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Instructions for Set-up, Operation, Maintenance & Storage
2-G
H
UN
OT
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.
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.
CO Poisoning
Skin/Eye Injury
Burns
Slips/Falls
Flying Debris
Fire/
v vapors in the vicinity. Hot exhaust from engine and burner can ignite
Explosion
Chemical
Exposure
Electric shock
A summary of important safety information is provided at the end of the manual.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
W
P
ATER
RESSURE
Portable Outdoor-Use Only
WARNING – READ THIS MANUAL
WARNING – SPECIAL HAZARDS
Exhaust from both the engine and burner contains carbon monoxide, a poisonous
gas that can cause carbon monoxide poisoning and possible death if inhaled.
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.
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.
Spray discharge can cause puddles and slippery surfaces.
Spray-gun kickback can cause operator loss of balance and falls.
High-pressure spray can cause surface damage and flying debris.
Engine and burner sparking can ignite fuel or other flammable liquids or
combustible materials.
Cleaning chemical vapors or contact with skin may be hazardous.
Spray contact with electrical sources can cause electric shock.
Call NorthStar Product Support 1-800-270-0810
M157598AI
ITEM NUMBER: 157598
SERIAL NUMBER: _____________
– 4000
W
ASHER
/ 7
PSI
GPM
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Summary of Contents for North Star M157598AI
- Page 1 M157598AI ITEM NUMBER: 157598 SERIAL NUMBER: _____________ Owner's Manual Instructions for Set-up, Operation, Maintenance & Storage – 4000 ATER RESSURE ASHER 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.
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Page 2: Hazard Signal Word Definitions
Hazard Signal Word Definitions This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER (red) indicates a hazardous situation, which if not avoided, will result in death or serious injury. -
Page 3: Table Of Contents
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. -
Page 4: About Your Pressure Washer
About Your Pressure Washer 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 7 gallons per minute at 4000 psi). The pressure washer may be operated in either dual- or single-gun mode. -
Page 5: Specifications
Specifications MODEL Model # 157598 FLOW OUTPUT Pressure Rating 4000 psi Flow Rate 7 gpm Maximum Temperature 200 F DIMENSIONS / COMPONENTS Length 47.25" Width 53.75" Height 47.25" Weight 800 lbs. Pump Type NorthStar TWS 7040 Engine Horsepower 25 hp High Pressure Discharge Hoses Two - 3/8"... -
Page 6: Component Identification
Component Identification HEAT HEAT THERMOSTAT INDICATOR LIGHTS POWER FLOW THERM. Ref # Description Ref # Description Indicator light (Power) Flow Switch Indicator light (Flow) Unloader Indicator light (Thermostat) Water Outlet Thermostat Engine (see engine manual) Heat Switch Engine Key Switch Control Panel Pump Gasoline Tank... - Page 7 Component Identification REFERENCE GUIDE 1. Indicator Light (Power) Instrument used to monitor unit operation. Should illuminate when the power switch is in the ON position. Instrument used to monitor unit operation. Illuminates if 2. Indicator Light (flow) water is flowing through the spray gun. 4.
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Page 8: Safety Labeling
Safety Labeling DANGER 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. NEVER use inside any building, structure or Only use OUTSIDE and far away from garage, EVEN IF doors and windows are open. -
Page 9: Special Equipment Safety Features
Special Equipment Safety Features High Pressure WARNING-If the high-pressure safety device ever discharges water, Safety Device turn the engine off and do not use the machine. The device will no longer (Rupture Disc) function properly. See a dealer or call Product Support at 1-800-270- 0810. -
Page 10: Assembly And Initial Set-Up
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 Each of these steps is discussed in the below: Step 1. - Page 11 Assembly and Initial Set-Up (2) 3/4" Hose Clamp Part # 17141 (2) Engine Keys #7.0 Nozzle 5 Pack (2) #3.5 Nozzle 5 Pack Part # 779544 Part # 38532 (2) Bulkhead Fittings 3/4" NPT x 3/4" Hose Part # 5370 Barb Elbow 4gpm Quick Connect Injector Part # 50NBR12...
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Page 12: Step 2. Attaching A Water Feed Tank (Customer Supplied)
Assembly and Initial Set-Up Step 2. Attaching a Water Feed Tank If Desired (customer supplied) Water must be supplied to your pressure washer by an external water tank which you provide. To connect an external water feed tank, follow the steps below: CAUTION : Inadequate plumbing between a feed tank and the pressure washer can... -
Page 13: Step 3. Initial Pump & Engine Preparation
Assembly and Initial Set-Up 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 –... -
Page 14: Step 4. Battery Installation
Assembly and Initial Set-Up Step 4. Battery Installation Install a 12-volt standard, top-post mount, automotive battery (Group 75) with a minimum 18 amp-hour rating. The engine will not run and 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. -
Page 15: Moving And Handling
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. To reduce risk of injury, only lift the pressure washer from underneath using a pallet jack or forklift. -
Page 16: Before Each Use
Before Each Use Follow the steps below prior to each use of the pressure washer. 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 Check/add pump oil. Caution: Never run the pump without sufficient lubrication! pump oil 1. -
Page 17: Step 2. Add Fuel(S)
Before Each Use 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 Always inspect (engine and burner) fuel systems & check for leaks system BEFORE starting pressure washer. - Page 18 Before Each Use Always follow these general safety rules when fueling: 1) Turn pressure washer off and allow to cool for at least two minutes before removing any fuel cap. Note: A running or still-hot engine or burner is hot enough to ignite fuel. 2) Fill fuel tank OUTDOORS –...
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Page 19: Step 3. Select A Suitable Worksite
Before Each Use water) empty space below fill neck to allow for fuel expansion. 3) Replace fuel cap securely before starting engine. 4) Wipe any excess fuel from unit before starting Step 3. Select Suitable Outdoor Worksite Before using the pressure washer, you must understand the criteria for selecting a suitable location for operation. - Page 20 Before Each Use or other vehicles, on boats, or on pick-up truck beds. WARNING Never attempt to attach ductwork to the engine muffler or burner exhaust to allow for installation inside an enclosure. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or overheating and damage to the pressure washer.
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Page 21: Operation
Operation After you have checked and fueled the equipment and positioned it in a suitable worksite, it is time to start your pressure washer. The following are the procedures necessary for safe, successful operation of 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: ... - Page 22 Operation 2. Ensure the water in your tank is clean. Debris can cause excess pump wear and reduce performance. Attach high Attach high pressure hose(s) to the pressure washer's water outlet. pressure hose WARNING: NEVER operate this pump with components (such as hose, connections, and spray gun) rated for lower pressure and/or temperature limits than the machine's maximum rated pressure and temperature, or component could rupture and cause serious personal injury from escaping high pressure...
- Page 23 Operation whether you are using two guns or one (size of nozzle). 1. One gun vs. two gun use: a) Use a #7.0 nozzle for single gun operation. This will ensure the rated flow and psi are achieved. b) Use two #3.5 nozzles when operating dual guns. WARNING: NEVER use #7.0 nozzles when operating both guns.
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Page 24: Step 2. Set Up For Chemical Spray (If Desired)
Operation 1. Make sure the engine is off and the hose line depressurized. 2. To install the nozzle, pull the collar back and twist the nozzle firmly into the coupler on the end of the wand. (Figure 9a) Lance Coupler Nozzle Collar Figure 9a... - Page 25 Operation cause pump damage if introduced upstream through the pump's water inlet. It mixes the cleaning chemical into a low pressure spray. Cleaning chemicals applied under low pressure adhere better to the surface being cleaned, allowing the formula time to react and remove dirt more effectively.
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Page 26: Step 3. Spraying
Operation Step 3. Spraying Safety rules for Before starting the pressure washer, review the following general safety operation rules for operation: Conditions for Use Know how to stop. Be thoroughly familiar with proper use of the equipment and all controls and connections. Know how to stop the pressure washer and depressurize system quickly if needed (see "Step 4. - Page 27 Operation No load bearing. 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. Lock trigger safety latch when not spraying. Spray gun is equipped with a built- in trigger safety latch to guard against accidental trigger release.
- Page 28 Operation Start engine Start the engine to power the pump. 1. Make sure water supply is connected and primed. CAUTION: Running the pump dry will cause damage and void the warranty. 2. To prevent accidental spraying, engage the safety latch on spray gun trigger by rotating it to the locked position.
- Page 29 Operation "Connect Hoses, Water Supply, and Nozzle". 9. Rinse with high-pressure spray, either hot or cold, as instructed below. Turn on burner If HOT spray or steam is desired, turn on the burner: (If hot spray or 1. First make sure vicinity is free of flammable vapors, dust, gases, or steam is desired) other potentially combustible materials.
- Page 30 Operation person. Do not allow any part of the body to come in contact with the fluid stream. High-pressure spray can cause serious skin, eye, or falling injuries, and hot water can burn. Injection injury will occur if high-pressure spray pierces the skin, injecting liquid under the skin.
- Page 31 Operation 4. 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. 5. Use the width of the spray pattern to wash a wide path. Overlap spray paths for complete coverage.
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Page 32: Step 4. Stopping
Operation Step 4. Stopping Stop the engine using the following steps: WARNING: 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. -
Page 33: Storage
Storage Storage When you are finished using the pressure washer, you must prepare the sprayer for storage and store it in a proper location. Note: o If you will be storing the sprayer in freezing conditions, follow the instructions for preparing the sprayer for storage in freezing conditions. - Page 34 Storage 3. Using a wrench, disconnect the plumbing that connects to the heating coil inlet. The water will flow out of the heating coil. This will protect the coil from freeze damage. 4. Open both water inlet ball valves and remove the cap from the water filter.
- Page 35 Storage Prepare pressure Prepare the pressure washer for storage. washer for storage 1. Disconnect the battery, remove it from the battery compartment, and store it indoors. 2. Make sure the engine start switch is OFF and fuel valve is OFF. 3.
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Page 36: Burner Adjustment
Burner Adjustment Oil Burner Adjustment (only needed if white exhaust smoke appears) The oil burner is preset and performance tested at the factory (elevation 1100 feet). Different altitudes may require a one-time initial burner adjustment. CAUTION: If white smoke appears from the burner exhaust vent during start-up or operation, discontinue use and readjust air bands. - Page 37 Burner Adjustment a. Locate the shutter as shown in Figure 14 below. The shutter is a thin circular metal plate located on the outside of the air band. The shutter adjusts independently from the air band and is used to fine-tune the amount of intake air.
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Page 38: Maintenance And Repair
Maintenance & Repair Inspect and maintain your pressure washer as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance instructions. WARNING ALWAYS shut off water supply, bleed water pressure, turn off engine and disconnect the spark plug before cleaning, adjusting, or servicing the pressure washer. - Page 39 Maintenance & Repair Major repair. Major service, including the installation or replacement of parts, should be performed only by a qualified electrical service technician. Obtain factory approved parts from NorthStar Product Support at 1-800-270- 0810. Replacement parts. If a part needs replacement, only use factory approved repair parts.
- Page 40 Maintenance & Repair 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. Good Water dripping or spraying, or localized moisture Exposed wire mesh due to wear Figure 15 Clean inlet filter...
- Page 41 Maintenance & Repair months or 500 hours of use after that. 1. Open oil drain valve on pump. 2. Drain pump oil into suitable container and dispose of responsibly. 3. Close oil drain valve. 4. Make sure unit is sitting level. Fill pump with 37 oz. of Universal Tractor Transmission Oil (UTTO) or Mobil1 15W50 synthetic oil to middle of sight glass (or at the indicator line on the dip stick if equipped).
- Page 42 Maintenance & Repair Descale heating coil Descale coil tubing annually or more frequently as needed. In hard water areas, scale can build up inside the heating coil tubing. Scale deposits will decrease the output pressure and temperature of heated spray, and may eventually clog water flow through the heating coil.
- Page 43 Maintenance & Repair Cleaning Flow Inspect and clean the flow switch as needed Mineral build-up and/or debris within the flow switch can occur and may Switch affect burner operation if not periodically cleaned. Mineral build-up and/or debris can stop the movement of the shuttle inside the flow switch body. Shuttle movement is important because the burner will not fire if the shuttle does not move.
- Page 44 Maintenance & Repair Shuttle Alignment Brass Flow Switch Body female guides Shuttle male tabs Shuttle Flow Switch Swivel Removable Outlet Assembly Fitting Fitting Figure 20 Inspect electrodes Inspect electrodes yearly and make adjustments as needed. 1) Remove the 3 nuts that attach the burner to the heating chamber. You do not have to disconnect the fuel lines or the electric cords.
- Page 45 Maintenance & Repair 2) Clean off carbon deposits, which may have accumulated on the tips of the electrodes. 3) Reset the spacing as shown below in Figure 22. Electrodes 1/16 ” ” 5/16 ” Figure 22 Drive belt Check drive belt tension after first 24 hours of running and then maintenance routinely with each oil change.
- Page 46 Maintenance & Repair Tension Specifications New belt Used Belt Static tension (per rib/strand): 87.0-93.2 lb. 74.5-80.8 lb. Rib/strand Deflections Distance: 0.2 in 0.2in Rib/Strand Deflection Force: 5.9-6.3 lb. 5.2-5.5 lb. Sonic Tension Meter: 387 to 414 N 332 to 359N Note: Some general rules of belt tension are: ...
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Page 47: Troubleshooting
Troubleshooting Engine Will Not Start Causes Solutions Low Oil Shutdown Fill engine with the adequate amount of oil. Cold Engine Choke engine to start. No Fuel Add gas to engine, make sure fuel shutoff valve is open. Dead Battery Recharge/Replace battery. Spark plug wire not attached Attach spark plug wire to spark plug. -
Page 48: Parts Explosion
Parts Exploded View- Rev AI... - Page 49 Parts Exploded View- Rev AI Part # Description Part # Description 5027 1/2" NPT elbow 779607 1/2" NPT x 1/4" HB 90° 17141 3/4" hose clamp 779614 QC injector, 4gpm 777375 Unloader 779627 Pump guide 777837 Hex Head Plug, 3/8” 779628 Pump guide riser 30048 1/2"...
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Page 50: Pump Explosion
Parts Exploded View- Rev AI... - Page 51 Parts Exploded View- Rev AI...
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Page 52: Wiring Diagram
Wiring Diagram – Rev AI... -
Page 53: Summary Of Important Safety Information
Instruct all operators. The pressure washer's owner must instruct all operators and potential renters in safe pressure washer set-up and operation. Do not allow anyone to operate the pressure washer who has not read the Owner's Manual and been instructed on its safe use. Owner's Manuals are available from North Star at 1-800-270-0810. - Page 54 Summary of Important Safety Information o When DISCONNECTING the battery, disconnect the BLACK cable from the NEGATIVE terminal FIRST Acid/skin contact. If battery acid contacts skin or clothing, flush immediately with water and neutralize with baking soda. Installation / Initial Set-up ...
- Page 55 Summary of Important Safety Information Safety – Operation Pre-start Review safety rules. Before each use of this pressure washer, review the "Rules for Safe Operation." Failure to follow these rules may result in serious injury or death. Know how to stop. Be thoroughly familiar with proper use of the equipment and all controls and connections.
- Page 56 Summary of Important Safety Information liquid under the skin. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene and possibly amputation. Dual gun use. During dual gun use, stay aware of the other operator's location at all times and keep spray directed away from them.
- Page 57 Summary of Important Safety Information serious. However, severe infection or reaction can result if proper medical treatment is not administered immediately by a doctor who is familiar with injection injuries. Other exhaust dangers. This product contains or emits chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
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Page 58: Limited Warranty
Limited Warranty Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. - Page 59 This page has intentionally been left blank.
- Page 60 Manufactured by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.com...