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  4. M157592O
  5. Owner's Manual

North Star M157592O Owner's Manual

Summary of M157592O

  • Page 1

    M157592o owner's manual instructions for set-up, operation, maintenance & storage h ot w ater p ressure w asher – 4000 psi / 4 gpm portable outdoor-use only this pressure washer produces both cold and hot water high pressure spray. Cleaning chemicals may be incorporated into the spray if desired. Th...

  • Page 2

    Hazard signal word definitions 2 equipment protection quick facts inspect upon delivery stop! Closely inspect to make sure no components are missing or damaged. See the "assembly and initial set-up" section for instructions on whom to contact to report missing or damaged parts. Fill with engine oil ...

  • Page 3

    Table of contents 3 about your pressure washer .................................................................................................... 4 specifications ................................................................................................................................ 5 comp...

  • Page 4: Read This Manual

    About your pressure washer 4 thank you for purchasing a northstar hot water pressure washer! Your machine is designed for long life, dependability, and the top performance you demand. This pressure washer is designed to: 1) produce a high-pressure spray of heated or unheated water (up to 4 gallons p...

  • Page 5

    Specifications 5 model model # 157592 flow output pressure rating 4000 psi flow rate 4 gpm maximum temperature 210 f dimensions / components length 47" width 37.75" height 42" weight (dry) 500 lbs. Pump type northstar rw4540s engine horsepower 18.8 hp high pressure discharge hose 3/8" x 50' chemical...

  • Page 6

    Component identification 6 ref # description ref # description ref # description 1 rupture disc 10 ball valve (city tap water) 18 pressure switch 2 unloader 11 engine key switch 19 water outlet 3 inlet plumbing 12 water inlet (city tap water) (trailer models use hose reel) 20 heat switch 4 pump 21 t...

  • Page 7: Reference Guide

    Component identification 7 reference guide 1. Rupture disc safety device that opens to relieve pressure in the event of system over pressurization. 2. Unloader valve that regulates pressure and directs flow into bypass when trigger is closed. 3. Inlet plumbing means of connecting garden hose to pump...

  • Page 8: On-Product Warning Labels

    Safety labeling 8 always make sure safety labels are in place and in good 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. On-product warning labels part n...

  • Page 9

    Special equipment safety features 9 high pressure safety device (rupture disc) warning - if the high pressure safety device ever discharges water, turn the engine off and do not use the machine. The device will no longer function properly. See a dealer or call product support at 1-800-270- 0810. Thi...

  • Page 10

    Assembly and initial set-up 10 steps for assembly / initial set-up step 1. Unpacking & delivery inspection step 2. Attaching a water feed tank (customer supplied) step 3. Initial pump & engine preparation step 4. Battery installation each of these steps is discussed in the below: step 1. Unpacking &...

  • Page 11

    Assembly and initial set-up 11 figure 3 – hardware bag contents suction hose assembly qty-1 part # 221222 and 777165 chemical injector qty-1 part # 779614 nozzles qty-5 part # 778946 - 0 °, red part # 778739 - 15 ° , yellow part # 778948 - 25 ° , green part # 778947 - 40 ° , white part # 778949 - so...

  • Page 12

    Assembly and initial set-up 12 step 2. Attaching a water feed tank if desired (customer supplied) water may be supplied to the pressure washer either via an external water tank or via a standard tap supply. Caution : inadequate plumbing between a feed tank and the pressure washer can cause damage to...

  • Page 13

    Assembly and initial set-up 13 step 5. Close the city tap water ball valve and open the feed tank ball valve, as shown in figure 4a. Step 6. Reroute the easy start valve so it discharges back to the feed tank as shown below in figure 4b. (this will aid pump priming on initial start-up.) figure 4b th...

  • Page 14

    Assembly and initial set-up 14 step 3. Initial pump & engine preparation prepare water pump verify pump oil level . Note: the pump is shipped with oil. 1. Verify that oil level is half way up the sight glass (or at the indicator line on the dip stick). 2. If oil level is low, fill using universal tr...

  • Page 15

    Assembly and initial set-up 15 step 4. Battery installation install a 12-volt battery (group 22nf) with a minimum 55 amp-hour rating. The engine will run but the burner will not fire unless a battery is installed. The battery is to be supplied by the customer and should be installed in the protectiv...

  • Page 16

    Moving and handling 16 warning the pressures washer is heavy. You can be injured when trying to lift it without mechanical assistance. It can crush and cause serious injury if it drops on someone. Follow the instructions below for safely moving the pressure washer. To reduce risk of injury, use a ho...

  • Page 17

    Before each use 17 follow the steps below prior to each use of the pressure washer. Steps to follow before each use step 1. Check equipment step 2. Add fuel(s) step 3. Select suitable worksite step 1. Check equipment check/add pump oil check/add pump oil . Caution: never run the pump without suffici...

  • Page 18

    Before each use 18 always replace it with a part that is rated at or above the pressure rating of this machine. 1) check hoses, fittings, wand, trigger gun and connections for signs of wear, cracks, looseness, or leaks. Replace as required. 2) check and clean the nozzle orifice. 3) clean inlet filte...

  • Page 19

    Before each use 19 2) fill fuel tank outdoors – never indoors. Fuel vapors can ignite if they collect inside and enclosure and explosion can result. 3) stay away from all sources of heat, sparks, and flames. Do not smoke. 4) never pump fuel directly into the fuel tank or burner at a gas station – it...

  • Page 20

    Before each use 20 step 3. Select suitable outdoor worksite before using the pressure washer, you must understand the criteria for selecting a suitable location for operation. Note that this pressure washer is for outdoor use only. Warning : you must choose a suitable site for operating your pressur...

  • Page 21

    Before each use 21 2. Away from combustible dust, liquids, or vapors do not locate and use the pressure washer in the presence of flammable vapors, dust, gases, or other potentially combustible materials. Burner is an open flame, which can ignite airborne dusts and flammable vapors. Operate only whe...

  • Page 22

    Operation 22 after you have checked and fueled the equipment and positioned it in a suitable worksite, it is time to start your pressure washer. The following are the procedures necessary for safe, successful operation of your pressure washer. Warning carefully read and follow all instructions and s...

  • Page 23

    Operation 23 connect your water supply if using tap water: follow these instructions when supplying water from a pressurized source such as city tap water: acquire a suitable garden hose and attach to the water supply: 1. Acquire a suitable garden hose: a. The water supply garden hose must have an i...

  • Page 24

    Operation 24 if using feed tank: follow these instructions when supplying water from a feed tank: 1. Make sure you have followed all instructions provided in this manual for attaching water feed tank. (see assembly/initial set-up section, "step 2. Attaching a water feed tank".) 2. Ensure that you ha...

  • Page 25

    Operation 25 3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. (figure 8b). Check the connection by pulling on the hose to ensure a positive connection. Figure 8b select spray nozzle your pressure washer is equipped with four high-pressure nozz...

  • Page 26

    Operation 26 1. Make sure the engine is off and the hose line depressurized. 2. To install the nozzle, pull the collar back and twist the nozzle firmly into the coupler on the end of the wand. (figure 9a) figure 9a 3. Release the collar, making sure it springs back and re-seats to its original (non-...

  • Page 27

    Operation 27 cause pump damage if introduced upstream through the pump's water inlet. It mixes the cleaning chemical into a low pressure spray. Cleaning chemicals applied under low pressure adhere better to the surface being cleaned, allowing the formula time to react and remove dirt more effectivel...

  • Page 28

    Operation 28 4. Submerge the suction strainer connected to the braided chemical hose into a bucket containing the chemical solution. See figure 10. Step 3. Spraying safety rules for operation before starting the pressure washer, review the following general safety rules for operation: conditions for...

  • Page 29

    Operation 29 avoid sharp objects . Keep hose away from sharp objects. Bursting hoses may cause injury. No load bearing . Do not use the pump to support other items of equipment that impose unacceptable loads on the pump. Do not attempt to use this machine as a prop. Lock trigger safety latch when no...

  • Page 30

    Operation 30 purge air from the water supply hose by squeezing the trigger until a steady stream of water flows out of the nozzle at low pressure. (air in the hoses can cause damage to the pump, so always make sure all the air is out of the hoses before starting the pressure washer engine.) make sur...

  • Page 31

    Operation 31 chemical label. If warm water is specified, start burner according to instructions provided below. 4. Apply chemicals by squeezing the spray gun trigger. The chemical injector will draw the chemical into the water stream. 5. 5. The chemical concentration of the spray can be changed by t...

  • Page 32

    Operation 32 5. When the trigger is released, a pressure switch automatically turns the burner off. Also, when the temperature setting is reached, the thermostat automatically turns the burner off. Warning : it is important that the burner stops firing when the trigger is released. If the burner rem...

  • Page 33

    Operation 33 3. Hold the spray gun firmly with two hands and a sturdy stance -- gun kicks back when triggered. Caution : spray gun metal gets extremely hot when using the burner and can burn you on contact. Never touch the metal screw or any metal parts of the spray gun when the heater is being used...

  • Page 34

    Operation 34 9. If temporarily interrupting spraying, rotate trigger safety latch downward to the locked position to guard against accidental trigger release. 10. Always turn off the engine and activate spray gun trigger to relieve system pressure when: the sprayer is unattended, or disconnecting ho...

  • Page 35

    Storage 35 storage when you are finished using the pressure washer, you must prepare the sprayer for storage and store it in a proper location. Note: o if you will be storing the sprayer in freezing conditions , follow the instructions for preparing the sprayer for storage in freezing conditions. O ...

  • Page 36

    Storage 36 3. Using a wrench, disconnect the plumbing that connects to the heating coil inlet. The water will flow out of the heating coil. This will protect the coil from freeze damage. 4. Open both water inlet ball valves and remove the cap from the water filter. This will drain the pump and water...

  • Page 37

    Storage 37 prepare pressure washer for storage prepare the pressure washer for storage. 1. Disconnect the battery, remove it from the battery compartment, and store it indoors. 2. Make sure the engine start switch is off. 3. Disconnect the high-pressure hose, garden hose, and spray gun. Move pressur...

  • Page 38

    Burner adjustment 38 oil burner adjustment (only needed if white exhaust smoke appears) the oil burner is preset and performance tested at the factory (elevation 1100 feet). Different altitudes may require a one-time initial burner adjustment. Caution: if white smoke appears from the burner exhaust ...

  • Page 39

    Burner adjustment 39 5. Slowly open the air band until white smoke just starts to appear. 6. Turn air band halfway back to the black smoke position previously noted. Tighten the locking screw. 7. Now fine tune the burner air by adjusting the shutter: a. Locate the shutter as shown in figure 14 below...

  • Page 40

    Maintenance & repair 40 inspect and maintain your pressure washer as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance instructions. Warning always shut off water supply, bleed water pressure, turn off engine and disconnect the...

  • Page 41

    Maintenance & repair 41 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...

  • Page 42

    Maintenance & repair 42 clean water filter clean the water 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 fl...

  • Page 43

    Maintenance & repair 43 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 oil drain plug on pump. 2. Drain pump oil into suitable container and dispose of responsibly. 3. Replace oil drain plug. 4. Make sure u...

  • Page 44

    Maintenance & repair 44 filter bowl water drain maintain burner's fuel filter/water separator drain water from burner's filter bowl as needed, and replace filter after every 500 hours of use or as needed. 1) after each use of the burner, visually check the filter bowl. If any water has accumulated, ...

  • Page 45

    Maintenance & repair 45 the hose in the bucket. 6) run the pressure washer in cold mode for 1 to 3 hours, recirculating the cleaning solution. Caution: do not run the burner. 7) dispose of the cleaning solution where it is not harmful to animals or the environment. 8) flush with fresh water and clea...

  • Page 46

    Maintenance & repair 46 inspect electrodes inspect electrodes yearly and make adjustments as needed. 1) remove the 4 nuts that attach the burner to the heating chamber. You do not have to disconnect the fuel lines or the electric cords. Figure 20 2) pull the burner out from underneath the heat excha...

  • Page 47

    Maintenance & repair 47 drive belt maintenance check drive belt tension after first 24 hours of running and then routinely with each oil change. Tighten or replace belts as needed . Always tighten belts if slipping. Warning: belt slippage can cause static electricity build-up, which may result in sp...

  • Page 48

    Maintenance & repair 48 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...

  • Page 49

    Troubleshooting 49 engine will not start causes solutions low oil shutdown fill engine with the adequate amount of oil. No fuel add diesel to diesel tank, bleed engine fuel line(see engine owner's manual) dead battery recharge/replace battery. Air in fuel line bleed air from fuel lines (pump purge) ...

  • Page 50

    Pump parts explosion m157592 – rev o 50

  • Page 51

    Pump parts explosion m157592 – rev o 51 ref part # description qty ref part # description qty 1 787796 belt guard back plate 1 74 777421 spray lance 1 2 787794 belt guard cover 1 75 777422 quick coupler, 3/8" npt m 1 3 788700 northstar rw4540s pump 1 76 777723 quick couple nipple, 3/8" npt f 1 4 200...

  • Page 52

    Pump parts explosion m157592 – rev o 52 ref part # description qty ref part # description qty 1 n/a screw 8 37 n/a washer 3 2 n/a plug 1 38 co0202002200 ceramic bushing 3 3 n/a pump manifold 1 39 n/a washer 3 4 n/a washer 1 40 n/a o-ring 3 5 n/a plug 1 41 n/a anti-extrusion ring 3 6 n/a washer 1 42 ...

  • Page 53

    Wiring diagram m157592 – rev o 53.

  • Page 54

    Summary of important safety information 54 this section provides a summary of the various safety procedures and measures that have been presented throughout the manual. Keep this summary handy and refer to it to refresh your memory about how to safely use your pressure washer. Warning carefully read...

  • Page 55

    Summary of important safety information 55 o when connecting the battery, connect the red cable to the positive terminal first. O when disconnecting the battery, disconnect the black cable from the negative terminal first acid/skin contact. If battery acid contacts skin or clothing, flush immediatel...

  • Page 56

    Summary of important safety information 56 safety – operation pre-start review safety rules . Before each use of this pressure washer, review the "rules for safe operation." failure to follow these rules may result in serious injury or death. Know how to stop. Be thoroughly familiar with proper use ...

  • Page 57

    Summary of important safety information 57 liquid under the skin. Injection injury can 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...

  • Page 58

    Summary of important safety information 58 other exhaust dangers . This product contains or emits chemicals known to the state of california to cause cancer, birth defects or other reproductive harm. Avoid inhalation of exhaust. After use cool engine before storing. Let engine cool for at least five...

  • Page 59

    Limited warranty 59 dear valued customer: the northstar product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a northstar product, you show a desire for quality and durability. Like al...

  • Page 60

    60 manufactured by northern tool + equipment co., burnsville, mn 55306 northerntool.Com.