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NorthStar 157119, Owner'S Manual

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NorthStar 157119 Owner'S Manual Download Page 31

31 

 

Pump Exploded View 

–

 Cat 4DNX 

 

Ref# 

Part# 

Description 

Qty 

 

Ref# 

Part# 

Description 

Qty 

5 

CA549360 

SCREW 

3 

106 

CA49816 

SEAL 

3 

8 

CA547153 

BEARING COVER 

1 

120 

Not Available

 

SEAL CASE 

3 

10 

CA14041 

O-RING, BEARING COVER 

1 

121 

CA13976 

O-RING FOR SEAL CASE 

3 

11 

CA55337 

OIL SEAL 

1 

125 

CA49824 

SEAL 

3 

15 

CA14488 

INNER BALL BEARING 

1 

160 

CA17428 

O-RING, INLET  

3 

20 

CA547048 

CONNECTING ROD 

3 

161 

CA547077 

SEAT, INLET 

3 

24 

Not Available 

OIL PLUG CAP 

1 

162 

CA48361 

BACK-UP RING 

3 

25 

CA49883 

CRANKSHAFT 

1 

163 

CA43358 

O-RING 

3 

27 

CA15710 

BALL BEARING 

1 

164 

CA547076 

SEAT, DISCHARGE 

3 

32 

CA547961 

CAP 

1 

166 

CA547098 

VALVE 

6 

33 

CA14179 

O-RING FOR OIL FILTER 
CAP 

1 

167 

CA46865 

SPRING 

6 

37 

CA92241 

GAUGE, BUBBLE OIL 
W/GASKET 

1 

168 

CA543988 

RETAINER, SPRING, INLET 

3 

38 

CA44428 

GASKET, FLAT FLEX OIL 
GAUGE 

1 

169 

CA49764 

RETAINER, SPRING, DISCHARGE  

3 

48 

CA44842 

DRAIN PLUG 

1 

172 

CA142807 

O-RING FOR PLUG 

3 

49 

CA14179 

O-RING FOR DRAIN PLUG 

1 

174 

CA547104 

PLUG, VALVE W/O-RING 

3 

53 

Not Available 

CRANKCASE 

1 

185 

Not Available

 

HEAD, MANIFOLD W/UNLOADER 
BODY 

1 

64 

CA46229 

CROSSHEAD PIN 

3 

188 

CA549357 

SCREW 

6 

65 

CA542402 

PLUNGER ROD 

3 

197 

CA941516 

INLET FITTING ASSEMBLY 

1 

70 

CA47215 

OIL SEAL 

3 

249 

CA30520 

ADAPTER MOUNT ASSEMBLY 

1 

90 

CA547091 

PLUNGER 

3 

255 

CA30516 

BOLT MOUNT ASSEMBLY 

1 

98 

CA46730 

WASHER  

3 

300 

CA76975 

SEAL KIT INCLUDES: 98, 106, 121, 
125 

1 

99 

CA542405 

RETAINER, PLUNGER 

3 

310 

CA76976 

VALVE KIT INCLUDES: 160, 161, 
162, 163, 164, 166, 167, 168, 169, 
172 

1 

100 

CA46233 

RETAINER, SEAL 

3 

 

 

 

 

 

Summary of Contents for 157119

Page 1: ... hazardous Fire Explosion Engine sparking can ignite fuel or other flammable liquids or vapors in the vicinity Hot exhaust from engine can ignite combustible materials Burns Pressure washer pump and engine are hot surfaces that can cause burn injuries Detailed safety information about these hazards appears throughout this manual Equipment Protection Quick Facts Inspect Upon Delivery FIRST Inspect ...

Page 2: ...Add Engine Oil 15 Inspect Fuel System Check for Leaks 16 Connect Hoses Water Supply and Spray Nozzle 17 Prime the Water Supply 18 Set Up for Chemical Spray if desired 19 Start Up Procedures 20 Start the Engine to Power the Pump 20 Apply Cleaning Chemical if desired 20 Begin High Pressure Spray 20 Shutdown 21 STORAGE 22 Between Use Storage 22 Prepare Pressure Washer for Freezing Conditions 22 Prepa...

Page 3: ...28 PARTS LIST MODEL 157119 157120 REV G 29 PUMP ASSEMBLIES 30 PUMP EXPLODED VIEW CAT 4DNX 31 PUMP UNLOADER EXPLODED VIEW CAT 4DNX 32 PUMP EXPLODED VIEW CAT 66DX 33 PUMP UNLOADER EXPLODED VIEW CAT 66DX 34 LIMITED WARRANTY 35 CALIFORNIA PROPOSITION 65 INFORMATION 36 ...

Page 4: ...ngine Other safety apparel includes waterproof insulated gloves and non slip protective footwear Cleaning chemicals may require the use of respiration mask refer to the chemical label for further instruction Adult Control Only Only trained adults should set up and operate the pressure washer Do not let children operate the pressure washer Under the Influence Never operate or let anyone else operat...

Page 5: ...OMPONENTS DIMENSIONS COMPONENTS Length 21 00 Length 23 00 Width 16 50 Width 18 00 Height 15 00 Height 19 00 Pump Model Cat 4DNX Pump Model Cat 66DX Pump Oil Capacity 8 5 oz Pump Oil Capacity 18 0 oz SUPPLIES REQUIRED not included SUPPLIES REQUIRED not included Engine Oil Refer to Engine Owner s Manual Engine Oil Refer to Engine Owner s Manual Pump Oil Shipped with oil but refills required SAE 30 N...

Page 6: ... suction and displacement 4 Engine Honda engine provides years of reliable use Air cooled engine that powers the pump 5 Nozzles Change nozzles for different spray patterns 6 Spray Gun Always use two hands for safe operation 7 Trigger Actuate to allow pressurized water to flow out of spray gun 8 High Pressure Outlet Connect your high pressure hose 9 Garden Hose Inlet Connect water supply for pump S...

Page 7: ...uation which if not avoided will result in death or serious injury WARNING orange indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION yellow used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury CAUTION yellow without the safety alert symbol is used to address practices not re...

Page 8: ...safety label is missing or not legible order new labels from NorthStar Product Support at 1 800 270 0810 On Product Warning Labels Location Part Numbers Description 1 801118 Poisonous Gas Decal 2 788936 Burn Hazard Decal 3 788935 Fuel Fire Explosion Hazard 4 801049 Pressure Washer Warning Instruction Decal 157119 157120 ...

Page 9: ...9 Safety Labeling Safety Decals To order replacement safety labels call NorthStar Product Support at 1 800 270 0810 ...

Page 10: ...sher and its components For missing or damaged components contact Product Support at 1 800 270 0810 If complete fill out product serial number information See Limited Warranty section of this manual Any Questions Comments Problems or Parts Orders call NorthStar Product Support at 1 800 270 0810 Engine Pump Base Assembly Pressure Hose Lance Spray Gun Hardware Bag Fig06732 157119 SHOWN ...

Page 11: ...Set Up Hardware Bag PART 82625 3 8 16 x 1 3 4 FLANGE BOLT QTY 4 MODEL 157119 157120 PART 800110 FOR MODEL 157119 OR PART 800111 FOR MODEL 157120 NOZZLES QTY 4 PART 82631 3 8 16 FLANGE NUT QTY 4 MODEL 157119 157120 ...

Page 12: ...sed or partially enclosed location such as a building garage barn shed or house These spaces can trap poisonous gases Running a fan or opening windows will not provide adequate ventilation to prevent dangerous CO build up 2 Only use the pressure washer outdoors at least 20 feet from the home away from windows vents and air intakes to allow proper ventilation If you start to feel sick dizzy or weak...

Page 13: ...BC nearby Keep it properly charged and be familiar with its use 4 Place the unit so that the exhaust fumes will not be directed towards people or building air intakes DANGER Carbon monoxide hazard Exhaust fumes from the engine contain carbon monoxide CO a poisonous gas you cannot see smell or taste The CO generated by the engine can rapidly accumulate even in areas that appear to be well ventilate...

Page 14: ...ct all operators and potential renters in safe 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 Adult Control Only Only trained adults should set up and operate the pressure washer Do not let children operate Pressure washers can generate forces greater than children can control and require judgment beyo...

Page 15: ... high pressure spray Eye injury from flying debris 1 Wear waterproof gloves safety glasses with side and top protection face protection and protective clothing when operating the machine If spraying pressure washer specific chemicals wear a respirator mask to avoid inhalation of vapors if directed on the chemical label 2 Wear non slip protective footwear Use of pressure washer can create puddles a...

Page 16: ... wait 5 minutes 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 immediately Fill Engine Fuel Tank Check the gasoline tank level If needed fill tank with fresh unleaded gasoline from a portable container 1 Remove engine gas cap 2 Add gasoline through the fill...

Page 17: ... and is 20 over the rated flow of your pump Use a stopwatch to time how long it takes to fill a 5 gallon bucket with your garden hose The bucket must fill faster than the times listed in the table below Model Time to fill 5 Gallon Bucket 157119 100 sec 157120 72 sec 3 The water supply garden hose must have an inside diameter of at least 5 8 If the hose is more than 100 ft long the diameter must be...

Page 18: ...e collar making sure it springs back and re seats to its original non retracted position Check the connection by pulling on the nozzle to ensure a tight connection if correctly inserted nozzle will rotate but not pull out Prime the Water Supply Turn on Water Supply and Squeeze the Trigger CAUTION Water Pressure Never run the pump without the water supply connected and turned on Operating the press...

Page 19: ...emicals such as bleach or those containing muriatic acid will cause pump damage if introduced upstream through the pump s water inlet WARNING Chemical Spraying Never spray acids corrosives or abrasive or flammable liquids Breathing hazards surface burns corrosion or fire explosion could result Follow the chemical manufacturer s label instructions for proper use and handling of the chemical Underst...

Page 20: ...Pressure Spraying Safety Keep spray away from people Never direct discharge stream at or near any person Do not allow any part of the body to come in contact with the fluid stream High pressure spray can cause serious skin eye or falling injuries Injection injury will occur if high pressure spray pierces the skin injecting liquid under the skin Injection injury can result in blood poisoning and or...

Page 21: ...nd activate spray gun trigger to relieve system pressure when the sprayer is unattended or disconnecting hoses installing cleaning nozzles or servicing the pump WARNING Injury Always turn off the engine and relieve system pressure when finished spraying or when leaving sprayer unattended Serious injury could result from unintentional release of high pressure spray Shutdown Stop the engine using th...

Page 22: ...prevent water from freezing in the system WARNING Freezing Conditions Do not allow water to freeze in the pressure washer high pressure hose or spray gun Freezing water can cause damage to the equipment and cause the spray gun to fail in the open position A spray gun that has failed in the open position can whip around and cause personal injury when the pressure washer is started 1 Drain the water...

Page 23: ...nd remove spark plug b Add one teaspoon oil through spark plug hole c Place rag over spark plug hole and slowly pull the recoil a few times to lubricate the combustion chamber Replace spark plug but do not reconnect the spark plug wire Prepare Pressure Washer for Storage 1 Make sure the engine start switch is OFF 2 Disconnect the engine spark plug wire if you haven t already done so 3 Disconnect t...

Page 24: ... Turn off relieve pressure first Always turn off pressure washer and relieve system pressure before inspection or maintenance Remove spark plug or spark plug wire to prevent accidental starting Fuel valve off Turn fuel shut off valve to OFF position before transporting or servicing the pressure washer Replace guards Make sure all guards and cover shields are replaced after servicing the pressure w...

Page 25: ...us fluids per local state and national guidelines 1 Unscrew garden hose from water inlet if connected 2 Use Allen wrench to remove garden hose coupler 3 Remove glass filter screen 4 Remove filter screen 5 Run water through filter screen to clean 6 Reassemble Inspect Fuel System Inspect the engine fuel system and check for leaks before each use Do not start pressure washer until all needed repairs ...

Page 26: ...nd 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 Have a staff person become familiar with the mechanical operation of the ...

Page 27: ...rned ON Place ON OFF switch in the ON position Spark plug wire not attached Attach spark plug wire to spark plug LOW SURGING PRESSURE Causes Solutions Insufficient water supply Increase water flow Check for kinked or pinched hose Plugged inlet screen Pull out and clean screen carefully Need to use high pressure nozzle Change to the green yellow white Plugged nozzle Remove nozzle check for blockage...

Page 28: ...28 Parts Explosion Model 157119 157120 Rev G 157120 SHOWN ...

Page 29: ...ANCE 1 157119 157120 6 791308 NOZZLE QUICK COUPLER 1 157119 157120 7 800110 NOZZLE 4 PACK 3 0 1 157119 800111 NOZZLE 4 PACK 3 5 1 157120 8 221222 CHEMICAL STRAINER 1 157119 157120 9 777165 BRAIDED CHEMICAL HOSE SOLD PER FOOT 3 FT 157119 157120 10 777914 COUPLING QC 3 8 FNPT 1 157119 157120 11 800419 50 PRESSURE HOSE ASSEMBLY 3 8 1 157119 157120 12 777915 NIPPLE QC 3 8 FNPT 1 157119 157120 13 82141...

Page 30: ...LVE 1 157119 157120 19 777834 HOSE CLAMP 2 157119 157120 20 777376 VALVE POP OFF 1 157120 21 777165 PVC BRAIDED HOSE SOLD BY FOOT 1 ft 157119 1ft 157120 22 777340 NPT X HOSE BARB FITTING 1 157119 157120 23 803642 FILTER INLET 3 8 NPT X 3 4 FGH 1 157119 803643 FILTER INLET 1 2 NPT X 3 4 FGH 157120 24 35918 THERMAL VALVE 1 157119 777836 157120 25 777838 1 4 NPT PLUG 1 157119 157120 A1578201 A1578171...

Page 31: ...OIL FILTER CAP 1 167 CA46865 SPRING 6 37 CA92241 GAUGE BUBBLE OIL W GASKET 1 168 CA543988 RETAINER SPRING INLET 3 38 CA44428 GASKET FLAT FLEX OIL GAUGE 1 169 CA49764 RETAINER SPRING DISCHARGE 3 48 CA44842 DRAIN PLUG 1 172 CA142807 O RING FOR PLUG 3 49 CA14179 O RING FOR DRAIN PLUG 1 174 CA547104 PLUG VALVE W O RING 3 53 Not Available CRANKCASE 1 185 Not Available HEAD MANIFOLD W UNLOADER BODY 1 64...

Page 32: ...G PISTON STEM 1 469 CA7332 CHEMICAL FIXED INJECTOR 1 423 CA46249 RETAINER VALVE 1 470 CA76179 UNLOADER REPAIR KIT INCLUDES 412 414 415 423 424 425 426 429 431 435 436 437 1 424 CA13966 O RING VALVE RETAINER OUTER 1 471 CA76146 CHECK VALVE KIT INCLUDES 438 439 443 444 446 1 425 CA547799 PISTON RETAINER 1 472 Not Available BARB 1 426 CA46250 WASHER 1 476 Not Available O RING BARB 70D 1 428 CA26133 O...

Page 33: ...P 1 166 CA46429 VALVE 6 37 CA92241 GAUGE BUBBLE OIL W GASKET 1 167 CA43750 SPRING 6 38 CA44428 GASKET FLAT OIL GAUGE 1 168 CA46583 RETAINER SPRING INLET 6 40 Not Available SCREW 4 172 CA17616 O RING FOR PLUG 6 48 CA25625 DRAIN PLUG 1 174 CA48760 PLUG VALVE W O RING 6 49 CA23170 O RING FOR DRAIN PLUG 1 185 CA48846 HEAD MANIFOLD W UNLOADER BODY 1 50 CA48862 COVER REAR 1 188 CA126512 SCREW 8 51 CA140...

Page 34: ...RING PISTON STEM 90D 1 464 CA49118 WASHER SEAL 1 2 2 423 CA49105 RETAINER VALVE 1 468 CA31708 KIT O RING INCLUDES 414 415 424 428 430 437 446 454 1 424 CA49106 O RING VALVE RETAINER 70D 1 469 CA7367 INJECTOR CHEMICAL FIXED 1 425 CA49102 RETAINER PISTON 1 470 CA31556 KIT REPAIR INCLUDES 418 425 428 436 437 1 426 CA49107 WASHER 1 471 CA76185 KIT CHECK VALVE INCLUDES 443 444 446 1 428 CA26133 O RING ...

Page 35: ...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 service center is the responsibility of the customer In...

Page 36: ...306 NorthernTool com WARNING This product can expose you to chemicals including gasoline which is known to the State of California to cause cancer and carbon monoxide which is known to the State of California to cause birth defects or other reproductive harm For more information go to www P65Warnings ca gov ...

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