M157597AW.1 ITEM NUMBER: 157597 SERIAL NUMBER: _____________ Owner's Manual Instructions for Set-up, Operation, Maintenance & Storage TRAILER MOUNTED, 2-GUN HOT WATER PRESSURE WASHER – 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 desired.
Hazard Signal Word Definitions Hazard Signal Word Definitions 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 DANGER (red) indicates a hazardous situation, which if not avoided, will result in death or serious injury. WARNING WARNING (orange) indicates a hazardous situation, which if not avoided, could result in death or serious injury.
Table of Contents About Your Pressure Washer .................................................................................................................. 4 Specifications .............................................................................................................................................. 5 Component Identification .......................................................................................................................... 6 Safety Labeling ........................
About Your Pressure Washer 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 per minute at 4000 psi). The pressure washer may be operated in either dual- or single-gun mode. 2) Incorporate cleaning chemicals into a low-pressure water spray.
Specifications MODEL Model # 157597 FLOW OUTPUT Pressure Rating 4000 psi Flow Rate 7 gpm Maximum Temperature 200 F DIMENSIONS / COMPONENTS Length 201.5" Width 78" Height 75" Weight 2000 lbs. – dry 6550 lbs. – water tank full Pump Type NorthStar TWS 7040 Engine Horsepower 23.5 hp High Pressure Discharge Hose Two - 3/8" x 150' Chemical Injector Maximum dilution ratio 15-to-1 Trailer GVWR 7000 lbs.
Component Identification HEAT SW. THERMOSTAT ON INDICATOR LIGHTS POWER FLOW OFF THERM.
Component Identification REFERENCE GUIDE 1. Indicator Light (Power) 2. Indicator Light (flow) 4. Indicator Light (Thermostat) 5. 6. 7. 8. 9. Thermostat Heat Switch Control Panel Gasoline Tank Water/Fuel Separator 10. Battery Box 11. Flow Switch 12. Unloader 13. Water Outlet 14. Engine 15. Engine Key Switch 16. Pump 17. Water Inlet 18. Fuel Oil/Kerosene/Diesel Tank 19. Heat Exchanger Instrument used to monitor unit operation. Should illuminate when the power switch is in the ON position.
Special Equipment Safety Features 1 5 WARNING - BATTERY HAZARDS BATTERIES: 1) contain caustic acid, 2) emit explosive gases, 3) can cause electric shock ALWAYS use eye protection. Caustic acid and explosive gases can cause blindness or severe burns. NO smoking, sparks, or flames. NEVER touch both battery terminals at the same time with your hand or any non-insulated tools. FLUSH immediately with water if battery acid contacts eyes, skin, or clothing.
Special Equipment Safety Features 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 1-800-2700810. This unit is equipped with a high pressure safety device, which acts as a backup safety feature. If the unloader malfunctions, the high pressure safety device will open and relieve excess system pressure.
Assembly and Initial Set-Up Steps for Assembly / Initial Set-Up Step 1. Unpacking & Delivery Inspection Step 2. Gun and Nozzle Storage Set-Up Step 3. Initial Pump & Engine Preparation Step 4. Battery Installation Each of these steps is discussed below: Step 1. Unpacking & Delivery Inspection Find and separate the components identified in Figure 2 – Overview of Pressure Washer Components and Figure 3 – Hardware Bag.
Assembly and Initial Set-Up Qty (2) Engine Keys Qty (2) #3.5 Nozzle 5 Packs Part # 38532 #7.
Assembly and Initial Set-Up Step 2. Gun and Nozzle Storage Set-Up 1. Guns. Store guns vertically on back of trailer using supplied pins. Rest guns with handle down on the back of the trailer and pins will hold guns in place. 2. Nozzles. Insert grommets and nozzles (provided) into the hose reel guides. Grommets Nozzles Insert holes Figure 4 Step 3. Initial Pump, Engine & High Pressure Hose Preparation Prepare Water Pump Verify pump oil level. Note: The pump is shipped with oil. 1.
Assembly and Initial Set-Up Prepare Completely unwrap / unwind the high pressure hose from the hose reel. High Psi Note: New hose will “grow” when charged for the first time and should always be Hose on Hose charged one time before being wrapped on the reel. Reel Step 4. Battery Installation Install a 12-volt standard, top-post mount, automotive battery (Group 75/86) with a minimum 18 amp-hour rating. The engine will not run and the burner will not fire unless a battery is installed.
Moving and Towing WARNING The filled pressure washer is heavy. It can crush and cause serious injury if it rolls out of control or tips over. • ALWAYS keep the jack cranked down to help balance the trailer when it is not connected to a vehicle hitch. • FOLLOW all the instructions below for safely connecting and towing the pressure washer. Connecting Trailer and Towing Inspect trailer Always inspect the trailer before hitching it to your vehicle. 1. Make sure tires are fully inflated and in good repair.
Moving and Towing 4. 5. with fingers. Proper adjustment is obtained when coupler is as tight as possible on ball and locking lever can still be opened and closed. Lock lever closed to secure the attachment. Insert safety pin. Attach safety cables Two safety cables must be used while towing. Cross safety cables under the coupler, allowing only enough slack for vehicle turns. Route breakaway switch cable Route breakaway switch cable.
Moving and Towing Plug in lights/brake Plug 7-way electrical pin connector into vehicle. Raise the jack Always crank the jack into the UP position before towing. Tow Tow the pressure washer to your desired work location. When towing, always adhere to the following safety rules. • • • • • • • • • If leaving unattended Read vehicle instructions. Review towing safety instructions in your towing vehicle manual. Driving skills.
Before Each Use 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 sufficient lubrication! 1. Check oil level. Verify that oil level is half way up the sight glass (or at the indicator line on the dip stick). 2.
Before Each Use 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 systems & check for leaks BEFORE starting pressure washer. Do not start pressure washer until all needed repairs have been completed.
Before Each Use 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 vapors can ignite if they collect inside an enclosure and explosion can result. 3) Stay away from all sources of heat, sparks, and flames. Do not smoke.
Before Each Use 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 selecting a suitable location for operation. Note that this pressure washer is for OUTDOOR USE only.
Before Each Use 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, resulting in possible exhaust leakage or overheating and damage to the pressure washer. 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.
Operation 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 safety information for using this pressure washer.
Operation 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) rated for lower pressure and/or temperature limits than the machine's maximum rated pressure and temperature, or component could rupture and cause serious personal injury from escaping high pressure fluids. 1.
Operation with a single gun. b) Use two #3.5 nozzles when operating dual guns. WARNING: NEVER use #7.0 nozzles when operating both guns. If two operators use #7.0 nozzles and one operator releases the trigger on their gun, the flow through the second operator's gun will suddenly increase from 3.5 to 7 GPM. This will cause the second operator's gun to kick without warning, which could result in loss of balance and/or spraying control. 2.
Operation coupler on the end of the wand. (Figure 9a) Nozzle Collar Lance Coupler Figure 9a 3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. (Figure 9b). Check the connection by pulling on the nozzle to ensure a tight connection -- if correctly inserted, nozzle will rotate but not pull out. WARNING: Make sure the nozzle is correctly inserted.
Operation low pressure adhere better to the surface being cleaned, allowing the formula time to react and remove dirt more effectively. Note: An external chemical injector pump is not recommended for use with this pressure washer. 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.
Operation 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 pressure washer and depressurize system quickly if needed (see "Step 4. Stopping"). Instruct all operators. The pressure washer's owner must instruct all operators and potential renters in safe set-up and operation.
Operation 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 builtin trigger safety latch to guard against accidental trigger release. Rotate safety latch to the locked position when not spraying. Leaving unattended. Always turn off the pressure washer and relieve system pressure before leaving the sprayer unattended.
Operation warranty. 2. To prevent accidental spraying, engage the safety latch on spray gun trigger by rotating it to the locked position. 3. Follow the instructions in the Engine Manual for starting the engine. - If the engine doesn't start on the first try, pressure may build up in the pump. Relieve pressure by squeezing the spray gun trigger before attempting to start engine again. This will make starting easier. DANGER: Do not inhale engine exhaust.
Operation 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, gases, or other potentially combustible materials. Operate only where open flame or torch is permitted. 2. Make sure there is fuel in the burner fuel tank. CAUTION: Do not run the machine in hot mode without fuel in the burner's fuel tank, or damage can occur. 3. Make sure the engine throttle is all the way open.
Operation and possibly amputation. Seek medical attention. • Do not secure trigger open. To reduce risk 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.
Operation 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 be washed in a basket so the pressure does not push them away. Larger, lightweight parts should be clamped down. 8. The pressure washer is set and locked to the maximum rated pressure when it leaves the factory. To reduce the pressure, turn the unloader knob counterclockwise.
Operation 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 heat switch OFF and run cold water through the coil for at least 3 minutes while spraying. 2. Turn engine OFF. 3. Turn water supply OFF. 4. Actuate spray gun trigger to relieve system pressure. 5. Remove garden hose.
Storage 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 If you will not be using the sprayer again for 30 days or more, follow the instructions for preparing the engine for long-term storage. WARNING • Fuel and its vapors can ignite and cause a fire.
Storage 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 inlet plumbing. Long Term freeze protection: (For more than 30 days) RV antifreeze will save the components from freeze damage and keep them lubricated. 1. Drain water from the feed tank. 2.
Storage Prepare pressure washer for storage Prepare the pressure washer for storage. Move pressure washer to storage location Let engine cool for 5 minutes before moving the pressure washer to its storage location. 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 already done so. 4.
Burner Adjustment 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 vent during start-up or operation, discontinue use and readjust air bands. Specific steps for burner correction are given below.
Burner Adjustment a. Locate the shutter as shown in Figure 13 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 attached to the shutter. It points to the same set of calibration numbers as the air band arrow. Observe which number it points to at the start of this adjustment step. c. Loosen the shutter lock screw.
Maintenance & Repair 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 spark plug before cleaning, adjusting, or servicing the pressure washer. After servicing, make sure all guards and cover shields are replaced before using.
Maintenance & Repair • • servicing the pressure washer. 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 Northern Tool Product Support at 1800-270-0810. Replacement parts. If a part needs replacement, only use factory approved repair parts.
Maintenance & Repair 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. Good Bad Water dripping or spraying, or localized moisture Exposed wire mesh due to wear Clean inlet filter Bad Figure 14 Clean the inlet filter before each use.
Maintenance & Repair Recharge and maintain battery Inspect, recharge, and maintain battery according to your battery manufacturer's instructions. Do not store with battery charger always connected. Batteries that are over-charged can boil themselves dry and produce excessive amounts of hydrogen, an explosive gas. Perform engine maintenance Perform engine maintenance as specified in the engine owner's manual. Engine maintenance items include: 1. Changing oil and oil filter 2.
Maintenance & Repair 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, drain it via the water drain at the bottom of the bowl. 2) After every 500 hours of operation, inspect the fuel filter/water separator. Replace filter as needed.
Maintenance & Repair Outlet Inlet Cleaning Flow Switch Figure 18 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 switch body. Shuttle movement is important because the burner will not fire if the shuttle does not move.
Maintenance & Repair 2) Remove the “Cap” fitting from the flow switch. Cap Fitting 3) Slide out the “Shuttle Assembly”. If the magnet in the shuttle assembly is damaged or missing, replace the entire flow switch assembly. To order a replacement flow switch assembly, call Northstar Product Support at 1-800-270-0810.
Maintenance & Repair 4) Observe the “Shuttle Assembly” and internal portion of “Body” for obstructions, hard water deposits and any other foreign debris. Remove the foreign debris with light scraping or compressed air. If no additional cleaning is required continue to Step 7. If additional cleaning is required continue to step 5. Internal Sections 5) Remove the “Body” from the plastic “Enclosure” and soak the “Body” in CLR or similar solution to dislodge excess buildup.
Maintenance & Repair 8) Insert the “Shuttle Assembly” with the rounded end first, into the body. Align with grooves. Body (female Guides) Shuttle (Male Tabs) Rounded End First 9) Inspect the O-ring on the “Cap”, if it is damaged, replace the entire flow switch assembly. To order a replacement flow switch assembly, call Northstar Product Support at 1-800-270-0810. If the O-ring is not damaged, re-install the “Cap” onto the “Body”. Torque the cap to 100lbin.
Maintenance & Repair 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. Nuts Figure 21 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.
Maintenance & Repair 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 sparking. Fire ignition can result. Instructions: 1) Make sure engine is off and spark plug wire is removed. 2) Remove belt guard. See "Parts Breakdown" section of this manual for location.
Maintenance & Repair Instructions: 1) Inspect magnets, shoes, and magnetic coil for wear. Replace as needed. Note: Magnets should always be replaced in pairs (both sides of an axle). a) Replace magnets and shoes if worn or scored. b) Replace magnets if wearing unevenly or abnormally. c) Replace magnets if any part of the magnetic coil becomes visible through the friction material facing of the magnet. 2) Reface the drum armature surface when replacing magnets.
Troubleshooting Engine Will Not Start Causes Low Oil Shutdown Cold Engine No Fuel Dead Battery Spark plug wire not attached Solutions Fill engine with the adequate amount of oil. Choke engine to start. Add gas to engine; make sure fuel shutoff valve is open. Recharge/Replace battery. Attach spark plug wire to spark plug. Pressure Washer Runs But Burner Doesn't Fire Causes Heat switch turned OFF Thermostat set too low or off Fuel tank empty Defective Flow Switch Solutions Turn heat switch ON.
Parts Explosion – M157597 Rev AW.
Parts Explosion – M157597 Rev AW.
Parts Explosion – M157597 Rev AW.
Parts Explosion – M157597 Rev AW.
Parts Explosion – M157597 Rev AW.
Pump Explosion 57
Pump Explosion 58
Wiring Diagram 59
Summary of Important Safety Information 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 and understand the following safety information before using the pressure washer.
Summary of Important Safety Information 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 immediately with water and neutralize with baking soda. Installation / Initial Set-up • Level, heat-resistant surface. Situate pressure washer on a firm, level, and heat-resistant surface with good drainage.
Summary of Important Safety Information • • • • • • • • • • • Hitch trailer properly. Follow all instructions for hitching trailer to towing vehicle. Make sure hitched trailer sits level Connect lights and breakaway switch. Jack. Keep jack cranked down to help balance the trailer when it is not connected to a vehicle hitch. Crank jack up before towing. Read vehicle instructions. Review towing safety instructions in your towing vehicle manual. Driving skills.
Summary of Important Safety Information • Check sprayer nozzle. Sprayer nozzle can become a projectile and cause serious personal injury or property damage if not properly connected to the spray gun. Check to ensure the nozzle has been properly attached to the spray gun before using the pressure washer. During use • Safety latch locked before starting engine. Always engage the safety latch on the spray gun trigger before starting the engine. • Incoming water supply on.
Summary of Important Safety Information • • • • • • • • • • • • • 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. Never pull by hose. Do not move this machine by pulling on the hose. Hose or connections could fail and result in catastrophic high-pressure release of fluid as well as hose whipping. Avoid sharp objects. Keep hose away from sharp objects.
Limited Warranty 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 all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
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. Manufactured by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.
