North Star M157594P.1, 157594, 157595 Maintenance Manual

®

M157594P.1

ITEM NUMBER: 157594, 157595

SERIAL NUMBER:

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.

Quick Facts

Engine Oil Engine is shipped with out oil. Fill before starting. Use SAE 10W-30 motor oil.
Pump Oil Pump is shipped with oil. Check pump oil level before starting.
Water Make sure your water flow is 20% higher than the pressure washer’s flow rate.

Make sure your water is clean and particle free.
Storage Do not allow water to freeze in the pump, hose, coil, or spray gun.
Spraying
Chemicals
Maintenance
Schedule

Pump: Oil: change after first 40 hours, then every 3 months or 500 hours.

Use any NorthStar brand or equivalent pressure washer chemicals.

Adjust soap adjustment knob to regulate cleaning power.

Engine: Oil: change after first 20 hours, then annually or every 100 hours.

Spark Plug: clean every 100 hours, replace annually or every 300 hours.
Air Filter: clean every 100 hours, replace annually or every 300 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 2 Long Term/Winter Storage 12
Specifications 3 Troubleshooting Guide 13
Machine Component Identification 4 Parts Breakdowns 14-16
Installation Instructions 5-6 Electrical Schematic 17
Operation Instructions 7-9 Trailer Assembly Instructions (157595) 18
Safety Features 9 California Emissions Statement 19
Maintenance Instructions 10 Limited Wa rranty 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 and understand operating instructions carefully before use.
WARNING - When using this product basic precautions should always be followed, including the followin g:

1.) Read all the instructions before using the product.

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.

7.) 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.

9.) 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. 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

2

Specifications

Pressure Rating 4000 psi
Flow Output 4 gpm
Pump Type Cat 66DX
Water Supply Standard tap water @ 20-75 psi or water feed tank
Engine Horsepower 18 hp
BTU Output 353,700 BTU
Maximum Temperature
Approved Fuels #1 or #2 Diesel, Kerosene, Fuel Oil
Fuel Capacity 4 Gal
Gasoline Capacity 4 Gal
Discharge Hose 3/8”
Dimensions (skid only) 47” L X 37.5” W X 42” H
Weight (skid only) 500 lbs

Specifications for Trailer Mounted Models

Trailer GVWR 3500 lbs
Hitch Ball Size 2”
Skid Dimensions 129” L X 75.75” W X 60” H
Weight (tank empty) 960 lb
Weight (tank full) 2500 lb

210° F

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Machine Component Identification

Ref # Description Ref # Description Ref # Description

1 Unloader 9 Ball Valve (feed tank) 16 Water Outlet
2 Lifting Eye 10 Ball Valve (city tap water) 17 Engine Key Switch
3 Engine (see engine manual) 11 Water Filter 18 Circuit Breaker
4 Inlet Plumbing 12 Water Inlet (city tap water) 19 Heat Switch
5 Diesel Tank (trailer models use hose reel) 20 Thermostat
6 Gasoline Tank 13 Control Panel 21 Indicator Light (pressure sw)
7 Pump 14 Battery Box 22 Indicator Light (thermostat)
8 Water Inlet (feed tank) 15 Pressure Switch

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Installation Instructions

r

port

t

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 (“positive” or “+”) cable first. When
disconnecting a battery, always remove the black
colored (“negative” 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 is recommended and may be required
by local code.

Place the pressure washer on a solid level surface in a
protected area where it is not readily influenced by
outside forces such as 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.

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.

Connec
feed line

here

1.) Use ¾” connection hose no longer than 6ft long.

2.) Make sure the connection hose does not kink.

3.) Make sure all fittings are ¾” 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.

Open
this ball

Close
this ball

Unloade

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.

Plug this

Reroute hose to
water feed tank

5

Installation Instructions

A

A

r

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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, and 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 an insufficient
supply of oxygen. Proper 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. A draft controller will permit proper upward air
flow of exhaust flue gases.

Oil 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.

ir Band

White

rrow

Locking

Screw

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 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.

Burner

Shutte

Shutte

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.

6

Operating Instructions

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r

Read and understand the entire manual before operating the pressure washer.

Follow these instructions every time you use the pressure washer.

I.) 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.

2.) 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).

II.) 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 inlet (city tap water).

Close this

ball valve

Open this ball
valve

III.) 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.

Couple

Colla

CORRECT

High Pressure
Output

INCORRECT

1.) Make sure the water supply is clean. Debris can
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.

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