTDOOR USE ONLY! Using this pressure washer indoors CAN KILL YOU IN MINUTES.

Engine exhaust and burner exhaust contain carbon monoxide. This is a poison you cannot see or smell.

High pressure spray can cause injection injury, eye injury, and loss of balance. Hot discharge fluid and hot surfaces can burn.

NEVER direct discharge stream at or near any person. Do not allow any part of the body to come in contact with the fluid stream. Gun kicks back - hold with two hands. Keep good footing and balance at all times. Surfaces of engine, burner, and wand can become very hot. Use only designated gripping area of wand. Avoid contact with hot engine and burner.

Spraying flammables can cause explosion. Fuel is flammable and explosive. Exhaust can ignite combustible materials.

NEVER spray flammable liquids. Operate only where open flame or torch is permitted. NEVER fuel a running or hot engine or oil burner. Ensure there are no fuel leaks before starting. Keep sources of sparks and flames away. Use approved container only for transferring fuel. Clean up fuel spills immediately. Keep engine and burner exhaust at least 7 feet from all combustible objects. Situate on heat-resistant flooring when using burner.

Understand all safety hazards and first aid measures for chemicals being used. Follow chemical manufacturer's directions when handling and cleaning with chemicals. Wear safety gear as directed.

Keep spray away from electrical wiring, or electric shock / electrocution could occur.

CAUTION: To Reduce Risk of Injury, Read Operating Instructions Carefully Before Using.

782325

Chemical Exposure Hazard

Electric Shock Hazard

Only use OUTSIDE and far away from

windows, doors, and vents.

Fire / Explosion Hazard

High Pressure Fluid Forces / Burn Hazards

ALWAYS use eye protection. Caustic 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 your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing. CONNECT cables in correct sequence: FIRST RED to POSITIVE 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.

BATTERIES:

1) contain caustic acid, 2) emit explosive gases,

3) can cause electric shock

WARNING - BATTERY HAZARDS

782397

Engines

Honda

Safety Labeling

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

Special Equipment Safety Features

High Pressure Safety Device (Rupture Disc)

WARNING: If the high-pressure safety device ever discharges water, turn the engine off and do not use the machine. The device will no longer function properly. See a dealer or call Product Support at 1-800-270-

0810.

This unit is equipped with a high pressure safety device, which acts as a backup safety feature. If the unloader malfunctions, the high-pressure safety device will open and relieve excess system pressure.

High Temperature Limit

This unit is equipped with a high temperature limit that measures discharge spray temperature and automatically turns the burner off when the temperature setting is reached. When the discharge spray temperature drops, the burner automatically reignites.

Thermal Relief Valve

This unit is equipped with a thermal relief valve to protect the pump from overheating. The pump continues to work in bypass mode when you are not spraying. If high temperatures are developed during bypass mode, the thermal relief valve will open and discharge hot water onto the ground, protecting the pump from overheating. The thermal relief valve is located on the pump.

Spray Gun Safety Latch

The spray gun is equipped with a built-in trigger safety latch to guard against accidental trigger actuation.

00417

Safety Latch

Thermal relief valve

Guard

removed

for clarity

High pressure

safety device

High temperature limit

Assembly and Initial Set-Up

Steps for Assembly / Initial Set-Up Step 1. Unpacking & Delivery Inspection Step 2. Attaching a Water Feed Tank (customer supplied) Step 3. Initial Pump & Engine Preparation Step 4. Battery Installation

Step 1. Unpacking & Delivery Inspection

Find and separate the components identified in Figure 2 – Overview of Pressure Washer Components and Figure 3 – Hardware Bag. Inspect the pressure washer immediately after you receive delivery for missing parts and damage.

 If you have missing or damaged components, contact Product Support at 1-800-270-0810.

Figure 2 – Overview of Pressure Washer Components

Pressure Washer

Spray Gun and Lance

High Pressure

Hose

Manual

bag

Each of these steps is discussed in the below:

Figure 3 – Hardware Bag Contents

Nozzles

Qty-5

Part # 778946 - 0°, red

Part # 778739 - 15°, yellow

Part # 778948 - 25°, green Part # 778947 - 40°, white

Part # 778949 - Soap, black

Suction Hose Assembly

Qty-1

Part # 221222 and 777165

Chemical Injector

Qty-1

Part # 779614

Assembly and Initial Set-Up

Step 2. Attaching a Water Feed Tank If Desired (customer supplied)

Water may be supplied to the pressure washer either via an external water tank or via a standard tap supply.

CAUTION: Inadequate plumbing between a feed tank and the pressure washer can

cause damage to the pump from cavitation. To avoid cavitation:

 Use 3/4" hose and fittings or larger. Hose should be no longer than 6 ft.  Place feed tank so bottom of tank is level or higher than bottom of skid

frame.

 Place the feed tank as close as possible to the pressure washer so the

connection hose will be as short as possible.

 Make sure the connection hose does not kink.  Never allow tank to run dry.

To connect an external water feed tank, follow the steps below:

Step 1. You will need to supply the following:

a. A 200 gallon or larger water feed tank. b. 3/4" connection hose no longer than 6 ft. c. 3/4" fittings. Do not use 90 elbow fittings unless absolutely necessary.

Step 2. Make sure the bottom of the water tank is level with or higher than the bottom of the

skid frame.

Step 3. Connect one end of the 3/4" hose to the water tank. Step 4. Connect the other end of the 3/4" hose to the pump as shown in Figure 4a. Make sure

the connection hose does not kink.

Figure 4a

Connect feed

line here

Open this ball valve

Close this ball valve

Assembly and Initial Set-Up

Step 5. CLOSE the city tap water ball valve and OPEN the feed tank ball valve, as shown in

Figure 4a.

Step 6. Reroute the easy start valve so it discharges back to the feed tank as shown below in

Figure 4b. (This will aid pump priming on initial start-up.)

Figure 4b

The easy start valve is located below the Unloader – see "Component Identification" section of this manual for location of Unloader.

The tank is now ready to be filled.

CAUTION: To protect the pump, do not add cleaning chemicals directly to the tank

water. Use the quick couple chemical injector provided and follow all instructions and precautions for chemical spraying see: "Operation Instructions, Step 2. Set Up for Chemical Spray" section in this manual.

Unloader

Plug this

port

Reroute hose to

water feed tank

Assembly and Initial Set-Up

Step 3. Initial Pump & Engine Preparation

Prepare Water Pump

Verify pump oil level.

Note: The pump is shipped with oil. *Change oil after first 40 hours, then every 3 months or 500 hours

1. Verify oil level: a. Remove shipping tape

from oil fill cap. Verify that oil level is half way up the sight glass (or at the indicator line on the dip stick, if equipped).

2. If oil level is low, fill

using SAE30 nondetergent oil or Cat Pump Oil Item #22158.

3. Replace oil fill cap.

Prepare Engine

Fill the engine with oil.

Note: The engine is shipped without oil. Refer to the Engine Manual to locate oil-fill port and for instructions on filling.

Use the oil grade and quantity specified in the Engine Manual.

Figure 5

Oil fill cap

Oil drain valve

Sight glass

Assembly and Initial Set-Up

Step 4. Battery Installation

Install a 12-volt standard automotive battery (Group 75) with a minimum 18 amp-hour rating.

The engine will run but the burner will not fire unless a battery is installed.

The battery is to be supplied by the customer and should be installed in the protective battery compartment located near the engine. The inside dimensions of the battery compartment are 111/8"L x 7-3/4"W x 10-1/8"H.

Follow the steps below for connecting and disconnecting the battery.

WARNING: Battery Hazards

Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause electric shock. Caution must be exercised when making connections to a battery to avoid shock and contact with the acid, and to prevent any sparking that could lead to an explosion. ALWAYS follow the general battery safety rules and instructions listed below.

General Battery Safety Rules

 ALWAYS use eye protection and protective clothing when handling

batteries.

 NEVER smoke or work near sparks or other sources of ignition.  NEVER touch both battery terminals at the same time with your hand or any

non-insulated tools.

 If battery acid contacts skin or clothing, flush immediately with water and

neutralize with baking soda.

Connecting the battery

Always connect the cables in the following sequence to avoid possible shock:

1. Find the battery cables located inside the battery compartment.

2. Connect the red cable to the positive (+) terminal of the battery.

3. Then connect the black cable to the negative (-) terminal of the battery.

Disconnecting the battery

Always disconnect cables in the following sequence to avoid possible shock.

1. First, disconnect the black cable from the negative (-) terminal of the

battery.

2. Next, disconnect the red cable from the positive (+) terminal of the battery.

3. Remove the battery from the battery compartment.

Moving and Handling

WARNING

The pressures washer is heavy. You can be injured when trying to lift it without mechanical assistance. It can crush and cause serious injury if it drops on someone. Follow the instructions below for safely moving the pressure washer.

Lifting eye

To reduce risk of injury, use a hoist to elevate or lower the pressure washer. Lift from the lifting eye when using a hoist.

Before Each Use

Steps to Follow Before Each Use Step 1. Check Equipment Step 2. Add Fuel(s) Step 3. Select Suitable Worksite

Step 1. Check Equipment

Check/add pump oil

Check/add pump oil. *Change oil after first 40 hours, then every 3 months or

500 hours Caution: Never run the pump without sufficient lubrication!

1. Check oil level. Verify that oil level is half way up the sight glass.

2. If oil level is low, fill using SAE30 non-detergent oil or Cat Pump Oil Item

#22158.

3. Replace oil fill cap.

Check/add engine oil

Check the engine oil level and add oil as needed.

Use the recommended oil type for your engine and expected ambient conditions. (See engine Owner's Manual for oil type and capacity, and more detailed oil check/fill instructions.)

WARNING: Burn hazard

Never open oil port while engine is running. Hot oil can spray over face and body.

Notes:

o Low oil shutdown feature prevents the engine from starting or running

without sufficient oil.

o Engine is shipped without oil. You must add oil before first use.

Inspect spray system

Always inspect spray system for damage and leaks before each use. Do not start pressure washer until all needed repairs have been completed.

WARNING: High pressure fluid injection hazard

High-pressure fluid discharge from leaks (even pin-sized) or ruptured components can pierce skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

 Never use a finger or skin to check for leaks.  Never operate machine with damaged or missing hoses/parts.  Never attempt to repair a high-pressure hose or component – Always

Follow the steps below prior to each use of the pressure washer.

Before Each Use

replace it with a part that is rated at or above the pressure rating of this machine.

1) Check hoses, fittings, wand, trigger gun and connections for signs of wear,

cracks, looseness, or leaks. Replace as required.

2) Check and clean the nozzle orifice.

3) Clean inlet filter. (See Maintenance instructions)

Inspect fuel system

Always inspect (engine and burner) fuel systems & check for leaks BEFORE starting pressure washer. Do not start pressure washer until all needed repairs have been completed.

WARNING: Fuel leak hazard

Gasoline and burner fuels are highly explosive and fuel leaks can result in fire or explosions. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

Inspect the entire fuel system. Look for:

 signs of leaks or deterioration,  chafed or spongy fuel hose,  loose connections,  loose or missing fuel hose clamps,  damaged gasoline tank, or  defective gasoline shut-off valve.

Perform other scheduled maintenance as needed

Make sure that any other regular maintenance has been performed as prescribed in this manual in the "Maintenance & Repair" section.

1. Refer to the engine owner's manual for engine maintenance instructions.

2. Make sure battery is charged. Charge as needed according to your battery

manufacturer's instructions.

Step 2. Add Fuel(s)

WARNING: Fuel fire/explosion hazard

Gasoline is highly flammable and explosive. Burner fuels are combustible at warm temperatures. Heat, sparks, and flames can ignite fuel vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Always use extreme care when handling fuels. Carefully follow all instructions to avoid the following conditions which could result in fuel ignition:

 gas vapor collection inside enclosures  static electric sparks  sparks from electric wiring, batteries, or running engines  sources of heat (such as a hot engine, burner or exhaust)  open flames, including pilot lights

+ 40 hidden pages

North Star M157594AF.1, 157594 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual