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North Star 999883 Owner'S Manual Download Page 51

 

51 

 

 

Troubleshooting 

 

WARNING

 

 
 

Before troubleshooting or attempting to service, read the following safety rules to 
avoid accidental exposure to chemical and also risk of electric shock. 

 

 

Note: A reserve, clean container capable of holding at least 31 gallons should be kept for use when the 

sprayer tank needs to be emptied temporarily for repairs.  It is advisable to purchase a reserve tank 
suitable for chemical storage from Northern Tool + Equipment for use in these circumstances.  The 
container should be properly labeled as to its contents if it is used. 

 

Before attempting to service the sprayer

: 

 

1.  Personal 

protective 
equipment 

Wear personal protective equipment as directed on the chemical label while 
servicing your sprayer. 

2.  Review 

troubleshooting 
table 

Review the Troubleshooting Table below for the type of problem you are 
experiencing.  

However,

 

DO NOT attempt to repair until the steps listed below 

are followed.

 

3. Empty and flush 

If the cause listed for your problem is Clogged intake tube, Clogged suction 
strainer, or Worn spray gun nozzle:

 empty the tank and flush the sprayer with 

water as directed in the section, "Operation – Step Four". 

 

- In order to avoid accidental exposure to chemicals, never attempt to unclog 
the intake tube or suction strainer, or service the spray gun nozzle, until the 
tank has been emptied and the sprayer flushed with water. 

4.  Disconnect 

power/relieve 
pressure 

Disconnect power to the sprayer and be sure all system pressure is relieved 
by squeezing the gun trigger. 

 

5. Perform repairs 

Follow the directions provided in the troubleshooting table to repair the 
sprayer. 

 

 

NOTE:  Never try to unclog the sprayer nozzle by blowing through it. 

6.  Test after 

servicing 

After servicing, ALWAYS test the sprayer for leaks with plain water before 
using. 

 

PROBLEM 

CAUSE

 

SOLUTION

 

Pump will not turn on 

Bad electrical connection 

Check battery connections 

Fuse blown 

Replace fuse 

Short in wires 

Check condition of wires 

Low voltage 

Check voltage 

Low pressure 

Worn spray gun nozzle 

Replace spray gun 

Worn boom nozzle 

Replace boom nozzle 

Low flow 

Clogged intake tube 

Remove obstruction 

Clogged suction strainer 

Clean suction strainer 

Low voltage 

Check voltage 

Poor spray distribution 

Clogged intake tube 

Remove obstruction 

Suction strainer clogged 

Clean suction strainer 

Worn spray gun nozzle 

Replace spray gun 

Pump cycles while not spraying 

Leak in the system 

Tighten leaking hose clamps or 
fittings, replace spray gun 

Summary of Contents for 999883

Page 1: ... DO NOT TURN ON POWER to sprayer until ready to spray in order to avoid unintentional spray release ALWAYS keep a fire extinguisher rated ABC nearby Improper use of the sprayer or handling of chemicals could result in serious injury or illness to the operator or nearby persons animals or could cause damage to the environment Only use the cable clamps provided with the sprayer to connect it with th...

Page 2: ...2 Hazard Signal Word Definitions ...

Page 3: ... Bag 11 Assembly 12 Machine Components 31 Operation Important Safety Information 32 Operation Preparing the Sprayer for Each Use 36 Operation Using the Sprayer 37 Storage 45 Troubleshooting 51 Specifications 52 Exploded View Parts List Rev A 53 Pump Exploded View 55 Appendix A Broadcast Spray Calibration Tables 56 Limited Warranty 57 ...

Page 4: ...ush the sprayer after each use to clean the chemical out of the pump hoses and spray gun The life of the sprayer will be shortened if it is not flushed after each use THE SPRAYER MUST NOT BE USED FOR OTHER PURPOSES ONCE IT HAS BEEN USED FOR BLEACH Any chemical will leave some residual in the tank liner or sprayer components even after the sprayer has been properly cleaned These residual chemicals ...

Page 5: ...dures before handling chemicals Carefully review Chemical Accident Procedures listed below and later in this manual Also see First Aid instructions on the chemical label WEAR protective clothing eye protection and chemical resistant gloves when filling using and cleaning the sprayer Wear additional protective gear such as facemask or apron as recommended on the chemical label EXERCISE EXTRA CAUTIO...

Page 6: ... stop o Avoid any sudden steering maneuvers starts or stops that could create sway SLOW DOWN AND EXERCISE EXTRA CAUTION ON SLOPED OR UNEVEN TERRAIN Pick the most level route possible Drive up and down slopes when necessary rather than across Use a vehicle equipped with a roll over protection system ROPS if you will be working on non level terrain BE AWARE of the added length of the sprayer and tha...

Page 7: ...el 3 Call a poison control center for further advice In the U S call 1 800 222 1222 Have the chemical label available for reference Chemical spills Chemical spills must be quickly contained and properly cleaned up Refer to the chemical label for any specific clean up instructions General procedures include 1 Controlling the spill by stopping the source of the spill 2 Containing the spill so that i...

Page 8: ...d condition If a safety label is missing or not legible order new labels or unsafe operation could result To order replacement safety labels call NorthStar Product Support at 1 800 270 0810 Part Description 802168 Decal Bleach Warning 802172 Decal Pump 802169 Decal Sprayer Warning ...

Page 9: ...sing or damaged components please contact NorthStar Product Support at 1 800 270 0810 Tank Draw Tube Hose Qty 1 792536 Hitch Bracket Qty 1 791985 Upper Hose Wrap Bracket Qty 1 Lower Hose Wrap Bracket Qty 1 Axle Qty 1 791980 Gun Hose 792547 Pump Qty 1 802178 Regulator Assembly Qty 1 Wheels Qty 2 791988 Spray Gun 779769 Manual Bag ...

Page 10: ...10 Unpacking continued Right Boom Bracket Assembly Qty 1 Left Boom Bracket Assembly Qty 1 Tow Bar Assembly Qty 1 Cart Assembly Qty 1 Draw tube Qty 1 792437 Front Tank Bracket Qty 2 792158 ...

Page 11: ... Qty 2 792778 5 16 x 2 Bolt Qty 2 82018 5 16 x 1 2 Bolt Qty 17 82014 5 16 Nut Qty 5 82019 Axle Washer Qty 2 82286 10 Washer Qty 4 82068 Suction Strainer Qty 1 35203 5 16 x 2 1 4 Bolt Qty 1 82484 Drain Cap Washer Qty 1 37680 5232 Hose Clamp Qty 2 777119 5 16 x 3 4 Bolt Qty 2 82015 Hose Clamp Qty 4 30746 Hose Clip Qty 1 777110 Screw 10 24 x 1 1 8 Qty 3 82061 Screw 10 24 x 1 1 4 Qty 1 82617 ...

Page 12: ...Assembly Step 1 Tow Bar Hitch Assembly Insert axle through rear holes in cart assembly Note If axle does not fit smoothly through holes in cart assembly cart bolts may need to be loosened Tools Needed N A ...

Page 13: ... Align tow bar assembly with cart assembly as shown below Insert bolts and secure with nuts Torque to 20 Ft Lbs Tools Needed 1 2 wrench Torque wrench Fasteners Needed from Owner s Manual Bag 5 16 x 2 Bolt Qty 2 82018 5 16 Nut Qty 2 82019 ...

Page 14: ...bly Align brackets with cart assembly as shown below Insert bolt and secure with nut Torque to 20 Ft Lbs Tools Needed 1 2 wrench Torque wrench Fasteners Needed from Owner s Manual Bag 5 16 x 2 1 4 Bolt Qty 1 82484 5 16 Nut Qty 1 82019 ...

Page 15: ... cart assembly on bottom of tank Insert bolts and torque to 5 Ft Lbs Note if holes do not properly align with tank inserts loosen bolts on cart After securing cart to tank torque cart bolts to 20 Ft Lbs Thread drain cap on to tank until hand tight Tools Needed 1 2 wrench Torque wrench Fasteners Needed from Owner s Manual Bag Drain Cap ...

Page 16: ...t wheels onto axle Install axle washer Insert axle pin through hole in axle Note Check that tires are inflated to the correct pressure Tools Needed Pliers Fasteners Needed from Owner s Manual Bag Axle Pin Qty 2 792416 Axle Washer Qty 2 82286 ...

Page 17: ...wet suction tube with soap and water solution before inserting through grommet to ease installation Remove tank cap and insert suction strainer on to end of suction tube Insert suction tube until the suction strainer touches bottom of tank Tools Needed N A Components Needed from Owner s Manual Bag Suction Strainer Qty 1 35203 Draw tube Qty 1 792437 ...

Page 18: ...ose Wrap Assembly Align upper and lower hose wrap brackets with inserts in tank Insert bolts and torque to 5 Ft Lbs Tools Needed 1 2 wrench Torque wrench Fasteners Needed from Owner s Manual Bag 5 16 x 1 2 Bolt Qty 4 82014 ...

Page 19: ...or assembly into Outlet port of pump and slide red QC clip closed Insert hose barb fitting into Inlet port of pump and slide red QC clip closed NOTE To insert quick connect fittings lubricate O ring with water and twist fitting while inserting into pump port Tools Needed N A Fasteners Needed from Owner s Manual Bag ...

Page 20: ...e in tank until tight Install 3 short screws through washers and pump feet and into threaded holes in tank until tight Note damage to rubber pump feet could occur if screws are over tightened Tools Needed Phillips head screwdriver Fasteners Needed from Owner s Manual Bag Screw 10 24 x 1 1 8 Qty 3 82061 10 Washer Qty 4 82068 Screw 10 24 x 1 1 4 Qty 1 82617 Washer Screw 10 24 x 1 1 8 Screw 10 24 x 1...

Page 21: ...s Slide hose clamp over hose Install hose onto hose barb on regulator assembly Secure with hose clamp until tight Tools Needed 1 2 wrench Torque wrench Flat head screwdriver Fasteners Needed from Owner s Manual Bag 5 16 x 1 2 Bolt Qty 2 82014 Hose Clamp Qty 1 30746 Hose barb on regulator assembly Hose clamp Hose on boom bracket assembly ...

Page 22: ... Torque to 5 Ft Lbs Slide hose clamp onto hose Install hose onto hose barb tee Secure with hose clamp until tight Tools Needed 1 2 wrench Torque wrench Flat head screwdriver Fasteners Needed from Owner s Manual Bag Hose on boom bracket assembly Hose clamp Hose barb tee 5 16 x 1 2 Bolt Qty 2 82014 Hose Clamp Qty 1 30746 ...

Page 23: ... Slide short end of hose over PVC draw tube Slide long end of hose over hose barb elbow fitting Secure both ends with hose clamps until tight Tools Needed Flat head screwdriver Fasteners Needed from Owner s Manual Bag Hose Clamp Qty 2 777119 Hose clamp Draw tube hose Draw tube Pump inlet fitting ...

Page 24: ...mp over the end of the gun hose Push the hose onto the gun hose barb Slide the hose clamp over the hose barb and tighten Tools Needed Philips head screwdriver Fasteners Needed from Owner s Manual Bag Spray gun Hose clamp Gun hose Hose barb Hose Clamp Qty 1 30746 ...

Page 25: ...ose barb fitting and tighten hose clamp Align hose clip with threaded insert on the side of the tank Insert bolt and torque to 5 Ft Lbs Tools Needed 1 2 wrench Torque wrench Flat head screwdriver Fasteners Needed from Owner s Manual Bag Hose clip Hose clamp Pump hose barb fitting 5 16 x 1 2 Bolt Qty 1 82014 Hose Clamp Qty 1 30746 Hose Clip Qty 1 777110 ...

Page 26: ...height of the towing vehicle Ensure sprayer has slight incline towards the rear of the tank when attached to tow vehicle This will ensure all the fluid is emptied from tank Insert bolts through holes and secure with nuts Torque to 27 Ft Lbs Tools Needed 1 2 wrench Torque wrench Fasteners Needed from Owner s Manual Bag Hitch bracket 5 16 x 3 4 Bolt Qty 2 82015 5 16 Nut Qty 2 82019 ...

Page 27: ... not included call 800 270 0810 and order Item 2501946 Make sure boom nozzles are pointed straight down If they are not loosen the nozzle retaining nut orient the opening of the boom nozzle to point straight down then retighten the nozzle retaining nut Tools Needed N A Fasteners Needed from Owner s Manual Bag ...

Page 28: ...ER touch both battery terminals at the same time or with any non insulated tools If battery acid contacts skin or clothing flush immediately with water and neutralize with baking soda 2 Connect remote switch to battery Connect the sprayer s remote switch to the vehicle battery using the following procedure a Disconnect the vehicle battery ground wire b Connect the remote switch s red battery clamp...

Page 29: ...AYS verify that the power has been disconnected or the remote switch is in the OFF position before adding chemicals or servicing 7 To disconnect permanently When it is necessary to disconnect the sprayer s remote switch from the battery use the following procedure 1 Disconnect sprayer s pump cord from the remote switch 2 Disconnect the remote switch from the vehicle battery as follows a Disconnect...

Page 30: ...ps are secure and bolts nuts are properly fastened b While it is unlikely that factory assembled components become loose they should also be checked to make sure they are tight 2 Test with water Test the system for leaks with water a Fill the tank with water b Connect the remote switch to the pump power cord and turn the remote switch ON The pump is an on demand pump When turned on the pump will p...

Page 31: ...hile towing 10 Pressure Gauge The pressure gauge is an indicator of the pressure in the system 11 Sprayer Tank The sprayer tank holds the chemical 12 Spray Gun Use the spray gun to apply chemical to specific areas 13 Hose Wrap The built in hose wrap provides a storage location for the gun hose on the tank 14 Fill Marks this mark the fluid capacity 15 Remote Switch The remote switch connects the ba...

Page 32: ...as well as the Statement of Practical Treatment on the chemical label Inhalation contact ALWAYS take precautions to avoid inhaling or coming into contact with the chemical Personal protective equipment ALWAYS wear protective clothing eye protection and chemical resistant gloves when filling using and cleaning the sprayer Wear additional protective gear such as facemask or apron as recommended on t...

Page 33: ...te recommended by chemical manufacturer Excess can be dangerous to humans damage desirable plants and contaminate soil and water sources Never point gun NEVER point the spray gun at people or animals Children pets ALWAYS exercise extra caution when spraying near areas accessible to children and pets Eating smoking DO NOT eat drink smoke rub your eyes or touch any part of your bare skin while handl...

Page 34: ...ow down and exercise extra caution on rough or sloped terrain in order to reduce risk of rollover Pick the most level route possible when transporting across fields Drive up and down slopes that cannot be avoided rather than across Use a vehicle equipped with a Roll Over Protection System ROPS if you will be operating on non level terrain BE AWARE of the added length of the sprayer and that visibi...

Page 35: ...ctim immediately seek assistance from nearby personnel because you may become incapacitated 2 Follow the emergency first aid instructions on the chemical label in the First Aid or Statement of Practical Treatment section 3 Call a poison control center for further advice In the U S call 1 800 222 1222 to be automatically linked to the nearest certified poison control center Have the chemical label ...

Page 36: ... Clean the suction strainer of any chemical residue It is important to clean the suction strainer before each use to ensure it is not clogged and to prevent residual chemical from contaminating sprayer contents IMPORTANT The strainer must be accessed by reaching into the tank so the tank must be empty to avoid immersing your hand in chemicals a Open fill cap on top of tank b USING RUBBER GLOVES re...

Page 37: ...ater than 4 MPH or if there are bystanders in the intended spray area 1 Assess wind speed Assess weather conditions to ensure that it is not too windy to spray DO NOT SPRAY if wind speeds are greater than 4 MPH Visible indication of wind speed If leaves are in constant motion or there is any branch movement DO NOT spray because the wind is too strong 2 Clear work area Clear the work area of all by...

Page 38: ...d in this manual 2 Choose safe mixing loading area Choose a safe chemical mixing and loading area Choose an outdoor well ventilated area away from unprotected people animals food and other items that might become contaminated 3 Wear personal protective equipment Wear personal protective equipment as directed on the chemical label Note that additional equipment may be specified for mixing and loadi...

Page 39: ...hat maximum tank capacity is 31 gallons Note Only purchase and mix as much chemical as you need for the planned application in order to minimize chemical over application and the need for storing unused chemicals c Add chemical to the tank through the fill cap If the chemical is not pre mixed add water and chemical concentrate in the order prescribed on the label 9 Ensure chemical mixed Ensure che...

Page 40: ... Safety Information related to Chemical Application Safety and ATV Vehicle Handling Safety provided in this manual 2 Wear personal protective equipment Wear personal protective equipment as directed on the chemical label 3 Close broadcast boom valves Close broadcast boom valves to prevent accidental spray release 4 Turn on power Turn on the power to the sprayer 1 Verify the remote switch is connec...

Page 41: ...operate as a demand pump and turn on only when spraying 6 Begin agitation if needed Some formulations of liquid chemicals do not remain in solution and should be agitated to maintain a uniform mix The pressure regulator on this sprayer can be used as an agitator If the pressure is set below the pump s pressure switch setting 70 psi the pump will continue to run even when not spraying Fluid will be...

Page 42: ... as recommended on the chemical label for proper delivery rate Note It is not unusual for the operator to be exposed to chemical drips while adjusting the nozzle gloves should be chemical resistant 8 Operate broadcast boom A Open boom valves Open the left right or both boom valves as desired B Remove pin s and unfold one or both boom arms as required Reinsert pin s to secure boom arms Open boom va...

Page 43: ...ray area Use the tables in Appendix A to determine what speed to drive your vehicle for the desired application rate E Begin to spray Turn the remote switch ON to begin spraying 9 Leaving unattended If the sprayer must be left unattended at any time a Disconnect power to the sprayer b Relieve system pressure by depressing the gun trigger c Turn off the vehicle Set brake or block the wheels 10 Disc...

Page 44: ...tore or dispose of unused chemical a If the unused chemical is to be stored for future use Store all unused chemical in its original or a suitably marked container in a secure location out of the reach of children animals b If remaining chemical is to be disposed Properly dispose of the remaining chemical and its container per the chemical manufacturer s recommendation and according to local hazar...

Page 45: ...h with water Fill the tank with fresh water and run through the system Operate the spray gun until the system is completely flushed DO NOT add antifreeze before flushing the system as bleach can react with antifreeze 2 Add antifreeze Pour 1 gallon of RV antifreeze DO NOT USE automotive antifreeze into the tank Note RV antifreeze is non toxic and biodegradable and generally safer for the environmen...

Page 46: ...46 Storage 2 Adjust tow bar Slide tow bar towards axle until bolt holes line up Insert bolts and tighten nuts 3 Secure with bolts and nuts Insert bolts and tighten nuts ...

Page 47: ... tow bar and wheels Remove hair pins and washers Slide wheels off the axle and then remove the axle from the cart 5 Insert into hitch bracket Insert axle into hitch bracket Install wheels and washers secure with hair pins ...

Page 48: ... position 7 Remove boom arm pins Remove pins from boom arms Caution Boom arms are spring loaded When the pin is removed the boom arms will want to swing towards the front of the sprayer Retain boom arm with hand before removing pin ...

Page 49: ...49 Storage 8 Boom arm storage position Rotate each boom arm towards the front to its storage position 9 Insert boom arm pins Lock boom arms into their storage position by inserting boom arm pins ...

Page 50: ...t in the tank through the tank drain hole into a suitable container 2 Flush with water Fill the tank with fresh water and run through the system Operate the spray gun until the system is completely flushed Be sure to set up containers to capture the antifreeze flush water DO NOT add bleach back into the sprayer before flushing the system as bleach can react with antifreeze 3 Disposal Dispose of th...

Page 51: ...ection Operation Step Four In order to avoid accidental exposure to chemicals never attempt to unclog the intake tube or suction strainer or service the spray gun nozzle until the tank has been emptied and the sprayer flushed with water 4 Disconnect power relieve pressure Disconnect power to the sprayer and be sure all system pressure is relieved by squeezing the gun trigger 5 Perform repairs Foll...

Page 52: ...EPDM Suction Tube Polypropylene PVC Stainless Steel Hose PVC EPDM Max Pressure 6 9bar 100psi Pump Polypropylene Viton Santoprene Stainless Steel Valves Polypropylene Polyacetal Viton Nylon Gun and Nozzle Nylon Polyacetal Aluminum Before using any chemical check to ensure the chemical is compatible with all materials in the system The noise emissions from this product do not exceed 70 dB A Note Pum...

Page 53: ...53 Exploded View Parts List Rev A ...

Page 54: ...loc Nut 1 43 792453 Hose Wrap Grommet 1 14 778560 Lance Clip 3 44 792536 Draw Tube Hose 1 15 779769 Spray Gun 1 45 792539 3 8 Outlet Hose 1 16 82059 10 24 x 1 2 Screw 3 46 792540 3 8 Left Boom Hose 1 17 779854 1 4 MPT x 3 8 HB 1 47 792541 3 8 Right Boom Hose 1 18 35203 Suction Strainer 1 48 792542 3 8 Boom Nozzle Hose 2 19 787212 QC x 3 8 HB 1 49 794455 3 8 Gun Hose 1 20 791998 Grommet 2 50 792611...

Page 55: ...iaphragm assembly 1 4 794989 Valve plate assembly 1 5 787015 Quick connect clip 2 6 787011 Upper housing assembly 1 7 786948 Pressure switch assembly 1 8 A2682272 Complete pump head assembly 1 N A 787381 Replacement fuse 1 Any Questions Comments Problems or Parts Orders Call NorthStar Product Support 1 800 270 0810 ...

Page 56: ... to help you calibrate your tow behind broadcast sprayer This is a very important step in operating the tow behind broadcast sprayer such that too much or too little chemical may be applied Pressure PSI Flow GPM 10 0 40 20 0 57 30 0 69 40 0 80 Approximate flow from one nozzle ...

Page 57: ...tions will void warranty Determining whether a part is to be replaced or repaired is the sole decision of NorthStar NorthStar will not provide for replacement of complete products due to defective parts Any costs incurred due to replacement or repair of items outside of a NorthStar approved facility is the responsibility of the buyer and not covered under warranty Transportation costs to and from ...

Page 58: ...58 Northern Tool Equipment Co Inc Burnsville MN 55306 NorthernTool com Made in China ...

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