NorthStar 990994 Owner'S Manual Download Page 29

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Pump Exploded View Continued – Cat 2SF35GS

REF#

PART#

DESCRIPTION

QTY

REF#

PART#

DESCRIPTION

QTY

CA549360

Screw, HH (M6x 14)

166

CA43723

Valve

CA547153

Cover, Bearing, Inner

167

CA541062 Spring

CA14041

O-Ring, Bearing Cover - 70D

168

CA44565

Retainer, Spring

CA55337

Seal, Oil (See Tech Bulletin 092)

185

CA44879

Manifold, Discharge

CA14488

Bearing, Ball, Inner

188

CA126762 Screw, HSH (M8x75)

CA547046

Rod, Connecting

249

CA30520

Assy, Adapter Mount, Gas

CA46017

Crankshaft, 3450 RPM, 3/4”, 5.6mm

255

CA30517

Assy, Bolt Mount

CA12385

Ring, Retaining

285

CA80228

Screw (M8-1.25x80) (Not Shown)

CA15710

Bearing, Ball, Outer

300

CA34053

Kit, Seal (Inclds: 106,125,139,152, 159)

CA547961

Cap, Oil Filler w/O-Ring

310

CA34052

Kit, Discharge Valve (Inclds:

152,159,164,166,167,168)

CA14179

O-Ring, Oil Filler Cap - 70D

311

CA34668

Kit, Inlet Valve (Inclds: 134-139,152,159)

CA92241

Gauge, Bubble Oil w/Gasket - 80D

400

CA7500S Unloader, Regulating

CA44428

Gasket, Flat Flex., Oil Gauge - 80D

402

CA540081 Cap, Hex Adjusting

CA44842

Plug, Drain [1/2" NPT(F)]

403

CA45070

Nut, Lock

CA14179

O-Ring, Drain Plug - 70D

408

CA32094

Spring, Pressure

CA547285

Crankcase

410

CA107672 Retainer, Spring

CA16948

Pin, Crosshead

412

CA45694

Stem, Piston (M5)

CA44865

Rod, Plunger

414

N/A SEE * Back-up-Ring, Piston Stem

CA126259

Washer (M24)

415

N/A SEE * O-Ring, Piston Stem - 70D

CA25461

Seal, Oil

425

CA107673 Retainer, Piston

CA45847

Plunger (M18x14)

428

N/A SEE * O-Ring, Piston Retainer - 70D

100

CA44869

Retainer, Seal

429

N/A SEE * O-Ring, Body

106

CA834378

Seal, LPS w/S-Spg

430

N/A SEE * Back-up-Ring, Body

110

CA44874

Manifold, Inlet

435

CA45696

Valve and Ball Assembly (M5)

125

CA43245

Seal, HPS w/S

436

CA107680 Seat

134

CA45854

Valve, Inlet

437

N/A SEE * O-Ring, Seat - 70D

135

CA549520

Spacer, Inlet

440

N/A

Body

136

CA44872

Spring, Inlet Valve

442

N/A SEE * O-Ring, By-Pass Fitting - 70D

137

CA88575

Washer, Conical (M6)

443

CA541060 Valve, Check w/NBR O-Ring

138

CA27000

Nut, Slotted (M6)

444

CA45924

Spring, Check valve

139

CA14158

Cotterpin (M1.6x10)

446

N/A SEE * O-Ring, Discharge Fitting - 70D

152

CA26089

O-Ring, Adapter, Inner - 80D

455

CA45695

Fitting, By-Pass [

3/8"

NPT(F)]

157

CA44878

Discharge Valve Adapter

460

CA107681 Fitting, Discharge [

3/8"

NPT(M)]

159

CA26089

O-Ring, Adapter, Outer - 80D

CA32097

Kit, O-Ring (Inclds: 414, 415,

428,

429,

430,

437,

442,

446)

164

CA44881

Seat

Summary of Contents for 990994

Page 1: ...cause operator loss of balance and falls 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 Inspec...

Page 2: ...ollow Safety Rules for Operation 13 Preparing for Operation 14 Check Add Oil to Pump 14 Check Add Engine Oil 14 Inspect Fuel System Check for Leaks 15 Connect Hoses Water Supply and Spray Nozzle 16 Prime the Water Supply 17 Start Up Procedures 18 Start the Engine to Power the Pump 18 Begin High Pressure Spray 18 Shutdown 19 STORAGE 20 Between Use Storage 20 Prepare Pressure Washer for Freezing Con...

Page 3: ...OSION MODEL 990994 REV A 2 26 PARTS LIST MODEL 990994 REV A 2 27 PUMP EXPLODED VIEW CAT 2SF35GS 28 PUMP EXPLODED VIEW CONTINUED CAT 2SF35GS 29 LIMITED WARRANTY 30 LIMITED WARRANTY CONTINUED 31 CALIFORNIA PROPOSITION 65 INFORMATION 32 ...

Page 4: ...loves 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 operate the pressure washer while fatigued or under the influenc...

Page 5: ... oz SUPPLIES REQUIRED not included Engine Fuel Regular Unleaded Gasoline Engine Oil Refer to Engine Owner s Manual Pump Oil Shipped with oil but refills required SAE 30 Non Detergent Oil or Cat Pump Oil part 22158 Input Water Supply Tank Ensure tank has enough water for the cleaning job Tap Standard tap water 20 75 psi Input Water Supply Hose For Tap Standard garden hose with inside diameter at le...

Page 6: ...tion and displacement 6 Ball Valve Tank Drain Allows for remote tank draining hose not included 7 Ball Valve Filter Allows for cleaning in line strainer while water is in the tank 8 In line Strainer The strainer prevents debris from entering the pump 9 Engine drain oil hose Allows for easy clean oil changes 10 Nozzles Change nozzles for different spray patterns 11 Spray Gun Always use two hands fo...

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: ...condition If a 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 PW Warning OP Instructions ...

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

Page 10: ...contact Product Support at 1 800 270 0810 If complete fill out product serial number information See Limited Warranty section of this manual Manual Bag Any Questions Comments Problems or Parts Orders call NorthStar Product Support at 1 800 270 0810 Engine Pump Base Assembly Spray Gun Lance Assembly Manual Bag Nozzles Qty 4 Part 778740 15 yellow Part 778741 25 green Part 778742 40 white Part 778949...

Page 11: ...nt tip over Select a suitable outdoor location 1 Never run the pressure washer in an enclosed 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...

Page 12: ...age or damage to the pressure washer 1 The exhaust gas from your pressure washer is extremely hot and can cause combustible materials to catch on fire 2 Make sure the engine is at least 7 feet from all combustible materials and structures during operation 3 Keep a fire extinguisher rated ABC nearby Keep it properly charged and be familiar with its use 4 Place the pressure washer so that the exhaus...

Page 13: ...ors 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 beyond what can b...

Page 14: ...eak while using the pressure washer shut off the engine and get to fresh air RIGHT AWAY See a doctor You may have carbon monoxide poisoning Wear Personal Protective Gear WARNING Wear personal protective gear to prevent Eye and skin injection injury from high pressure spray Eye injury from flying debris 1 Wear waterproof gloves ANSI Z87 1 compliant safety goggles face protection and protective clot...

Page 15: ... sitting inside a vehicle trailer trunk or pick up truck bed Dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources Keep nozzle in contact with container while filling Do not use a nozzle lock open device 5 Clean up fuel spills splashes immediately If possible move the pressure washer away from spilled fu...

Page 16: ...lon 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 990994 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 at least 3 4 4 Always use a flexible rubber hose for your water supply Do not use rigid piping Attach High Pressure...

Page 17: ...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 ball valves open for tank supplied water Operating the pressure washer without a ...

Page 18: ...isk of injury do not attempt to secure the spray gun open by blocking or tying the spray gun in the open position Prevent slips loss of balance High pressure spray could cause you to lose balance from kickback forces and wet surfaces can be slippery Keep good footing and balance at all times Do not overreach Do not stand on unstable support when spraying If spraying from an elevated surface use fa...

Page 19: ...aying use the spray gun safety lock to prevent accidental high pressure discharge 10 Always turn off the engine and activate spray gun trigger to relieve system pressure when the pressure washer 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 pressure ...

Page 20: ...apors can ignite and cause a fire Select a well ventilated storage area away from sources of heat flame or sparks A hot engine can ignite flammable materials Always let engine cool at least five minutes before storing Prepare Pressure Washer for Freezing Conditions If you will be storing the pressure washer in freezing temperatures you must properly prepare the pressure washer to prevent water fro...

Page 21: ...facturer s instructions Fuel stabilizer steps a Ensure gas tank is full 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 cylinder and piston a Disconnect spark plug wire and remove spark plug b Add one teaspoon oil through spark plug hole c Place rag over sp...

Page 22: ...sporting or servicing the pressure washer Replace guards Make sure all guards and cover shields are replaced after servicing the pressure washer Major repair Major service including the installation or replacement of parts should be performed only by a qualified service technician Obtain factory approved parts from NorthStar Product Support at 1 800 270 0810 Replacement parts If a part needs repla...

Page 23: ... 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 Always dispose of hazardous fluids per local state and national guidelines 1 Close Ball Valve Filter to prevent water from tank from flowing out line strainer during cleaning 2 Unscrew in line strainer cover 3 Remove filter ...

Page 24: ... center or service station for reclamation Do not throw it in the trash pour it on the ground or pour it down a drain 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 ...

Page 25: ...ngine Choke engine to start No fuel Add gas to fuel tank Make sure fuel shutoff valve is open Pressure build up from initial use Trigger spray gun to relieve pressure Engine not turned 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 pin...

Page 26: ...26 Parts Explosion Model 990994 Rev A 2 ...

Page 27: ... 82622 5 16 18 X 1 1 2 HHFB 4 16 802193 Harness Wire Float Switch To GND 1 48 606512 Engine 6 5HP Honda GX200UT2QX2 1 17 779268 3 4MPT X 1 2HB Polypro CS 1 49 801445 Fitting 9 16 18 Male JIC X 10MM Elbow 1 18 777119 Clamp 1 2 Hose GN PW CS 2 50 801097 Fitting 3 8 FPT Cap 1 19 32808 3 8 NPT X 1 2 HB Elbow 1 51 779666 Clamp 1 Loop 1 20 802191 Float Switch 1 52 801089 Hose Oil Drain 1 21 2264 Hose 1 ...

Page 28: ...28 Pump Exploded View Cat 2SF35GS ...

Page 29: ...179 O Ring Drain Plug 70D 1 408 CA32094 Spring Pressure 1 53 CA547285 Crankcase 1 410 CA107672 Retainer Spring 1 64 CA16948 Pin Crosshead 3 412 CA45694 Stem Piston M5 1 65 CA44865 Rod Plunger 3 414 N A SEE Back up Ring Piston Stem 1 69 CA126259 Washer M24 3 415 N A SEE O Ring Piston Stem 70D 1 70 CA25461 Seal Oil 3 425 CA107673 Retainer Piston 1 90 CA45847 Plunger M18x14 3 428 N A SEE O Ring Pisto...

Page 30: ...om date of purchase In addition to the normal warranty NorthStar shall warrant any normal wear item from defects in material or workmanship for a period of 90 days from the date of purchase by user Normal wear items include but are not limited to nozzles quick connect fittings valves high pressure hoses O rings filter elements Gun Lance Tires and unloader valves Consumer use means personal residen...

Page 31: ...eaning and obstruction due to build up is not covered by this NorthStar warranty Please fill in the following information and have it on hand when you call in on a warranty claim Customer Number ______________________________________________________________ Date of Purchase _______________________________________________________________ NorthStar Serial Number _____________________________________...

Page 32: ...hernTool 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 California to cause birth defects or other reproductive harm For more information go to www P65Warnings ca gov ...

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