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North Star M157592O Owner's Manual

Instructions for set-up, operation, maintenance & storage
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Instructions for Set-up, Operation, Maintenance & Storage
H
W
OT
ATER
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
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
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
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
M157592O
ITEM NUMBER: 157592
SERIAL NUMBER: _____________
– 4000
W
ASHER
/ 4
PSI
GPM

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Summary of Contents for North Star M157592O

  • Page 1 M157592O ITEM NUMBER: 157592 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 diesel engine and the water is heated by a kerosene/fuel-oil fired, open flame burner.

  • 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: Produce a high-pressure spray of heated or unheated water (up to 4 gallons per minute at 4000 psi). Incorporate cleaning chemicals into a low-pressure water spray.

  • Page 5: Specifications

    Specifications MODEL Model # 157592 FLOW OUTPUT Pressure Rating 4000 psi Flow Rate 4 gpm Maximum Temperature 210 F DIMENSIONS / COMPONENTS Length 47" Width 37.75" Height 42" Weight (dry) 500 lbs. Pump Type NorthStar RW4540S Engine Horsepower 18.8 HP High Pressure Discharge Hose 3/8"...

  • Page 6: Component Identification

    Component Identification Ref # Description Ref # Description Ref # Description Rupture Disc 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. Rupture Disc Safety device that opens to relieve pressure in the event of system over pressurization. 2. Unloader Valve that regulates pressure and directs flow into bypass when trigger is closed. Means of connecting garden hose to pump inlet. 3.

  • 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...

  • 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.

  • Page 14: Step 3. Initial Pump & Engine Preparation

    Assembly and Initial Set-Up Step 3. Initial Pump & Engine Preparation Verify pump oil level. Prepare Note: The pump is shipped with oil. Water Pump 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 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 pump oil. Check/add pump oil Caution: Never run the pump without sufficient lubrication!

  • Page 18: Step 2. Add Fuel(S)

    Before Each Use 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. Replace as required. 2) Check and clean the nozzle orifice.
  • Page 19 Before Each Use 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 – it could cause a static electric spark.

  • Page 20: 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 21 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.

  • 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 Connect your If using tap water: Follow these instructions when supplying water from a pressurized source water supply 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...

  • 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 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.

  • Page 28: Step 3. Spraying

    Operation 4. Submerge the suction strainer connected to the braided chemical hose into a bucket containing the chemical solution. See Figure 10. 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 29 Operation 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. Do not attempt to use this machine as a prop.
  • Page 30 Operation  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 31 Operation 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. 5. 5. The chemical concentration of the spray can be changed by turning the chemical adjustment knob located on the chemical injector.
  • Page 32 Operation 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 33 Operation 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. Never touch the metal screw or any metal parts of the spray gun when the heater is being used.

  • 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 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 storage location.

  • 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.

  • 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 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. Do not allow air intakes to become blocked. CAUTION: Do not spray pressure washer with a garden hose or pressure washer.
  • Page 42 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 43 Maintenance & Repair Change pump oil Change the pump oil after the first 40 hours of use, and then after every 3 months or 500 hours of use after that. 1. Remove oil drain plug on pump. 2. Drain pump oil into suitable container and dispose of responsibly. 3.
  • Page 44 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 45 Maintenance & Repair the hose in the bucket. 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 46 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 47 Maintenance & Repair Drive belt Check drive belt tension after first 24 hours of running and then maintenance routinely with each oil change. Tighten or replace belts as needed. Always tighten belts if slipping. WARNING: Belt slippage can cause static electricity build-up, which may result in sparking.
  • Page 48 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:...

  • Page 49: 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 50 Pump Parts Explosion M157592 – Rev O...

  • Page 51: Parts Explosion

    Pump Parts Explosion M157592 – Rev O PART # DESCRIPTION PART # DESCRIPTION 787796 Belt Guard Back Plate 777421 Spray lance 787794 Belt Guard Cover 777422 Quick coupler, 3/8" NPT M 788700 NorthStar RW4540S Pump 777723 Quick couple nipple, 3/8" NPT F 2006 Pump Pulley 791274...
  • Page 52 Pump Parts Explosion M157592 – Rev O 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...

  • Page 53: Wiring Diagram

    Wiring Diagram M157592 – Rev O...

  • Page 54: 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 55 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 56: During Use

    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 57 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.  Prevent surface damage & flying debris – Surfaces being sprayed must be strong enough to withstand high- pressure spray, or damage may result.

  • Page 58: After Use

    Summary of Important Safety Information  Other exhaust dangers. This product contains or emits chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust. After use  Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine is a fire hazard.

  • Page 59: 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 60 Manufactured by Northern Tool + Equipment Co., Burnsville, MN 55306 NorthernTool.com...

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