North Star 157114 Owner'S Manual Download Page 6

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Component Identification

Ref #

Description

Ref # Description

High PSI limit switch

High Pressure Outlet

Heat Switch

Flow Switch

Fuel Filter/Water Separator

High-Temp. Limit Switch

Heating Coil

Heat Exchanger

Nozzle Storage

Garden Hose Water
Inlet

Gas Tank & Cap

Thermal Relief Valve

Pump

Spray Gun

Air, Fuel, Ignition System

Diesel Fuel Tank

Grip

Chemical injector

Diesel Fuel Cap

Wand

Rupture Disc Fitting

Unloader

Control Box (See Detail A)

Flame Sensor

Engine

Circuit Protector

SEE DETAIL C

AIR, FUEL, IGNITION SYSTEM

DETAIL D

SEE DETAIL D

SEE DETAIL A

SEE DETAIL B

DETAIL A

DETAIL B

DETAIL C

FAN, FLYWHEEL,

& STATOR ASSEMBLY

BURNER FUEL PUMP

FUEL PUMP SHEAVE

PRESSURE WASHER PUMP

BELT, MICRO-V J 4

RIB X 36"

Fig06828

Summary of Contents for 157114

Page 1: ...es 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 Skin Eye Injury High pressure spray can cause...

Page 2: ...mp is shipped with oil Check pump oil level before starting Water Flow Requirements Make sure your supply water flow rate is 20 higher than the pressure washer s flow rate see Specifications section f...

Page 3: ...t Hose s Water Supply and Spray Nozzle s 20 Step 2 Set Up for Chemical Spray if desired 23 Step 3 Spraying 24 Step 4 Stopping 30 Storage 31 Burner Adjustment 35 Maintenance and Repair 36 Troubleshooti...

Page 4: ...lan to acquire and wear safety apparel during operation of this pressure washer Safety apparel includes waterproof insulated gloves safety glasses with side and top protection and non slip protective...

Page 5: ...uded Engine Fuel Regular Unleaded Gasoline Engine Oil See Engine Owner s Manual and Step 3 of the Assembly and Initial Set up section for additional oil quantity needed due to oil drain hose Burner Fu...

Page 6: ...ump 14 Spray Gun 23 Air Fuel Ignition System 6 Diesel Fuel Tank 15 Grip 24 Chemical injector 7 Diesel Fuel Cap 16 Wand 25 Rupture Disc Fitting 8 Unloader 17 Control Box See Detail A 26 Flame Sensor 9...

Page 7: ...ns out dirt and debris from fuel 12 Heat Exchanger Device that heats the water by forcing a flame across steel pipe 13 Gas Tank Cap Gas tank is a container for holding gas and gas cap is cover for gas...

Page 8: ...n Qty 1 782325 Decal Danger and Warning 1 2 786632 Decal Rotating Equipment Warning 1 3 3 1 798057 32821 Hangtag Rupture Disk Warning Lanyard Hangtag Warning 1 1 4 797513 Decal Burn Hazard Decal 1 5 7...

Page 9: ...hermal Relief Valve This unit is equipped with a thermal relief valve to protect the pump from overheating The pump continues to work in bypass mode when you are not spraying If high temperatures are...

Page 10: ...ents identified in Figure 06832 Unpacking delivery inspection assembly and initial set up and Figure 06833 Hardware Bag Inspect the pressure washer immediately after you receive delivery for missing p...

Page 11: ...k Nut Qty 2 Part 777495 Nozzle Pack Qty 1 Part 800110 Steam Nozzle Qty 1 Part 801091 Bolt 5 16 18 Hex Head Flange Bolt Qty 6 Part 82621 Hose Hook Qty 1 Part 800615 Nut 5 16 18 Hex Flange Nyloc Qty 6 P...

Page 12: ...ION INSTALL HOSE HOOK INTO RIGHT SIDE OF HANDLE USING TWO 2 M8 1 25 NYLOC NUTS 5 16 18 X 3 4 SIX 6 FLANGE BOLTS 5 16 18 X 3 4 SIX 6 FLANGE NUTS Step 1 Install handle with six 6 5 16 18 x 3 4 Flange Bo...

Page 13: ...ynthetic 15W 50 oil Prepare Engine Fill the engine with oil Note The engine is shipped without oil Refer to the Engine Manual to locate oil fill port and for instructions on filling Use the oil grade...

Page 14: ...E Moving your pressure washer around 1 Use the handle to manually move the pressure washer 2 To turn push down slightly on the handle and pivot the pressure washer on its back wheels 3 Lock wheels wit...

Page 15: ...oil check fill instructions WARNING Burn hazard Never open oil port while engine is running Hot oil can spray over face and body Notes o Low oil shutdown feature prevents the engine from starting wit...

Page 16: ...ance as needed Make sure that any other regular maintenance has been performed as prescribed in this manual in the Maintenance Repair section 1 Refer to the engine owner s manual for engine maintenanc...

Page 17: ...for excess fuel to evaporate before starting engine Fuel soaked rags are flammable and should be disposed of properly If fuel is spilled on your skin or clothes change clothes and wash skin immediatel...

Page 18: ...ressure washer in order to avoid carbon monoxide poisoning The location you choose to operate the pressure washer must be OUTDOORS and at least 20 feet from the home away from windows vents and air in...

Page 19: ...aust clearance The exhaust gas from your pressure washer is extremely hot and can cause combustible materials to catch on fire Make sure both the engine exhaust and burner exhaust are at least 7 feet...

Page 20: ...3 Select Suitable Worksite section of this manual A suitable location is OUTDOORS only away from all building air intakes Where no flammable vapors dusts and gases are present Where there is adequate...

Page 21: ...fill a 5 gallon bucket with your garden hose It should take less than 100 seconds Attach garden hose to garden hose inlet Attach garden hose to garden hose inlet 1 See Component Identification sectio...

Page 22: ...reen 25 General 43207 3 0 White 40 Light Cleaning 778949 Soap Nozzle 65 Chemicals 801091 2 0 Orange Steam 15 Steam Note You must use the black low pressure nozzle for spraying chemicals Attach nozzle...

Page 23: ...r is equipped with a chemical injection point on the downstream side of the pump for introducing cleaning chemicals into the water stream A braided chemical hose is provided to connect at this point S...

Page 24: ...and national guidelines Acquire cleaning chemical Use only NorthStar pressure washer chemicals or chemicals specifically formulated for use with pressure washers CAUTION Non approved chemicals can da...

Page 25: ...work area of all bystanders Keep children and pets away Keep spray away from electrical wiring Spray contact with electrical wiring will likely result in severe electrical shock or electrocution Hot e...

Page 26: ...wet surfaces Prime the water supply Turn on water supply and squeeze the trigger CAUTION Never run the pump without the water supply connected and turned on Operating the pressure washer without a suf...

Page 27: ...react with the dirt before rinsing 7 Prepare to rinse by changing to a high pressure nozzle Changing the nozzle from the low pressure black nozzle to a high pressure nozzle will stop the flow of chemi...

Page 28: ...pment damage Begin high pressure spray High Pressure Spray Procedure WARNING High pressure spraying safety Keep spray away from people Never direct discharge stream at or near any person Do not allow...

Page 29: ...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 g...

Page 30: ...igh pressure spray STEP 4 STOPPING Stop the engine using the following steps WARNING Never disconnect the high pressure hose from the high pressure outlet or spray gun while the system is pressurized...

Page 31: ...ot lights even if the pressure washer s engine and burner fuel tanks are empty Residual fuel fumes from tank can ignite o Away from extreme high or low temperatures Do not store the pressure washer in...

Page 32: ...cing end into 5 gallon bucket of antifreeze 5 With the nozzle removed trigger gun off and with burner off point trigger gun into a second empty 5 gallon bucket and start the unit 6 With unit running s...

Page 33: ...er gun 6 Remove thermal relief valve located at the bottom of the unloader see Component identification page and allow water from the bypass loop to drain out Once drained reinstall thermal relief fit...

Page 34: ...eplace spark plug but do not reconnect the spark plug wire Prepare pressure washer for storage Prepare the pressure washer for storage 1 Make sure the engine start switch is OFF and fuel valve is OFF...

Page 35: ...the burner ignites Note Typical factory calibration is between 5 7 4 Locate and loosen the locking set screw fig06839 and rotate the cover clockwise close until either of following happens black smoke...

Page 36: ...ck tire pressure Each use Perform engine maintenance As specified in Engine Owner s manual Change pump oil Each use After first 40 hours of use Every 3 months or 500 hours of use after that Maintain b...

Page 37: ...washer and will void the warranty Keep pressure washer clean Keep pressure washer clean If dust or debris accumulates on the pressure washer clean the pressure washer with a damp cloth or soft bristle...

Page 38: ...nnections for signs of wear cracks looseness or leaks Replace as required 2 Check and clean the nozzle orifice Garden hose water inlet Clean the garden hose water inlet filter before each use WARNING...

Page 39: ...ement 5 Inspecting and cleaning muffler and spark arrestor if equipped 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...

Page 40: ...ale can build up inside the heating coil tubing Scale deposits will decrease the performance of pressure washer by reducing both water flow and water pressure The use of a water softener and an additi...

Page 41: ...Serious injury or death can result if safety instructions are not followed To descale the coil 1 Remove the outlet coil quick connect nipple fitting from the coil outlet 2 Remove the inlet coil swive...

Page 42: ...water 14 Turn on the circulating pump to begin circulating the fresh water 15 Run the circulating pump for 5 minutes recirculating the fresh water 16 Repeat steps 11 15 at least 3 times to ensure all...

Page 43: ...e burner will not fire if the shuttle does not move The shuttle movement actuates a switch inside the flow switch housing which allows the burner to fire during spray mode 1 Disconnect the swivel fitt...

Page 44: ...he Body from the plastic Enclosure and soak the Body in CLR or similar solution to dislodge excess buildup The screws QTY 5 in the Enclosure are TORX T10 6 Rinse Body 7 When cleaning is complete reins...

Page 45: ...not damaged re install the Cap onto the Body Torque the cap to 100lb in 10 On the elbow on the inlet of the coil remove any remaining thread tape sealant Re apply new thread tape sealant on the elbow...

Page 46: ...ter Wrap 3 Remove 4 5 16 Bolts from Outer Cover 4 Remove Outer Cover set aside 5 Remove 4 5 16 bolts and nuts off the hold down brackets on the Outer Wrap 6 Remove all inlet and outlet fittings 7 Remo...

Page 47: ...t flame sensor and electrode wires Disconnect fuel line 4 Clean off carbon deposits which may have accumulated on the tips of the electrodes 5 If electrodes are outside of manufacturing specification...

Page 48: ...e Guarding and reconnect spark plug Air Fuel Ignition System Drive belt maintenance Check drive belt tension after first 24 hours of running and then routinely with each oil change Tighten or replace...

Page 49: ...ause damage and early belt failure 5 Re tighten Tension Bracket mounting bolts 3 and Lower fuel pump mount bolt 1 6 Replace belt guard WARNING Do not operate unless belt guard is in place to prevent a...

Page 50: ...e strongly recommend the following Have a staff person become familiar with the mechanical operation of the pressure washer and capable of making minor repairs and performing all preventative maintena...

Page 51: ...uel solenoid coupler or pump itself may need to be replaced Contact product support Check fuel pressure and replace if needed Ignition Electrodes damaged or worn Clean adjust or replace electrodes See...

Page 52: ...tment Poor quality fuel Use kerosene for the cleanest burn Belt broken Replace belt WATER NOT HEATING SUFFICIENTLY Causes Solutions Scale build up in coil See Coil Descaling under Maintenance Instruct...

Page 53: ...tion Page 1 Frame 52 2 Heat Exchanger 54 3 Blower and ignition flywheel 56 4 Engine Water pump Fuel pump and drive parts 58 5 Accessories Gun hose chemical injector 61 These components go into more de...

Page 54: ...Parts Explosion Frame Rev B 3 54 Fig157114 1 10 11 12 30 13 8 31 25 28 29 26 27 7 17 18 2 3 1 32 33 4 22 21 5 20 19 6 16 9 14 15 23 34 35 36 37 24 38 39...

Page 55: ...1 17 788040 MANUAL TUBE 1 18 799875 BRAKE 1 19 82630 NUT 5 16 18 HEX FLANGE NYLOC 20 20 800619 ISO MOUNT 4 21 82008 NUT 10 32 KEPS 3 22 800618 GROMMET 1 25 ID 125 1 23 82007 SCREW 10 32 X 3 4 SHCS 1...

Page 56: ...B 3 56 Fig06846 1 1 19 1 16 1 29 1 13 1 23 1 30 1 18 1 22 1 15 1 8 1 12 1 28 1 21 1 20 1 9 1 1 1 33 1 32 1 17 1 10 1 2 1 3 1 4 1 5 1 6 1 7 1 11 1 14 1 25 1 24 1 27 2 1 26 1 31 3 4 12 6 7 8 9 19 5 11 1...

Page 57: ...32 x BHCS not shown sold separately 1 1 23 802067 Fuel nozzle 1 35 60A GPH 2 5 gpm 1 1 24 797751 Combustion head assembly 1 1 25 82006 Screw 10 32 x 1 2 button head cap 3 1 26 793595 Flame sensor bra...

Page 58: ...2613 M6 1 0X8MM SET SCREW KNURL CUP 1 10 82020 NUT 5 16 18 NYLON INSERT 4 11 788016 2 MM SPACER 2 12 802061 INLET DAMPER CAP MEDIUM 1 13 801982 AC HOUSING ASSEMBLY W ADJUSTABLE DAMPER 1 14 801658 PLAT...

Page 59: ...4 HHSF BOLT 1 11 788016 2 MM SPACER 1 15 82004 8 32 x 5 BHCS 1 16 802202 M5 FLAT WASHER 2 17 802343 8 32 X 75 SHCS 4 18 799538 STATOR ASSY 1 19 799566 STATOR BLADE ASSEMBLY 1 20 800782 IGNITION COIL A...

Page 60: ...Fuel Pumps Drive Parts Rev B 3 60 8 38 37 36 40 41 35 43 42 25 22 21 20 23 24 26 27 28 29 34 33 32 31 30 3 4 19 18 17 16 15 14 13 12 9 5 6 7 10 11 1 2 44 46 47 48 49 50 47 48 FIG157114 2_A 39 45 SEE D...

Page 61: ...5 PLATE UPPER BELT GUARD DWD 1 17 801170 PUMP SHEAVE 13MM 1 18 801443 BELT TENSION BRACKET 1 19 82088 BOLT 5 16 18 X 75 CARR 3 20 801477 BELT 36 MICRO V J SEC 1 21 800725 EMF SHEAVE DWD PUMP 1 23 8272...

Page 62: ...G 1 42 791252 HOSE 3 4 ID PVC SUCTION 4 5 45 786501 DECAL ADD OIL 1 46 801447 FITTING 9 16 18 MALE JIC X 1 4 19 BSPP STRAIGHT 1 47 801490 HOSE 1 4 FUEL LINE HOSE 1 83 48 801490 HOSE 1 4 FUEL LINE HOSE...

Page 63: ...QUICK COUPLE SOCKET X 3 8 MPT O RING NOT SHOWN 1 1 5 777915 NIPPLE 3 8 1 6 799880 HOSE 3 8 X 50 HIGH PRESSURE 1 7 777165 CHEMICAL HOSE 4 FT 8 779613 INJECTOR QC 3 GPM PW 1 9 221222 STRAINER CHEMICAL P...

Page 64: ...Pump Explosion DWD2500 Rev B 3 64...

Page 65: ...ve Seat 3 101 5019 0766 Water Seal Kit 1 23 1210 0465 O Ring 1 78X8 73 3 102 5019 0769 Oil Seal Kit 1 24 3604 0063 Suction Discharge Valve 3 25 1802 0257 Suction Discharge Valve Spring 3 26 1205 0094...

Page 66: ...ry Control 12vdc 793568 1 9 Circuit Breaker 5a 802307 1 10 Switch Toggle 777855 1 11 Harness Flow Switch to Primary Board White 800729 1 Fig06873_157114 FLOW SWITCH HI TEMP LIMIT HI PRESSURE LIMIT BUR...

Page 67: ...ldren Under the influence Never operate or let anyone else operate the pressure washer while fatigued or under the influence of alcohol drugs or medication Understand intended use Carefully read about...

Page 68: ...emperatures You can be burned or seriously injured when handling fuel Use extreme care when handling fuel including these preventative measures Fuel outdoors Fill fuel tank outdoors never indoors Fuel...

Page 69: ...ects debris can cause injury Serious injection injury can result if high pressure spray penetrates the skin Operators should wear waterproof thermally insulated gloves safety glasses with side and top...

Page 70: ...d all safety hazards and first aid for all chemicals being used Wear protective gear as directed Always wear protective gloves when handling and cleaning with chemicals When cleaning filters check whe...

Page 71: ...least five minutes before storing A hot engine is a fire hazard Prevent accidental starting When pressure washer is not in use remove spark plug or spark plug wire in order to ensure that pressure was...

Page 72: ...oll cage bumper and axles Heat Exchanger Coil Weldment 5 years from date of purchase NorthStar shall warrant the Coil from defects in material or workmanship for a period of 5 years from the date of p...

Page 73: ...rting batteries damage related to rodent and or insect infestation Damage caused by freezing and damage caused by vandalism Additional exclusions loss of running time inconvenience loss of income or l...

Page 74: ...Tool com WARNING This product can expose you to chemicals including gasoline engine exhaust which is known to the State of California to cause cancer and carbon monoxide which is known to the State of...

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