North Star 157116 Owner'S Manual Download Page 61

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Parts Explosion: Engine, Water & Fuel Pumps, Drive Parts – Rev C.2

ITEM

PART#

DESCRIPTION

QTY

6066
HC17210ZE3505
HC17218ZE3505

ENGINE, HONDA GX390
ELEMENT, AIR CLEANER
FILTER, OUTER

1
1

801096

FITTING MJIC-6 x 12MM

801089

HOSE, OIL DRAIN

801097

FITTING, 3/8" FPT CAP

799630

PUMP, 66DX CAT 4.0@ 3000

798262

ELBOW, 3/8 FORGED

777836

PROTECTOR, THERMAL

799879

HOSE, 3/8X43" 3000 PSI

796160

FITTING, 1/2" MPT x 3/4 HB ELBOW

791252

HOSE 3/4" ID PVC SUCTION

4.5’

796618

CLAMP, T-BOLT 1.06-1.14 OD

777837

PLUG, HEX HEAD 3/8

801447

FITTING, 9/16-18 MALE JIC X 1/4-19 BSPP
STRAIGHT

779666

CLAMP, 1" LOOP

801494

ASSEMBLY TANK DIESEL 5 GAL

305206

DIESEL, FUEL CAP

777834

CLAMP, ¼” HOSE

796282

FITTING, 1/4 FPT X 1/4 HB

795027

FITTING, ELBOW 1/4 NPT BULKHEAD

20.1

799864

799865

FUEL FILTER

FILTER ELEMENT

783212

1/4"MPT X 1/4"HB ELBOW

801490

HOSE, 1/4" FUEL LINE (CARB 2020)

1.83’

801490

HOSE, 1/4" FUEL LINE (CARB 2020)

.83’

801490

HOSE, 1/4" FUEL LINE (CARB 2020)

.67’

802412

TANK STRAP

800144

KEY, M6

82088

BOLT, 5/16"-18 X .75" CARR

786632

DECAL, TOTATING MACH. WARN.

82720

5/16-18 BLACK SHORT EXTRUDED U NUT

800724

EMF SHEAVE 66DX PUMP

801477

BELT, 36" MICRO V, J SEC.

801170

PUMP SHEAVE, 13MM

801465

PLATE, UPPER BELT GUARD 66DX

82630

NUT, 5/16-18 FLANGE NYLOC

801443

BELT TENSION BRACKET

82088

BOLT, 5/16-18X .75 CARR.

800048

LOWER BACK GUARD PLATE

802344

LOWER FRONT GUARD PLATE

Summary of Contents for 157116

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: ...il level before starting Remove shipping tape and black vent plug if present from oil fill cap Water Flow Requirements Make sure your supply water flow rate is 20 higher than the pressure washer s flo...

Page 3: ...pply 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 34 Maintenance and Repair 35 Troubleshooting 50 Major Compo...

Page 4: ...plan 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 protectiv...

Page 5: ...o 1 SUPPLIES REQUIRED not included 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 d...

Page 6: ...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 Engine 18 Circuit Pr...

Page 7: ...d 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 tank 14 Spray...

Page 8: ...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 5 788...

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: ...te the components identified in Fig157116_3 Unpacking delivery inspection assembly and initial set up and Fig157116_21 Hardware Bag Inspect the pressure washer immediately after you receive delivery f...

Page 11: ...6_21 1 4 Braided Chemical Hose Qty 4 Part 777165 Steam Nozzle Qty 1 Part 801092 Nozzle Pack Qty 1 Part 800653 Nipple 1 Qty 1 Part 779086 Ball Valve 1 Qty 1 Part 780441 Chemical Strainer Qty 1 Part 221...

Page 12: ...Refer to Fig157115_4 and follow the steps listed below INSTALL NOZZLES INTO DESIGNATED NOZZLE STORAGE LOCATION Step 1 Install Nozzles into designated nozzle storage location Step 2 Install 1 Nipple 1...

Page 13: ...0 non detergent oil or Cat Pump Oil Item 22158 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...

Page 14: ...ing the pressure washer MOVING AND HANDLING SKID Moving your pressure washer around 1 Use the fork lift to skid around 2 Use for a fork lift to be inserted at the shown location Elevating or lowering...

Page 15: ...tailed 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 starti...

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 778737 4 5 White 40 Light Cleaning 778949 Soap Nozzle 65 Chemicals 801092 3 5 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: ...tar pressure washer chemicals or chemicals specifically formulated for use with pressure washers CAUTION Non approved chemicals can damage pressure washer components seals wand hoses pump etc and be h...

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: ...AUTION Never run the pump without the water supply connected and turned on Operating the pressure washer without a sufficient incoming flow of water will damage the pump Turn on the water supply Make...

Page 27: ...sure spray either hot or cold as instructed below Turn on burner If hot spray or steam is desired If HOT spray or steam is desired turn on the burner 1 First make sure vicinity is free of flammable va...

Page 28: ...ng and or severe tissue damage leading to infection gangrene and possibly amputation Seek medical attention Do not secure trigger open To reduce risk of injury do not attempt to secure the spray gun o...

Page 29: ...is washes away heavy dirt and allows the detergent to soak as you work toward the top 5 Use the width of the spray pattern to wash a wide path Overlap spray paths for complete coverage 6 The nozzle sh...

Page 30: ...f high 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 pressuriz...

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: ...cket and start the unit 4 With unit running spay into the empty bucket for several seconds then release trigger for 2 seconds Continue cycling the trigger gun multiple times until all the antifreeze h...

Page 33: ...ll b Add fuel stabilizer to fuel tank c Run pressure washer with high pressure hose at least 5 minutes after adding stabilizer to allow it to enter the fuel system d Shut off engine 2 Lubricate cylind...

Page 34: ...the burner ignites Note Typical factory calibration is between 6 8 4 Locate and loosen the locking set screw fig06839 and rotate the cover clockwise close until either of following happens black smoke...

Page 35: ...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 36: ...e 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 brush Do not allow air...

Page 37: ...ace as required 2 Check and clean the nozzle orifice Garden hose water inlet Clean the garden hose water inlet filter before each use WARNING When cleaning filters check whether dangerous chemicals ha...

Page 38: ...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 1 Remove drain plug from pump 2...

Page 39: ...e 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 addition...

Page 40: ...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 41: ...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 42: ...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 43: ...ue to step 5 5 Remove the 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 cle...

Page 44: ...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 Re connect the swivel...

Page 45: ...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 46: ...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 47: ...uarding 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 bel...

Page 48: ...ause damage and early belt failure 6 Re tighten Tension Bracket mounting bolts 3 and Lower fuel pump mount bolt 1 7 Replace belt guard WARNING Do not operate unless belt guard is in place to prevent a...

Page 49: ...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 50: ...k empty Fill fuel tank with kerosene diesel or fuel oil Fuel filter water separator is clogged or full of water Drain or replace if needed Clogged fuel nozzle Replace Fuel pump malfunctioning Fuel sol...

Page 51: ...ld up in coil See Coil Descaling under Maintenance Instructions Coil is full of soot See Coil Desooting under Maintenance Instructions PRESSURE WASHER RUNS BUT NO PRESSURE Causes Solutions Partially c...

Page 52: ...gent container Make sure chemical strainer is fully submerged High pressure hose too long Use less hose Move machine closer to the work Chemical strainer or injector clogged Clean the strainer and inj...

Page 53: ...ge 1 Frame 51 2 Heat Exchanger 53 3 Blower and ignition flywheel 55 4 Engine Water pump Fuel pump and drive parts 57 5 Accessories Gun hose chemical injector 60 6 Tank 61 These components go into more...

Page 54: ...Parts Explosion Frame Rev C 2 54 Fig157116_13 17 18 16 5 37 12 3 2 1 4 6 7 8 9 10 11 20 19 31 30 23 35 28 36 34 29 26 25 24 27 22 32 33 13 39 14 15 38 21 40 41...

Page 55: ...4 5 16 18 X 1 2 HHSF BOLT 4 18 82096 BOLT 5 16 18 X 3 5 HHFB 1 19 800556 PLATE ENGINE RISER 1 20 82626 BOLT 3 8 16 X 2 5 HHFB 4 21 82631 NUT 3 8 16 HEX FLANGE NYLON 4 22 800044 CONTROL BOX BASE 1 23 8...

Page 56: ...er Rev C 2 56 Fig157116_22 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...

Page 57: ...1 82005 Nut 8 32 kepts not shown sold separately 1 1 22 2 82004 Bolt 8 32 x BHCS not shown sold separately 1 1 23 799677 Fuel nozzle 2 00 GPH 90B 1 1 24 797751 Combustion head assembly 1 1 25 82006 S...

Page 58: ...613 M6 1 0X8MM SET SCREW KNURL CUP 1 10 82020 NUT 5 16 18 NYLON INSERT 4 11 788016 2 MM SPACER 2 12 801874 INLET DAMPER CAP LARGE 1 13 801982 AC HOUSING ASSEMBLY W ADJUSTABLE DAMPER 1 14 801658 PLATE...

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 1 SHCS 4 18 799538 STATOR ASSY 1 19 799566 STATOR BLADE ASSEMBLY 1 20 800782 IGNITION COIL A...

Page 60: ...Water Fuel Pumps Drive Parts Rev C 2 60 14 51 15 16 17 18 19 20 21 22 25 23 24 50 28 27 14 29 26 30 31 32 33 34 35 36 37 38 SEE DETAIL A 39 40 41 42 43 44 45 46 47 48 34 1 2 3 4 49 5 6 7 8 9 10 11 3 1...

Page 61: ...MBLY TANK DIESEL 5 GAL 1 16 305206 DIESEL FUEL CAP 1 17 777834 CLAMP HOSE 6 18 796282 FITTING 1 4 FPT X 1 4 HB 1 19 795027 FITTING ELBOW 1 4 NPT BULKHEAD 1 20 20 1 799864 799865 FUEL FILTER FILTER ELE...

Page 62: ...FUEL PUMP 12V 1 42 1 RWB21754U FUEL SOLENOID COIL 12V 1 42 2 RWB21877U FUEL SOLENOID STEM 1 43 777340 1 4 MPT X 1 4 HB 1 44 801448 FITTING 1 4 HB X 1 4 NPT 1 45 801472 FITTING 1 8 HEX NIPPLE 1 46 7941...

Page 63: ...COUPLER 1 4 780455 3 8 QUICK COUPLE SOCKET X 3 8 MPT 1 4 1 GP2701020 O RING NOT SHOWN 1 5 777915 NIPPLE 3 8 1 6 799880 HOSE 3 8 X 50 HIGH PRESSURE 1 7 777165 CHEMICAL HOSE 4 FT 8 779614 INJECTOR QC 5...

Page 64: ...TCH FLOAT LOW WATER 1 4 1 32417 WIRE SNAP PLUG TERM MALE NOT SHOWN 1 4 2 32420 WIRE SNAP PLUG TERM MALE NOT SHOWN 1 5 34744 FITTING BULKHEAD 1 4 NPT BR AC 1 6 794031 INLET FLOAT VALVE 1 7 779086 1 NIP...

Page 65: ...p Domed OilFiller 1 166 CA46429 Valve 6 33 CA14179 O Ring FillerCap 70D 1 167 CA43750 Spring 6 37 CA92241 Gauge OilBubblew Gasket 80D 1 168 CA44565 Retainer Spring 6 38 CA44428 Gasket Flat Oil Gauge 8...

Page 66: ...up Ring Piston Stem 1 446 O Ring Body 80D 1 415 O Ring Piston Stem 90D 1 454 O Ring Manifold 70D 1 418 Assy Piston IncludedinRepairKit 1 456 Manifold 1 423 CA49105 Retainer Valve 1 460 CA126974 Fittin...

Page 67: ...POSITION LEVER LOCK 5 POSITION LEVER LOCK PLUG BRN BROWN BLK BLACK WHT WHITE BL BLUE STANDARD CONTROL BOX DIAGRAM 115 116 8 4 5 7 9 8 10 8 8 3 6 1 2 3 11 12 13 Balloon Description Part Number Qty 1 Sw...

Page 68: ...ion Part Number Qty 1 Harness Wire Low Water Shutdown 799919 1 IGNITION COIL ENGINE STOP SWITCH OIL LEVEL SWITCH YLW BLK YLW YLW C3 C1 C2 BLK BLK RED RED ENGINE WATER TANK SPARK PLUG BLK BLACK YLW YEL...

Page 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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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