NorthStar M157117B Owner'S Manual Download

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Pump Explosion-CAT 66DX- Rev B

REF#

PART#

DESCRIPTION

QTY

REF#

PART#

DESCRIPTION

QTY

401

CA49100

Handle, Adjusting (Black)

435

—

Valve/Ball Assembly

402

CA49099

Cap, Adjusting

436

—

Seat

403

CA12 5521

Nut, Locking (M25x1)

437

—

O-Ring, Seat - 70D

404

CA88953

Screw, Set (M4x4)

440

—

Valve Body

408

CA4519 8

Spring, Pressure

442

CA49121

Washer, Seal (3/8

”

)

410

CA49101

Retainer, Spring

443

—

Valve, Check w/NBR O-Ring

412

—

Stem, Piston

444

—

Spring, Check Valve

414

—

Back-up-Ring, Piston Stem

446

—

O-Ring, Body - 80D

415

—

O-Ring, Piston Stem - 90D

454

—

O-Ring, Manifold - 70D

418

—

Assy, Piston (Included in Repair Kit)

456

—

Manifold

423

CA49105

Retainer, Valve

460

CA12 6974

Fitting, Discharge [3/8

”

NPT(M)]

424

—

O-Ring, Valve Retainer - 70D

462

CA4912 0

Screw, Flo-Thru [3/8

”

NPT(M)]

425

—

Retainer, Piston

463

CA49117

Screw, Flo-Thru [1/2

”

NPT(M)]

426

—

Washer

464

CA4911 8

Washer, Seal (1/2

”

)

428

—

O-Ring, Piston Retainer - 80D

468

CA317 08

Kit, O-Ring, (Inclds: 414, 415, 424,
428-430, 437, 446, 454)

429

—

O-Ring, Valve Retainer - 70D

470

CA31556

Kit, Repair (Inclds: 418, 425, 428,
436,437)

430

Back-up-Ring, Valve Retainer

471

CA76185

Kit, Check Valve (Inclds: 443, 444,
446)

Summary of Contents for M157117B

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 serious skin or eye injury including injection injury if fluid pierces the skin Injection injury can result in blood poisoning and or severe tissue damage Burns Hot spray can scald and burn skin Hot ...

Page 2: ... not included The engine will run but the burner will not fire unless a bat tery is installed Purchase a standard lawn and garden Group U1 battery The engine requires a 12V battery with a minimum rating of 18 Ah Amp hour Water Flow Requirements Make sure your supply water flow rate is 20 higher than the pressure washer s flow rate see Specifications section for detail and that your water is clean ...

Page 3: ...peration 20 Step 1 Connect 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 Troubleshooting 51 Major Components 53 Parts Explosion Frame Rev B 54 Parts Explosion Heat Exchanger Rev B 57 Parts Explosion Blower EMF Rev B 59 Parts Explosion Engine Water Fuel Pumps Dr...

Page 4: ...manual The user should 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 protective footwear Some cleaning chemicals may require the use of a respirator mask as instructed on chemical label Before using this washer the user shall determine the suitability of t...

Page 5: ...gine Fuel Regular Unleaded Gasoline Capacity 8 Gal 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 Fuel 1 or 2 Diesel B5 or lower Biodiesel Kerosene or Fuel Oil Capacity 8 Gal Pump Oil shipped with oil but refills required SAE 30 non detergent oil Input Water Supply Standard tap water 20 75 p...

Page 6: ...ector 5 Pump 14 Spray Gun 23 Rupture Disc Fitting 6 Diesel Fuel Tank 15 Wand 24 Flame Sensor 7 Diesel Fuel Cap 16 Control Box See Detail A 25 Hose reel sold by Separately 8 Unloader 17 Circuit Protector 26 Battery Box 9 Engine 18 Heat Switch Fig06883 1 3 6 9 SEE DETAIL D 5 7 8 11 13 2 4 10 12 16 SEE DETAIL A 19 SEE DETAIL B 22 25 14 15 DETAIL B 20 AIR FUEL IGNITION SYSTEM FAN FLYWHEEL STATOR ASSEM...

Page 7: ...es water and screens 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 tank 14 Spray Gun Used to divert water out to nozzle 15 Grip Section of wand to extend length and provide stability 16 Wand Rod to extend length 17 Control Box Housing device for mo...

Page 8: ... Support at 1 800 270 0810 Ref Part Description 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 2 5 788936 Decal Burn Hazard Warning 1 6 801160 Decal Recoil Warning 1 7 802203 Decal Descaling Warning 1 8 782397 Decal Battery Warning 1 Fig157117 2 5 6 8 3 ...

Page 9: ...s Thermal 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 developed during bypass mode the thermal relief valve will open and discharge hot water onto the ground protecting the pump from overheating The thermal relief valve is located on the unloader bypa...

Page 10: ... and separate the components identified in Fig157117 3 Unpacking delivery inspection assembly and initial set up and Fig157117 16 Hardware Bag Inspect the pressure washer immediately after you receive delivery for missing parts and damage If you have missing or damaged components contact Product Support at 1 800 270 0810 Fig157117 3 Hardware Bag Handle Weldment Qty 1 800118 Pressure Washer High Pr...

Page 11: ...k Qty 1 Part 800652 Steam Nozzle Qty 1 Part 801090 Bolt 5 16 18 Hex Head Flange Bolt Qty 2 Part 82621 Hose Hook Qty 1 Part 800615 Nut 5 16 18 Hex Flange Nyloc Qty 2 Part 82630 Chemical Injector Qty 1 Part 779614 1 4 Braided Chemical Hose Qty 4 Part 777165 Washer 5 16 flat Qty 2 Part 82021 Funnel flexible hose Qty 1 Part 801131 ...

Page 12: ...T SIDE OF HANDLE USING TWO 2 5 16 18 X 3 4 FLANGE NUTS 5 16 18 X 3 4 TWO 2 FLANGE NUTS 5 16 18 X 2 1 2 TWO 2 HHSF GR5 BOLT 5 16 TWO 2 FLAT WASHER Step 1 Install handle with two 2 5 16 18 x 2 1 2 Bolts two 2 5 16 flat washer through Base and Handle and secure with two 2 5 16 18 Flange Nuts Step 2 Install Hose Hook into right side of Handle using two 2 5 16 18 Flange Nuts Step 3 Install Nozzles into...

Page 13: ...ttery Hazards Batteries are hazardous because they contain caustic acid can emit explosive gases and can cause electric shock Caution must be exercised when making connections to a battery to avoid shock and contact with the acid and to prevent any sparking that could lead to an explosion ALWAYS follow the general battery safety rules and instructions listed below General Battery Safety Rules ALWA...

Page 14: ...ing 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 with brake to prevent inadvertent movement Elevating or lowering your pressure washer To reduce risk of injury do not attempt to lift the pressure washer Use a shallow ramp to raise or lower the pressure wash...

Page 15: ...er 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 without sufficient oil o Engine is shipped without oil You must add oil before first use Inspect spray system Always inspect spray system for damage and leaks before each use Do not start pressure washer until all needed repairs have been completed WARNIN...

Page 16: ... the Maintenance Repair section 1 Refer to the engine owner s manual for engine maintenance instructions 2 Make sure battery is charged Charge as needed according to your battery manufacturer s instructions STEP 2 ADD FUEL S WARNING Fuel fire explosion hazard Gasoline is highly flammable and explosive Burner fuels are combustible at warm temperatures Heat sparks and flames can ignite fuel vapors w...

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 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 opening Use on...

Page 18: ...pressure 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 intakes 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 Never run the pressure washer in an enclo...

Page 19: ...haust 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 from all combustible materials and structures during operation Equip the engine with a spark arrestor if the pressure washer will be used near any ignitable forest brush or grassy land See the engine...

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 unobstructed ventilation airflow With adequate clearance from combustible materials On a firm level heat resistant surface with good drainage and nearby access to a continuous water supply DANGER Car...

Page 21: ...o 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 section of this manual for location of garden hose water inlet 2 Confirm rubber washer and inlet screen are in the garden hose inlet before attaching the garden hose Attach high pressure hose Attach the hi...

Page 22: ...5º General 778947 4 0 White 40º Light Cleaning 778949 Soap Nozzle 65º Chemicals 801090 3 0 Orange Steam 15º Steam Note You must use the black low pressure nozzle for spraying chemicals Attach nozzle Attach nozzle to the spray gun WARNING Depressurize first Any time you remove install change a nozzle you must depressurize hose line by squeezing the spray gun trigger while the engine is off Even if ...

Page 23: ...er 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 Suction pressure at this connection automatically draws the chemical solution in through the hose mixing in 1 part chemical to 15 parts water Adequate suction pressure is created only when the low pre...

Page 24: ...Star 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 harmful to the environment Prepare for chemical spray if planning to use Prepare the pressure washer for chemical spraying using the following steps 1 Prepare dilute chemical cleaning solution as requ...

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 exhaust parts Stay clear of engine and burner exhausts Never touch hot engine muffler burner heating coil or other hot surfaces All are very hot and will burn you Do not direct spray at this machine D...

Page 26: ...ery surfaces Wear footwear capable of maintaining a good grip on 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 sufficient incoming flow of water will damage the pump Turn on the water supply Make sure the water supply is steady and flowing at a rate...

Page 27: ...igh pressure nozzle will stop the flow of chemicals into the water stream Refer to instructions in section select spray nozzle in Step 1 Connect Hoses Water Supply and spray Nozzle 8 Rinse with high pressure 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...

Page 28: ...dy to come in contact with the fluid stream High pressure spray can cause serious skin eye or falling injuries and hot water can burn 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 severe tissue damage leading to infection gangrene and possibly amputation Seek medical attention Do not secure ...

Page 29: ...when the heater is being used Use only designated grip areas 4 Wash from the bottom to the top using side to side motions This 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 should be 12 to 24 from the work closer for tough areas 7 Small parts should b...

Page 30: ...of 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 pressurized Relieve pressure by squeezing the spray gun trigger after the engine is turned OFF 1 If the heater was used turn heat switch OFF and run cold water through the coil for at least 2 minutes while sp...

Page 31: ...lot 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 freezing conditions unless it is prepared as directed below for those conditions Perform regular maintenance Perform periodic maintenance as directed in this manual to keep the pressure washer in sa...

Page 32: ...acing 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 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 has be drawn from the supply bucket Note if s...

Page 33: ...ger 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 fitting Prepare engine for long term storage if storing more than 30 days First prepare the engine for long term storage if you will not be using the pressure washer again for more than 30 days Fuel can...

Page 34: ...he spark plug wire Prepare pressure washer for storage Prepare the pressure washer for storage 1 Disconnect the battery remove it from the battery compartment and store indoors 2 Make sure the engine start switch is OFF and fuel valve is OFF 3 Disconnect the engine spark plug wire if you haven t already done so 4 Disconnect the high pressure hose garden hose and spray gun Move pressure washer to s...

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 appears from the burner exhaust vent or a rumbling sound is heard Note which number the arrow is near 5 Slowly rotate air intake cover counterclockwise open until white smoke just starts to appear N...

Page 36: ...e Each use Recharge and maintain battery As specified in Battery Manufacturer s instructions Perform engine maintenance As specified in Engine Owner s manual Change pump oil After first 40 hours of use Every 3 months or 500 hours of use after that Maintain burner s fuel filter water separator Drain water as needed Change filter after every 500 hours of use Descale coil Annually or more frequently ...

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 brush Do not allow air intakes to become blocked CAUTION Do not spray pressure washer with a garden hose or pressure washer Water may enter the pressure washer and cause damage Inspect fuel system s...

Page 38: ...ar 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 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...

Page 39: ...1 Changing oil and oil filter 2 Air filter check replacement 3 Spark plug cleaning and replacement 4 Fuel filter check replacement 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 1 Remove drain plug from pump 2 Drain pump oil into suitable container and ...

Page 40: ...le 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 additional strainer may be needed in areas that have high mineral content in the water supply More frequent descaling may be required if higher temperatures or steam mode is used regularly Descale the coil t...

Page 41: ...n 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 swivel fitting from the coil inlet 3 Connect hose s as shown below to the coil inlet coil outlet and the circulating pump Do not hook up the pressure washer hose or gun 4 Add commercial coil cleaner to wa...

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 remaining coil cleaning residue has been flushed out with fresh water 17 Reinstall the outlet coil quick connect nipple fitting to the coil outlet 18 Reinstall the inlet coil swivel fitting to the co...

Page 43: ...he 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 fitting from elbow to the inlet of the coil 2 Remove the Cap fitting from the flow switch 3 Slide out the Shuttle Assembly If the magnet in the shuttle assembly is damaged or missing replace the entire f...

Page 44: ...nue 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 cleaning is complete reinstall the Body into the Enclosures taking care not to cause damage Tighten the Screws into the body until they are snug Do not over tighten the screws 8 Insert the Shuttle Assem...

Page 45: ...amaged 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 Re connect the swivel to the elbow Hand tighten the swivel onto the elbow and once snug using a wrench continue to tighten the swivel two additional revolutions Cap Fitting Torque to 100lb in Body female S...

Page 46: ...uter 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 Remove the 2 1 1 4 Jam nuts and the 3 8 bolt underneath the base 8 Lift off Outer Wrap Inner Wrap and Inner Cover Set aside 9 Using a couple of straps wrap them around the Coil and attach to a hoist to l...

Page 47: ...ct 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 Replace electrodes NOTICE Wipe combustion head flame sensor lens every 100 hours If the flame sensor lens gets sooted up the flame sensor will be unable to sense a flame and therefore the burner will...

Page 48: ...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 belt as needed Always tighten belt if slipping WARNING Belt slippage can cause static electricity build up which may result in sparking Fire ignition can result Instructions 1 Make sure engine is off an...

Page 49: ...cause 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 access to rotating parts Clothing or hair can become rapidly entangled in unguarded rotating parts resulting in serious injury or death FIG 157114 11 TENSION BRACKET MOUNT BOLTS FIG A TENSIONING NUT F...

Page 50: ...we 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 maintenance procedures Keep a stock of recommended service parts for maintenance and minor repairs IMPORTANT If a part needs replacement only use parts that meet the manufacturer s part number specifications...

Page 51: ...ning Fuel 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 maintenance and repair section of manual Ignition coil failure or improperly gapped see maintenance and repair section or contact product support Other Heat switch turned OFF Turn heat switch O...

Page 52: ...stment 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 Instructions Coil is full of soot See Coil Desooting under Maintenance Instructions POOR OR NO DETERGENT SUPPLY Causes Solutions Inadequate detergent supply Refill detergent container Make sure chemical stra...

Page 53: ...ption Page 1 Frame 52 2 Heat Exchanger 55 3 Blower and ignition flywheel 57 4 Engine Water pump Fuel pump and drive parts 59 5 Accessories Gun hose chemical injector 62 These components go into more detail on the following pages 1 2 3 4 5 Fig157117 ...

Page 54: ...arts Explosion Frame Rev B 54 Fig157117 1 41 49 48 47 46 42 24 21 23 22 40 25 53 27 50 26 20 34 36 35 37 33 38 44 43 31 30 29 28 52 18 32 19 17 16 51 15 14 12 13 6 11 10 9 5 45 8 1 3 2 4 7 39 54 55 56 57 ...

Page 55: ...5 BRAKE LEVER ASSEMBLY HWPG 1 18 82008 NUT 10 32 KEPS Price per 100 2 19 800593 PLATE BRAKE MOUNT 1 20 82014 BOLT 5 16 18 X 1 2 HHSF GR5Z 4 21 87435 SCREW 4 40 X 3 4 PHIL PAN M S ZN 8 22 82068 WASHER NO 10 FLAT Z Price per 100 2 23 82067 NUT 10 32 CLIP NUT Z 3 24 800044 PLATE CONTROL BOX BOTTOM 1 25 800062 PLATE CONTROL BOX COVER 1 26 87961 NUT 4 40 NYLOC 16 27 800978 DECAL OP CONTROL 115 116 117 ...

Page 56: ...46 800107 PLATE BILLBOARD 1 47 788920 DECAL 4X9 NORTHSTAL LOGO PW 1 48 777666 DECAL GASOLINE ONLY PW 1 49 787827 DECAL DIESEL ONLY PW 1 50 801440 WELDMENT ENGINE PUMP MOUNT 1 51 801053 FITTING 3 8 QC SOCKET X 3 8 FPT 1 52 777838 PLUG HEX 1 4 C SUNK PW 2 53 800186 SPACER NYLON 4 X 1 4 OD X 1 4 THK 4 54 82626 BOLT 3 8 16 X 2 5 HHFB 4 55 782706 1 2 NPT X 3 4 HB STEEL AS 1 56 800986 FILTER INLET 1 2 N...

Page 57: ...t Exchanger Rev B 57 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 11 6 7 8 9 5 10 12 4 13 14 15 Fig06885 ...

Page 58: ... MD HX Painted 1 1 22 796314 Diffuser 9 fin 3 5 inch weldment sm 1 1 22 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 Screw 10 32 x 1 2 button head cap 8 1 26 793595 Flame sensor bracket kit 1 1 27 799294 Electrodes HX 1 1 28 791883 Coil weldment 1...

Page 59: ...9 82613 M6 1 0X8MM SET SCREW KNURL CUP 1 10 82020 NUT 5 16 18 NYLON INSERT 4 11 788016 2 MM SPACER 3 12 801874 INLET DAMPER CAP LARGE 1 13 801982 ASSEMBLY FAN HUB STATOR 157117S 1 14 801658 PLATE ISO MOUNT STIFFENER BRACKET 1 15 82720 CLIP NUT 2 16 82096 BOLT 5 16 18 X 3 5 1 17 800619 MOUNT ISO HWPG 40 DURO 1 18 82630 5 16 FLANGE NYLOC NUT 1 19 82624 BOLT 3 8 16 X1 HEX HEAD FLANGE 4 20 82631 NUT 3...

Page 60: ...PTION QTY 5 SEE ABOVE TABLE 2 82015 5 16 18 X 3 4 HHSF BOLT 1 11 788016 2 MM SPACER 1 15 802202 M5 FLAT WASHER 2 16 800469 STATOR ASSEMBLY 1 17 800782 IGNITION COIL ASSEMBLY 1 18 800468 FLYWHEEL HUB 1 19 802343 8 32 X 1 SHCS 2 5 2 11 15 16 17 18 19 Fig06884 ...

Page 61: ...umps Drive Parts Rev B 61 1 2 3 4 6 7 8 9 5 10 11 12 13 14 15 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 66 65 64 63 58 60 56 61 55 62 59 57 54 53 50 16 17 19 51 18 52 67 68 69 Fig157117 12 ...

Page 62: ...GAL 1 16 793588 GAS TANK PRE ASM 8 GAL 1 17 792908 GAS CAP RATCHET TETHER 2 25 1 18 801490 HOSE TANK TO FUEL PUMP 4 19 793575 TANK VENT FITTING 1 20 800112 PLATE TANK STRAP 1 21 82623 5 16 18 X 2 5 2 22 801448 FITTING 1 4 HB X 1 4 NPT 1 23 794146 FITTING 1 4 JIC TO 1 8 NPT 45 1 24 777340 BARB HOSE BR 1 4 MPT X 1 4 PW 1 25 801590 VALVE SCHRADER 1 8 NPT 1 26 801471 FITTING 1 8 TEE 1 27 801472 FITTIN...

Page 63: ... HOSE TANK TO FILTER 14 51 801490 HOSE TANK TO CARBON CANISTER 14 52 801490 HOSE ENGINE TO CARBON CANISTER 12 53 82315 BOLT CARRIAGE 1 4 20 X 1 LS 3 54 30755 FILTER FUEL RED 150 MICRON GN 1 55 777834 CLAMP 1 4 HOSE 13 56 794381 FUEL PUMP 2 3 5PSI 15 GPH 1 57 795084 STRAP CARB CANISTER 603 4 GN 1 58 32420 WIRE SNAP PLUG TERM FEMALE LS 1 59 32417 WIRE SNAP PLUG TERM MALE LS 1 60 800604 FITTING ELBOW...

Page 64: ... PRESSURE HOSE 1 7 777165 CHEMICAL HOSE 4 8 779614 INJECTOR QC 5 to 8 GPM 1 9 221222 STRAINER CHEMICAL PW 1 10 800615 HOSE HOOK 1 11 800652 NOZZLE 4 PACK 4 0 PW 1 12 801090 NOZZLE 15 ORANGE 3 0 1 13 777495 M8 1 25 NYLOCK NUT 2 14 82095 BOLT 5 16 18 X 2 5 HEX HEAD FLANGE BOLT 2 15 82630 NUT 5 16 18 HEX FLANGE NYLOC 2 16 801053 COUPLING 3 8 1 16 1 GP2701020 O RING NOT SHOWN 1 17 796634 FITTING 3 8 G...

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 80D 1 172 CA17616 O Ring ValvePlug 80D 6 40 CA125824 Screw HHC M6x16 4 174 CA48760 Plug Valvew O Ring 6 48 CA25625 Plug Drain 1 4 x19BSP 1 185 CA48846 Head Manifold 1 49 CA23170 O Ring DrainPlug 70D 1 ...

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 Fitting Discharge 3 8 NPT M 1 424 O Ring ValveRetainer 70D 1 462 CA49120 Screw Flo Thru 3 8 NPT M 1 425 Retainer Piston 1 463 CA49117 Screw Flo Thru 1 2 NPT M 1 426 Washer 1 464 CA49118 Washer Seal 1 2 2 42...

Page 67: ...r to Switch 800458 1 13 Controller Temp Assembly 802972 1 14 Primary Control Board 12VDC 792287 1 157117 BRN BROWN BLK BLACK WHT WHITE BL BLUE BATTERY RED SWITCH BREAKER RED BURNER RED BLK BLK 1 2 3 4 5 6 7 8 BLK CONTROL BOARD THERMISTOR BLK BLK HI PRESSURE LIMIT FLOW SWITCH THERMOSTAT BOARD 4 3 2 1 8 7 6 5 4 3 2 1 WHT BLK BRN BL WHT BLK 1 2 3 4 5 6 7 RED 2 POSITION LEVER LOCK 3 POSITION LEVER LOC...

Page 68: ...IGNITION COIL OIL LEVEL SWITCH YLW C3 SPARK PLUG ST BAT EXT EXT YLW CHARGE COIL 1A OR 3A BATTERY CONTROL BOX BLK RED RED BLK WHT BL W BL W WHT STARTER MOTOR STARTER SOLENOID FUSE 15A CIRCUIT BREAKER 3 5A RECTIFIER COMBINATION SWITCH BLK BLK RED RED WHT C1 C2 C5 T1 C4 C6 C7 1 2 WHT WHT WHT WHT WHT GR FUEL PUMP LED OIL_ALT EXT EXT ENGINE RED BLK 4 3 1 2 1 Fig157117 15 ...

Page 69: ...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 and understand the intended use of this pressure washer Do not use for other purposes as unforeseen hazards or equipment damage may result PROHIBITION AGAINST MODIFICATIONS Never modify or alter the pressure washer in any way...

Page 70: ...te clearance around pressure washer to allow for airflow at least 7 from any non combustible wall or obstruction Never place any objects against or on top of pressure washer CO alarms Ensure that working battery operated or battery back up carbon monoxide alarms are used in any dwelling structure that is in close proximity to the running pressure washer Hot exhaust fires Exhausts from engine and b...

Page 71: ...ified in pressure washer and engine manuals Never operate machine with damaged or missing hoses parts Never attempt to repair a high pressure hose or component Always replace it with a part that is rated at or above the pressure rating of this machine Never run the machine without sufficient lubrication or sufficient water to cool the pump Never operate unless all safety guards are in place Positi...

Page 72: ...an result in blood poisoning and or severe tissue damage leading to infection gangrene and possibly amputation Prevent surface damage flying debris Surfaces being sprayed must be strong enough to withstand high pressure spray or damage may result In addition high pressure spray will dislodge unsecured objects as well as surface chips and debris resulting in hazardous flying objects that can cause ...

Page 73: ...efore leaving the sprayer unattended or when disconnecting hoses removing nozzles or servicing the pump Refueling Never add gasoline to the engine or fuel to the burner unless unit is off and has cooled Do not direct spray at this machine Do not attempt to clean this machine with its own spray Engine damage will result Cleaning should be done with a damp sponge with the engine OFF Seek medical aid...

Page 74: ... to prevent accidental starting Fuel valve off Turn fuel shut off valve to OFF position before transporting or servicing the pressure washer Follow maintenance schedule Follow all maintenance instructions in this pressure washer manual and the engine manual Replace guards shields Make sure all guards and shields are replaced after servicing the pressure washer Replacement parts If a part needs rep...

Page 75: ...Roll 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 purchase by user Warranty does not cover damage from freezing or obstruction due to buildup of scale or soot Pump 5 years from date of purchase Lifetime on pump manifold NorthStar shall warrant the pr...

Page 76: ...tarting 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 loss of use including any implied warranty of merchantability of fitness for a specific use Also Outdoor Power Equipment needs periodic parts and service to perform well and this warranty does not co...

Page 77: ...California Proposition 65 Information 77 This page is intentionally left blank ...

Page 78: ...nTool 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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NorthStar M157117B, Owner'S Manual

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