Table of Contents
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Instructions for Set-up, Operation, Maintenance & Storage
H
W
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/
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
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. 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.
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
vapors in the vicinity.
Hot exhaust from engine and burner can ignite 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
M157594AF.1
ITEM NUMBERS: 157594
SERIAL NUMBER: _____________
– 4000
W
ASHER
/ 4
PSI
GPM
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Related Manuals for North Star M157594AF.1
Summary of Contents for North Star M157594AF.1
- Page 1 M157594AF.1 ITEM NUMBERS: 157594 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 Equipment Protection Quick Facts STOP! Closely inspect to make sure no components are missing or damaged. See the Inspect Upon "Assembly and Initial Set-Up" section for instructions on whom to contact to report Delivery missing or damaged parts. STOP! Engine is shipped without oil. -
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 4 gallons per minute at 4000 psi). 2) Incorporate cleaning chemicals into a low-pressure water spray. -
Page 5: Specifications
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"... -
Page 6: Component Identification
Component Identification Ref # Description Ref # Description Ref # Description Unloader Ball Valve Engine Key Switch (feed tank) Lifting Eye Ball Valve Circuit Breaker (city tap water) Engine Water Filter Heat Switch (see engine manual) Inlet Plumbing Water Inlet Thermostat (city tap water) Diesel Tank... - Page 7 Component Identification REFERENCE GUIDE Valve that regulates pressure and directs flow into bypass 1. Unloader 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. Diesel fuel storage container.
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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 Chemical Injector Nozzles Qty-1 Qty-5 Part # 779614 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...
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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 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. - Page 13 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.
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Page 14: Step 3. Initial Pump & Engine Preparation
Assembly and Initial Set-Up Step 3. Initial Pump & Engine Preparation Verify pump oil level. Prepare Water Pump Note: The pump is shipped with oil. *Change oil after first 40 hours, then every 3 months or 500 hours 1. Verify oil level: Oil fill cap a. -
Page 15: Step 4. Battery Installation
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. -
Page 16: 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, use a hoist to elevate or lower the pressure washer. -
Page 17: 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. *Change oil after first 40 hours, then every 3 months or pump oil 500 hours Caution: Never run the pump without sufficient lubrication! -
Page 18: Step 2. Add Fuel(S)
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. - Page 19 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 20: 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 21 Before Each Use Note that this pressure washer is NOT designed or approved for use in vehicles or marine applications. Never run the pressure washer inside RVs 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.
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Page 22: 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 make sure you understand all instructions and safety information before using the pressure washer. - Page 23 Operation Connect your If using tap water: water supply Follow these instructions when supplying water from a pressurized source such as city tap water: Acquire a suitable garden hose and attach to the water supply: 1. Acquire a suitable garden hose: a.
- Page 24 Operation If using feed tank: Follow these instructions when supplying water from a feed tank: 1. Make sure you have followed all instructions provided in this manual for attaching water feed tank. (See Assembly/Initial Set-Up section, "Step 2. Attaching a Water Feed Tank".) 2.
- Page 25 Operation 3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. (Figure 8b). Check the connection by pulling on the hose to ensure a positive connection. Correct Insertion Not Fully Inserted Collar Seated Collar NOT Seated Figure 8b Select spray Your pressure washer is equipped with four high-pressure nozzles and one...
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Page 26: 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 27 Operation 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. Note: An external chemical injector pump is not recommended for use with this pressure washer. WARNING: Chemical spraying ...
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Page 28: 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 29 Operation 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. Rotate safety latch to the locked position when not spraying. Leaving unattended. Always turn off the pressure washer and relieve system pressure before leaving the sprayer unattended.
- Page 30 Operation Make sure the water supply hose is not kinked. A kinked hose will provide insufficient water supply to the pump and reduce its life. Make sure the hose remains unkinked after moving the pressure washer. If using water feed tank: ...
- Page 31 Operation injector will draw the chemical into the water stream. 5. The chemical concentration of the spray can be changed by turning the chemical adjustment knob located on the chemical injector. 6. Apply chemicals evenly to the cleaning surface. Never use more chemical than is necessary to clean the surface.
- Page 32 Operation WARNING It is important that the burner stops firing when the trigger is released. If the burner remains firing, discontinue use until the pressure washer is serviced. Extremely high temperatures can result in serious injury and equipment damage. Begin high pressure High Pressure Spray Procedure spray WARNING:...
- Page 33 Operation CAUTION Spray gun metal gets extremely hot when using the burner and can burn you on contact. Never touch the metal screw or any metal parts of the spray gun when the heater is being used. Use only designated grip areas. Safety Latch 00417 4.
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Page 34: Step 4. Stopping
Operation 9. If temporarily interrupting spraying, rotate trigger safety latch downward to the locked position to guard against accidental trigger release. 10. Always turn off the engine and activate spray gun trigger to relieve system pressure when: the sprayer is unattended, or ... -
Page 35: 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 36 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 37 Storage d. Replace spark plug, but do not reconnect the spark plug wire. 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 38: 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 39 Burner Adjustment 5. Slowly open the air band until white smoke just starts to appear. 6. Turn air band halfway back to the black smoke position previously noted. Tighten the locking screw. 7. Now fine tune the burner air by adjusting the shutter: a.
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Page 40: 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 41 Maintenance & Repair approved repair parts. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the pressure washer and will void the warranty. Keep pressure Keep pressure washer clean. If dust or debris accumulates on the pressure washer, clean the pressure washer clean washer with a damp cloth or soft bristle brush.
- Page 42 Maintenance & Repair Good Water dripping or spraying, or localized moisture Exposed wire mesh due Figure 15 to wear Clean water filter Clean the water filter before each use. WARNING: When cleaning filters, check whether dangerous chemicals have been used with the filter and take any precautions that may be recommended by the manufacturer of these chemicals.
- Page 43 Maintenance & Repair Change the pump oil after the first 40 hours of use, and then after every 3 Change pump oil 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.
- Page 44 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 45 Maintenance & Repair surface of the heating coil tubing. These deposits will insulate the coil, which then restricts air flow through the heat exchanger and further aggravates the soot build-up. If soot has built up on the exterior of the coil tubing, clean as follows: 1) Wear protective clothing, goggles, and gloves.
- Page 46 Maintenance & Repair 4) Reset the spacing as shown below in Figure 21. Electrodes 1/16” 1/8” 5/16” Figure 21 NOTE TO COMMERCIAL USERS: All mechanical equipment, no matter how well designed, will need maintenance and repairs. A Northstar pressure washer is no exception. At times, a Northstar pressure washer may become inoperable because repairs are required.
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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 Explosion-Rev AF... - Page 49 Parts Explosion-Rev AF PART # DESCRIPTION PART # DESCRIPTION 783394 Honda engine 18hp 783034 Tank support 783396 Honda muffler kit 777838 1/4" NPT plug 777837 3/8" NPT plug 790561 Thermostat 38198 CAT pump, 4gpm 777855 Toggle switch 777347 3/8" NPT tee 31085 Circuit breaker, 20A 777378...
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Page 50: Pump Explosion
Parts Explosion-Rev AF... -
Page 51: Wiring Diagram
Wiring Diagram- Rev AF... -
Page 52: Summary Of Important Safety Information
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. Adult control only. Only trained adults should set up and operate the pressure washer. Do not let children operate. - Page 53 Summary of Important Safety Information Prevent carbon monoxide poisoning – Use outside only! Exhaust fumes from both the engine and the burner contain carbon monoxide (CO), a poisonous gas you cannot see, smell, or taste. The CO generated by the pressure washer can rapidly accumulate, even in areas that appear to be well ventilated, resulting in dangerous and fatal concentrations within minutes.
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Page 54: During Use
Summary of Important Safety Information Never operate unless all safety guards are in place. Position safely. Place sprayer on firm, level ground to prevent accidental falls and equipment tip-over. Not in presence of combustibles. Do not use the pressure washer in the presence of flammable vapors, dust, gases, or other potentially combustible materials. -
Page 55: After Use
Summary of Important Safety Information whether dangerous chemicals have been used with the filter and take any precautions that may have been recommended by the supplier of these chemicals. Always dispose of hazardous fluids per local, state, and national guidelines. ... -
Page 56: 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 57 This page has intentionally been left blank.
- Page 58 Manufactured by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.com...