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North Star M157597AG Owner's Manual

Trailer mounted, 2 - gun hot water pressure washer – 4000 psi/7 gpm
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Instructions for Set-up, Operation, Maintenance & Storage
T
RAILER MOUNTED
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
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
, 2-G
UN
– 4000
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 tipover.
Call NorthStar Product Support 1-800-270-0810
M157597AG
ITEM NUMBER: 157597
SERIAL NUMBER: _____________
H
W
OT
ATER
/ 7
PSI
GPM
P
W
RESSURE
ASHER

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Summary of Contents for North Star M157597AG

  • Page 1 M157597AG ITEM NUMBER: 157597 SERIAL NUMBER: _____________ Owner's Manual Instructions for Set-up, Operation, Maintenance & Storage , 2-G RAILER MOUNTED ATER RESSURE ASHER – 4000 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.

  • Page 2: Hazard Signal Word Definitions

    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 # 157597 FLOW OUTPUT Pressure Rating 4000 psi Flow Rate 7 gpm Maximum Temperature 200 F DIMENSIONS / COMPONENTS Length 201.5" Width 78" Height 75" 2000 lbs. – dry Weight 6550 lbs. – water tank full Pump Type NorthStar TWS 7040 Engine Horsepower 23.5 hp...

  • 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 Instrument used to monitor unit operation. Should 1. Indicator Light (Power) illuminate when the power switch is in the ON position. 2. Indicator Light (flow) Instrument used to monitor unit operation. Illuminates if water is flowing through the spray gun. Instrument used to monitor unit operation.

  • Page 8: Safety Labeling

    Special Equipment Safety Features WARNING - BATTERY HAZARDS BATTERIES: MOVING/TOWING INSTRUCTIONS 1) contain caustic acid, 2) emit explosive gases, Towing trailer: 3) can cause electric shock -Latch coupler securely to class 4 or higher hitch with 2" ball. ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns.

  • 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. Gun and Nozzle Storage Set-Up Step 3. Initial Pump & Engine Preparation Step 4. Battery Installation Each of these steps is discussed below: Step 1.
  • Page 11 Assembly and Initial Set-Up Qty (2) Engine Keys Qty (2) #3.5 Nozzle 5 Packs #7.0 Nozzle 5 Pack Part # 38532 Part # 779544 Qty (16) Grommets Part # 777111 Qty (2) Pin Catches Part # 778498 Figure 3 – Hardware Bag contents...

  • Page 12: Step 2. Gun And Nozzle Storage Set-Up

    Assembly and Initial Set-Up Step 2. Gun and Nozzle Storage Set-Up 1. Guns. Store guns vertically on back of trailer using supplied pins. Rest guns with handle down on the back of the trailer and pins will hold guns in place. 2.

  • Page 13: Step 4. Battery Installation

    Assembly and Initial Set-Up Prepare Completely unwrap / unwind the high pressure hose from the hose reel. Note: New hose will “grow” when charged for the first time and should always be High Psi Hose on Hose charged one time before being wrapped on the reel. Reel Step 4.

  • Page 14: Moving And Towing

    Moving and Towing WARNING The filled pressure 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 15 Moving and Towing with fingers. Proper adjustment is obtained when coupler is as tight as possible on ball and locking lever can still be opened and closed. 4. Lock lever closed to secure the attachment. 5. Insert safety pin. Attach safety Two safety cables must be used while towing.
  • Page 16 Moving and Towing Plug in Plug 7-way electrical pin connector into vehicle. lights/brake Raise the jack Always crank the jack into the UP position before towing. Tow the pressure washer to your desired work location. When towing, always adhere to the following safety rules. ...

  • 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. pump oil Caution: Never run the pump without sufficient lubrication! 1.

  • Page 18: 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 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 –...

  • 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 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.

  • 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 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 23 Operation 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 fluids.
  • Page 24 Operation with a single gun. b) Use two #3.5 nozzles when operating dual guns. WARNING: NEVER use #7.0 nozzles when operating both guns. If two operators use #7.0 nozzles and one operator releases the trigger on their gun, the flow through the second operator's gun will suddenly increase from 3.5 to 7 GPM.

  • Page 25: Step 2. Set Up For Chemical Spray (If Desired)

    Operation coupler on the end of the wand. (Figure 9a) Lance Nozzle Coupler Collar Figure 9a 3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. (Figure 9b). Check the connection by pulling on the nozzle to ensure a tight connection -- if correctly inserted, nozzle will rotate but not pull out.

  • Page 26: Step 3. Spraying

    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.
  • Page 27 Operation 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 28 Operation 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 29 Operation trigger by rotating it to the locked position. 3. Follow the instructions in the Engine Manual for starting the engine. - If the engine doesn't start on the first try, pressure may build up in the pump. Relieve pressure by squeezing the spray gun trigger before attempting to start engine again.
  • Page 30 Operation steam is desired) other potentially combustible materials. Operate only where open flame or torch is permitted. 2. Make sure there is fuel in the burner fuel tank. CAUTION: Do not run the machine in hot mode without fuel in the burner's fuel tank, or damage can occur.
  • Page 31 Operation secure the spray gun open by blocking or tying the spray gun in the open position.  Prevent slips / loss of balance. High-pressure spray could cause you to lose balance from kickback forces, and wet surfaces can be slippery. Keep good footing and balance at all times.
  • Page 32 Operation 6. The nozzle should be 12" to 24" from the work, closer for tough areas. 7. Small parts should be washed in a basket so the pressure does not push them away. Larger, lightweight parts should be clamped down. 8.

  • Page 33: 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 34: 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 35 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 36 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.

  • Page 37: 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 38 Burner Adjustment a. Locate the shutter as shown in Figure 13 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.

  • Page 39: 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 40 Maintenance & Repair servicing the pressure washer.  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 Northern Tool Product Support at 1- 800-270-0810.
  • Page 41 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 14 Clean inlet filter...
  • Page 42 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. Perform engine Perform engine maintenance as specified in the engine owner's maintenance...
  • Page 43 Maintenance & Repair Maintain burner's Drain water from burner's filter bowl as needed, and replace filter fuel filter/water after 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 44 Maintenance & Repair Outlet Inlet Figure 18 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.
  • Page 45 Maintenance & Repair 3) Unthread the removable outlet fitting with the swivel still attached from the flow switch assembly 4) Remove the shuttle 5) Clean the inside of the brass flow switch body and the shuttle with water and a soft brush 6) Insert the shuttle into the brass flow switch in the orientation shown Note: Aligning the male tabs on the shuttle to the female guides inside the brass flow switch body can be difficult since the shuttle is...
  • Page 46 Maintenance & Repair Nuts Figure 21 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 " " 7/16" Figure 22 Drive belt Check drive belt tension after first 24 hours of running and then maintenance routinely with each oil change.
  • Page 47 Maintenance & Repair WARNING: Belt slippage can cause static electricity build-up, which may result in sparking. Fire ignition can result. Instructions: 1) Make sure engine is off and spark plug wire is removed. 2) Remove belt guard. See "Parts Breakdown" section of this manual for location.
  • Page 48 Maintenance & Repair Instructions: 1) Inspect magnets, shoes, and magnetic coil for wear. Replace as needed. Note: Magnets should always be replaced in pairs (both sides of an axle). a) Replace magnets and shoes if worn or scored. b) Replace magnets if wearing unevenly or abnormally. c) Replace magnets if any part of the magnetic coil becomes visible through the friction material facing of the magnet.

  • Page 49: 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 50: Parts Explosion

    Parts Explosion – M157597 Rev AG (Skid)
  • Page 51 Parts Explosion – M157597 Rev AG (Skid) 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"...
  • Page 52 Parts Explosion – M157597 Rev AG (Trailer)
  • Page 53 Parts Explosion – M157597 Rev AG (Trailer) PART # DESCRIPTION 779612 Skid 779580 Tank Strap 779500 525 Gallon Tank 777779 3/8", 150" 6000 PSI Hose 791279 28" Lance 779165 Gun with Lance 784105 3/8" 4000 PSI Hose 23" 778498 Pin Catch 777111 Grommet 38532...

  • Page 54: Pump Explosion

    Pump Explosion...
  • Page 55 Pump Explosion...

  • Page 56: Wiring Diagram

    Wiring Diagram...

  • Page 57: 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 58 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 59 Summary of Important Safety Information  Hitch trailer properly. Follow all instructions for hitching trailer to towing vehicle. Make sure hitched trailer sits level Connect lights and breakaway switch.  Jack. Keep jack cranked down to help balance the trailer when it is not connected to a vehicle hitch. Crank jack up before towing.

  • Page 60: 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 61: After Use

    Summary of Important Safety Information 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.  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.
  • Page 62 This page has intentionally been left blank.

  • Page 63: 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 64 Manufactured by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.com...

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