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Instructions for Set-up, Operation, Maintenance & Storage
T
M
RAILER
OUNTED
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 diesel
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
Trailer tipover
A summary of important safety information is provided at the end of the manual.
Any Questions, Comments, Problems, or Parts Orders
Owner's Manual
, H
W
OT
ATER
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
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.
Sudden stopping or turning while towing the pressure washer with a
filled water tank can result in driving instability and/or trailer tip over.
Call NorthStar Product Support 1-800-270-0810
M157593E
ITEM NUMBER: 157593
SERIAL NUMBER: _____________
®
P
W
RESSURE
ASHER
– 4000
/ 4
PSI
GPM
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Related Manuals for North Star M157593E
Summary of Contents for North Star M157593E
- Page 1 M157593E ITEM NUMBER: 157593 SERIAL NUMBER: _____________ ® Owner's Manual Instructions for Set-up, Operation, Maintenance & Storage – 4000 RAILER OUNTED 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.
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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 missing or Delivery damaged parts. -
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 # 157593 FLOW OUTPUT Pressure Rating 4000 psi Flow Rate 4 gpm Maximum Temperature 210 F DIMENSIONS / COMPONENTS Length 142" Width 76" Height 61" 1460lbs. – dry Weight 3400lbs. – water tank full Pump Type NorthStar NSRW4540 Engine Horsepower 18.8 HP High Pressure Discharge Hose... -
Page 6: Component Identification
Component Identification Ref # Description Ref # Description Ref # Description Pressure Relief Valve Ball Valve (city tap water) Pressure Switch Unloader Engine Key Switch Water Outlet Inlet Plumbing Water Inlet (city tap water) Heat Switch Pump (trailer models use hose reel) Thermostat Belt Guard Throttle Control... - Page 7 Component Identification REFERENCE GUIDE 1. Pressure Relief Valve Valve that opens to relief pressure in the event of system over pressurization. Valve that regulates pressure and directs flow into bypass 2. Unloader when trigger is closed. 3. Inlet Plumbing Means of connecting garden hose to pump inlet. 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. WARNING - BATTERY HAZARDS 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 relief valve ever discharges water, Relief Valve turn the engine off and do not use the machine. The valve will no longer 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. Trailer Assembly 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 1/2 x 5” Bolt 1/2” Flat Washer Qty-1 Part # 82119 Qty-2 Part # 82122 1/2” Class G Nut 1/2 x 4” Bolt Qty-3 Part # 82291 Qty-2 Part # 82250 5/16 x 1” Bolt 3/8 x 1” Bolt Qty-4 Qty-3 Part # 82016...
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Page 12: Step 2. Trailer Assembly
Assembly and Initial Set-Up Step 2. Trailer Assembly WARNING: The pressure washer is heavy. It can crush and cause serious injury if it rolls out of control or tips over. Follow all assembly instructions exactly as presented below. 1.) Remove the top and four sides of the steel crate. - Page 13 Assembly and Initial Set-Up Step 2. Trailer Assembly (continued) 14.) Attach coupler to a-frame with two 1/2x4" bolts and Class G lock nuts. Tighten each bolt to 90ft.-lbs. Use a torque wrench. Truck chest 15.) Attach safety cables to the a-frame with 1/2"...
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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. 1. Verify that oil level is half way up the sight glass (or at the indicator line on the dip stick). -
Page 15: Step 4. Battery Installation
Assembly and Initial Set-Up Step 4. Battery Installation Install a 12-volt battery (Group 22NF) with a minimum 55 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 Towing
Moving and Towing WARNING The filled pressures washer is heavy. It can crush and cause serious injury if it rolls out of control or tips over. ALWAYS keep the jack cranked down to help balance the trailer when it is not connected to a vehicle hitch. - Page 17 Moving and Towing Attach safety Two safety cables must be used while towing. Cross safety cables under the coupler, allowing only enough slack for vehicle cables turns. Plug light pin connector into vehicle. Plug in lights Raise the jack Always crank the jack into the UP position before towing. Tow the pressure washer to your desired work location.
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Page 18: 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. pump oil Caution: Never run the pump without sufficient lubrication! 1. -
Page 19: Step 2. Add Fuel(S)
Before Each Use Never attempt to repair a high-pressure hose or component – Always 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. - Page 20 Before Each Use Note: A running or still-hot engine or burner is hot enough to ignite fuel. 2) Fill fuel tank OUTDOORS – never indoors. Fuel vapors can ignite if they collect inside and enclosure and explosion can result. 3) Stay away from all sources of heat, sparks, and flames. Do not smoke. 4) Never pump fuel directly into the fuel tank or burner at a gas station –...
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Page 21: Step 3. Select A Suitable Worksite
Before Each Use Step 3. Select Suitable Outdoor Worksite Before using the pressure washer, you must understand the criteria for selecting a suitable location for operation. Note that this pressure washer is for OUTDOOR USE only. WARNING You must choose a suitable site for operating your pressure washer to avoid equipment damage and/or injury and possible death from carbon monoxide poisoning, fire/explosion, uncontrolled equipment movement/tip over, or slips and falls. - Page 22 Before Each Use 2. Away from Do not locate and use the pressure washer in the presence of flammable vapors, dust, gases, or other potentially combustible materials. Burner is an combustible dust, liquids, open flame, which can ignite airborne dusts and flammable vapors. Operate only or vapors where open flame or torch is permitted.
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Page 23: 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 24 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 25 Operation If using water tank: Follow these instructions when supplying water from the feed tank: 1. Ensure that you have the tank feed ball valve OPEN, and the city tap water ball valve CLOSED, as indicated in the diagram below. Open this ball valve Close this ball valve...
- Page 26 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 27: 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 28 Operation 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 Never spray acids, corrosives, or abrasive or flammable liquids. Breathing hazards, surface burns/corrosion, or fire/explosion could result.
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Page 29: Step 3. Spraying
Operation 4. Submerge the suction strainer connected to the braided chemical hose into a bucket containing the chemical solution. See Figure 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. - Page 30 Operation connections could fail and result in catastrophic high pressure release of fluid as well as hose whipping. Avoid sharp objects. Keep hose away from sharp objects. Bursting hoses may cause injury. No load bearing. Do not use the pump to support other items of equipment that impose unacceptable loads on the pump.
- Page 31 Operation Hoses, Water Supply, and Nozzle"). Purge air from the water supply hose by squeezing the trigger until a steady stream of water flows out of the nozzle at low pressure. (Air in the hoses can cause damage to the pump, so always make sure all the air is out of the hoses before starting the pressure washer engine.) ...
- Page 32 Operation water stream. 3. You can apply chemicals with either warm or cold water. Check chemical label. If warm water is specified, start burner according to instructions provided below. 4. Apply chemicals by squeezing the spray gun trigger. The chemical injector will draw the chemical into the water stream.
- Page 33 Operation "Oil Burner Adjustment Instructions" step in the "Set-Up" section of this manual. 5. 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. WARNING It is important that the burner stops firing when the trigger is released.
- Page 34 Operation pressure first and follow instructions for attaching a nozzle). 2. Clear the cleaning area of all persons. Keep children and pets away. 3. Hold the spray gun firmly with two hands and a sturdy stance -- Gun kicks back when triggered. CAUTION Spray gun metal gets extremely hot when using the burner and can burn you on contact.
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Page 35: 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 36: 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 37 Storage Remove the spray gun from the hose. 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 38 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. 3. Disconnect the high-pressure hose, garden hose, and spray gun. Move pressure Let engine cool for 5 minutes before moving the pressure washer to it's washer to storage...
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Page 39: 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 40 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 41: 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 42 Maintenance & Repair 0810. Replacement parts. If a part needs replacement, only use factory 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.
- Page 43 Maintenance & Repair Good Water dripping or spraying, or localized moisture Exposed wire mesh due to wear Figure 15 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 44 Maintenance & Repair Recharge and Inspect, recharge, and maintain battery according to your battery maintain battery manufacturer's instructions. Do not store with battery charger always connected. Batteries that are over- charged can boil themselves dry and produce excessive amounts of hydrogen, an explosive gas.
- Page 45 Maintenance & Repair Maintain burner's Drain water from burner's filter bowl as needed, and replace filter after fuel filter/water every 500 hours of use or as needed. separator 1) After each use of the burner, visually check the filter bowl. If any water has accumulated, drain it via the water drain at the bottom of the bowl.
- Page 46 Maintenance & Repair 6) Run the pressure washer in cold mode for 1 to 3 hours, recirculating the cleaning solution. CAUTION: Do not run the burner. 7) Dispose of the cleaning solution where it is not harmful to animals or the environment.
- Page 47 Maintenance & Repair Inspect electrodes Inspect electrodes yearly and make adjustments as needed. 1) Remove the 4 nuts that attach the burner to the heating chamber. You do not have to disconnect the fuel lines or the electric cords. Figure 20 2) Pull the burner out from underneath the heat exchanger.
- Page 48 Maintenance & Repair Drive belt Check drive belt tension after first 24 hours of running and then routinely with each oil change. Tighten or replace belts as needed. Always maintenance tighten belts if slipping. WARNING: Belt slippage can cause static electricity build-up, which may result in sparking.
- Page 49 Maintenance & Repair 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. NorthStar Product Support will assist in these repairs as needed, but if an inoperable pressure washer creates a major expense to your business, then we strongly recommend the following:...
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Page 50: Troubleshooting
Troubleshooting Engine Will Not Start Causes Solutions Low Oil Shutdown Fill engine with the adequate amount of oil. No Fuel Add diesel to diesel tank, bleed engine fuel line(see engine owner's manual) Dead Battery Recharge/Replace battery. Air in fuel line Bleed air from fuel lines (pump purge) Pressure Washer Runs But Burner Doesn't Fire Causes... -
Page 51: Parts Explosion
Parts Explosion M157593 – Rev E... - Page 52 Parts Explosion M157593 – Rev E PART # DESCRIPTION PART # DESCRIPTION 787796 Belt Guard Back Plate 777723 Quick couple nipple, 3/8" NPT F 787794 Belt Guard Cover 777904 Quick coupler, 1/4" NPT F 786485 NorthStar RW4540 Pump 777396 Hose, 50ft, includes #76 & #79 2006 Pump Pulley 777722...
- Page 53 Parts Explosion M157593 – Rev E PART # DESCRIPTION PART # DESCRIPTION 3/4" –1/2" Reducer 783427 Hose Reel 50CSC128 1/2" – 3/8" Reducer 30198 200 Gal Tank 30048 3/8" – 1/4" Reducer 777707 Tank Strap 777338 82080 Eye Bolt, 1/4" 777340 1/4"...
- Page 54 Pump Parts Explosion – Rev E PART # DESCRIPTION PART # DESCRIPTION Screw Washer Plug CO0202002200 Ceramic Bushing Pump Manifold Washer Washer O-Ring Plug Anti-Extrusion Ring Washer Piston Plug Gudgeon Pin Valve Plug Kit + O-Ring Connecting Rod O-Ring O-Ring CO1220003000 Suction/Delivery Valve Cover...
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Page 55: Wiring Diagram
Wiring Diagram – Rev E... -
Page 56: 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 57 Summary of Important Safety Information o When CONNECTING the battery, connect the RED cable to the POSITIVE terminal FIRST. 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.
- Page 58 Summary of Important Safety Information Hitch trailer properly. Follow all instructions for hitching trailer to towing vehicle. Make sure hitched trailer sits level Jack. Keep jack cranked down to help balance the trailer when it is not connected to a vehicle hitch. Crank jack up before towing.
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Page 59: During Use
Summary of Important Safety Information Check sprayer nozzle. Sprayer nozzle can become a projectile and cause serious personal injury or property damage if not properly connected to the spray gun. Check to ensure the nozzle has been properly attached to the spray gun before using the pressure washer. -
Page 60: After Use
Summary of Important Safety Information Never pull by hose. Do not move this machine by pulling on the hose. Hose or connections could fail and result in catastrophic high-pressure release of fluid as well as hose whipping. Avoid sharp objects. Keep hose away from sharp objects. Bursting hoses may cause injury. ... -
Page 61: 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. - Page 62 ® Manufactured by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.com...