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North Star M157598AI Owner's Manual

Manual is about: 2-GUN HOT WATER PRESSURE WASHER – 4000 PSI / 7 GPM

Summary of M157598AI

  • Page 1

    M157598ai owner's manual instructions for set-up, operation, maintenance & storage 2-g un h ot w ater p ressure w asher – 4000 psi / 7 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 des...

  • Page 2

    Hazard signal word definitions 2 this is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Danger (red) indicates a hazardous situation, which if not avoided, will result in death...

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

  • 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 7 gallons p...

  • Page 5

    Specifications 5 model model # 157598 flow output pressure rating 4000 psi flow rate 7 gpm maximum temperature 200 f dimensions / components length 47.25" width 53.75" height 47.25" weight 800 lbs. Pump type northstar tws 7040 engine horsepower 25 hp high pressure discharge hoses two - 3/8" x 50' ch...

  • Page 6

    Component identification 6 ref # description ref # description 1 indicator light (power) 11 flow switch 2 indicator light (flow) 12 unloader 4 indicator light (thermostat) 13 water outlet 5 thermostat 14 engine (see engine manual) 6 heat switch 15 engine key switch 7 control panel 16 pump 8 gasoline...

  • Page 7: Reference Guide

    Component identification 7 reference guide 1. Indicator light (power) instrument used to monitor unit operation. Should illuminate when the power switch is in the on position. 2. Indicator light (flow) instrument used to monitor unit operation. Illuminates if water is flowing through the spray gun. ...

  • Page 8: Danger

    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 ref# pa...

  • 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. This ...

  • 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 (2) engine keys (2) #3.5 nozzle 5 pack part # 38532 #7.0 nozzle 5 pack part # 779544 (2) 3/4" hose clamp part # 17141 4gpm quick connect injector part # 779614 3/4" npt x 3/4" hose barb elbow part # 50nbr12 chemical strainer w/ 72" hose...

  • Page 12

    Assembly and initial set-up 12 step 2. Attaching a water feed tank if desired (customer supplied) water must be supplied to your pressure washer by an external water tank which you provide. To connect an external water feed tank, follow the steps below: caution : inadequate plumbing between a feed t...

  • Page 13

    Assembly and initial set-up 13 the tank is now ready to be filled. Caution : to protect the pump, do not add cleaning chemicals directly to the tank water. Use the quick couple chemical injector provided and follow all instructions and precautions for chemical spraying – see "operation instructions,...

  • Page 14

    Assembly and initial set-up 14 step 4. Battery installation install a 12-volt standard, top-post mount, automotive battery (group 75) with a minimum 18 amp-hour rating. The engine will not run and the burner will not fire unless a battery is installed. The battery is to be supplied by the customer a...

  • Page 15

    Moving and handling 15 to reduce risk of injury, only lift the pressure washer from underneath using a pallet jack or forklift. 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...

  • Page 16

    Before each use 16 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 sufficie...

  • Page 17

    Before each use 17 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 filter. (see maintenance instructions) inspect fuel system always inspect (engine and burner) fuel...

  • Page 18

    Before each use 18 always follow these general safety rules when fueling: 1) turn pressure washer off and allow to cool for at least two minutes before removing any fuel cap. Note: a running or still-hot engine or burner is hot enough to ignite fuel. 2) fill fuel tank outdoors – never indoors. Fuel ...

  • Page 19

    Before each use 19 water) empty space below fill neck to allow for fuel expansion. 3) replace fuel cap securely before starting engine. 4) wipe any excess fuel from unit before starting step 3. Select suitable outdoor worksite before using the pressure washer, you must understand the criteria for se...

  • Page 20

    Before each use 20 or other vehicles, on boats, or on pick-up truck beds. Warning : never attempt to attach ductwork to the engine muffler or burner exhaust to allow for installation inside an enclosure. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulti...

  • Page 21

    Operation 21 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 22

    Operation 22 2. Ensure the water in your tank is clean. Debris can cause excess pump wear and reduce performance. Attach high pressure hose attach high pressure hose(s) to the pressure washer's water outlet. Warning: never operate this pump with components (such as hose, connections, and spray gun) ...

  • Page 23

    Operation 23 whether you are using two guns or one (size of nozzle). 1. One gun vs. Two gun use: a) use a #7.0 nozzle for single gun operation. This will ensure the rated flow and psi are achieved. B) use two #3.5 nozzles when operating dual guns. Warning: never use #7.0 nozzles when operating both ...

  • Page 24

    Operation 24 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 25

    Operation 25 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 26

    Operation 26 step 3. Spraying safety rules for operation before starting the pressure washer, review the following general safety rules for operation: conditions for use know how to stop. Be thoroughly familiar with proper use of the equipment and all controls and connections. Know how to stop the p...

  • Page 27

    Operation 27 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 not spraying. Spray gun is equipped with a built- in trigger safety latch to guard against ac...

  • Page 28

    Operation 28 start engine start the engine to power the pump. 1. Make sure water supply is connected and primed. Caution: running the pump dry will cause damage and void the warranty. 2. To prevent accidental spraying, engage the safety latch on spray gun trigger by rotating it to the locked positio...

  • Page 29

    Operation 29 "connect hoses, water supply, and nozzle". 9. 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 vapors, dust, g...

  • Page 30

    Operation 30 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, and hot water can burn. Injection injury will occur if high-pressure spray pierces the skin, injecting liquid under the skin. Injecti...

  • Page 31

    Operation 31 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 2...

  • Page 32

    Operation 32 step 4. Stopping stop the engine using the following steps: warning: never disconnect the high-pressure hose from the pump 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 he...

  • Page 33

    Storage 33 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 i...

  • Page 34

    Storage 34 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 35

    Storage 35 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 and fuel valve is off. 3. Disconnect the engine spark plug wire if you haven't ...

  • Page 36

    Burner adjustment 36 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 37

    Burner adjustment 37 a. Locate the shutter as shown in figure 14 below. The shutter is a thin circular metal plate located on the outside of the air band. The shutter adjusts independently from the air band and is used to fine-tune the amount of intake air. B. Observe that the aluminum pointer attac...

  • Page 38

    Maintenance & repair 38 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 39

    Maintenance & repair 39 major repair. Major service, including the installation or replacement of parts, should be performed only by a qualified electrical service technician. Obtain factory approved parts from northstar product support at 1-800-270- 0810. Replacement parts. If a part needs replacem...

  • Page 40

    Maintenance & repair 40 bad exposed wire mesh due to wear water dripping or spraying, or localized moisture good bad figure 15 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. Clean...

  • Page 41

    Maintenance & repair 41 months or 500 hours of use after that. 1. Open oil drain valve on pump. 2. Drain pump oil into suitable container and dispose of responsibly. 3. Close oil drain valve. 4. Make sure unit is sitting level. Fill pump with 37 oz. Of universal tractor transmission oil (utto) or mo...

  • Page 42

    Maintenance & repair 42 descale heating coil descale coil tubing annually or more frequently as needed. In hard water areas, scale can build up inside the heating coil tubing. Scale deposits will decrease the output pressure and temperature of heated spray, and may eventually clog water flow through...

  • Page 43

    Maintenance & repair 43 cleaning flow switch inspect and clean the flow switch as needed mineral build-up and/or debris within the flow switch can occur and may affect burner operation if not periodically cleaned. Mineral build-up and/or debris can stop the movement of the shuttle inside the flow sw...

  • Page 44

    Maintenance & repair 44 inspect electrodes inspect electrodes yearly and make adjustments as needed. 1) remove the 3 nuts that attach the burner to the heating chamber. You do not have to disconnect the fuel lines or the electric cords. Figure 21 nuts shuttle alignment figure 20 shuttle male tabs sh...

  • Page 45

    Maintenance & repair 45 2) clean off carbon deposits, which may have accumulated on the tips of the electrodes. 3) reset the spacing as shown below in figure 22. Drive belt maintenance check drive belt tension after first 24 hours of running and then routinely with each oil change. Tighten or replac...

  • Page 46

    Maintenance & repair 46 tension specifications new belt used belt static tension (per rib/strand): 87.0-93.2 lb. 74.5-80.8 lb. Rib/strand deflections distance: 0.2 in 0.2in rib/strand deflection force: 5.9-6.3 lb. 5.2-5.5 lb. Sonic tension meter: 387 to 414 n 332 to 359n note: some general rules of ...

  • Page 47

    Troubleshooting 47 engine will not start causes solutions low oil shutdown fill engine with the adequate amount of oil. Cold engine choke engine to start. No fuel add gas to engine, make sure fuel shutoff valve is open. Dead battery recharge/replace battery. Spark plug wire not attached attach spark...

  • Page 48

    Parts exploded view- rev ai 48.

  • Page 49

    Parts exploded view- rev ai 49 ref part # description qty ref part # description qty 1 5027 1/2" npt elbow 1 50 779607 1/2" npt x 1/4" hb 90° 1 2 17141 3/4" hose clamp 9 51 779614 qc injector, 4gpm 1 3 777375 unloader 1 52 779627 pump guide 1 4 777837 hex head plug, 3/8” 2 53 779628 pump guide riser...

  • Page 50

    Parts exploded view- rev ai 50

  • Page 51

    Parts exploded view- rev ai 51.

  • Page 52

    Wiring diagram – rev ai 52.

  • Page 53

    Summary of important safety information 53 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 54

    Summary of important safety information 54 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 immediately with water and neutralize with baking soda. Installation / initial set-up level, he...

  • Page 55

    Summary of important safety information 55 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 o...

  • Page 56

    Summary of important safety information 56 liquid under the skin. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene and possibly amputation. Dual gun use. During dual gun use, stay aware of the other operator's location at all times and keep sp...

  • Page 57

    Summary of important safety information 57 serious. However, severe infection or reaction can result if proper medical treatment is not administered immediately by a doctor who is familiar with injection injuries. Other exhaust dangers. This product contains or emits chemicals known to the state of ...

  • Page 58

    Limited warranty 58 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...

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    59 this page has intentionally been left blank..

  • Page 60

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