North Star 990990 User manual

M990990A.1
Owner’s Manual
Pressure Washer: Machine that cleans dirty surfaces with
high pressure water.
Instructions for Installation/Set-up, Operation, Maintenance, & Storage
This pressure washer produces cold-water high-pressure spray. Cleaning chemicals may be incorporated into the
spray if desired. The pressure pump for this equipment is powered by an electric motor.
WARNING
SPECIAL HAZARDS
•Injection Injury: High-pressure spray can pierce skin and underlying tissues, leading to serious injury and possible
amputation. Such an injection injury can result in blood poisoning and/or severe tissue damage.
•Flying Debris: High-pressure spray can cause flying debris and possible surface damage.
•Electric Shock: Operating equipment in wet conditions or near water can cause electric shock.
•Chemical Exposure: Cleaning chemical vapors or contact with skin may be hazardous.
•Fire/Explosion: Motor sparking can ignite fuel or other flammable liquids or vapors in the vicinity.
•Burns: Pressure washer pump and motor are hot surfaces that can cause burn injuries.
Detailed safety information about these hazards appears throughout this manual.
Equipment Protection Quick Facts
Inspect Upon Delivery: FIRST! Inspect for missing or damaged components. See “Initial Set-Up”section for where
to report missing or damaged parts.
Pump: Pump is shipped with oil. Check pump oil level before starting. Remove shipping plug and install vented fill
cap.
Water Flow Requirements: Make sure your supply water flow rate is 20% higher than the pressure washer's flow
rate (see "Operations" section for detail) and that your water is clean and particle free.
Chemical Spraying: Use only approved pressure washer chemicals designed for high-pressure use.
Storage: Do not allow water to freeze in the pump, hose, or spray gun(s). See “Storage” for more information.
Maintenance Schedule: Motor and pump require periodic inspection and servicing to keep pressure washer
functioning efficiently. See “Maintenance Schedule Summary”for frequency of servicing.
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
ITEM NUMBER: 990990, 990991
SERIAL NUMBER: _____________

2
Table of Contents
Equipment Protection Quick Facts ........................................................................................................................................ 1
TABLE OF CONTENTS................................................................................................................................................2
ABOUT YOUR PRESSURE WASHER.........................................................................................................................4
SPECIFICATIONS ........................................................................................................................................................5
COMPONENT IDENTIFICATION..................................................................................................................................6
SAFETY ........................................................................................................................................................................7
Hazard Signal Word Definitions ............................................................................................................................................ 7
SAFETY LABELING.....................................................................................................................................................8
Safety Decal Locations ......................................................................................................................................................... 8
INITIAL SET-UP..........................................................................................................................................................10
Step 1. Inspect & Unpack...................................................................................................................................................... 10
Step 2. Assembly................................................................................................................................................................... 12
Handle Assembly ................................................................................................................................................................ 12
Spray Gun Assembly .......................................................................................................................................................... 12
Step 3. Select Suitable Location........................................................................................................................................... 12
Moving and Handling .......................................................................................................................................................... 12
GROUNDING INSTRUCTION.....................................................................................................................................13
OPERATION ...............................................................................................................................................................14
Follow Safety Rules for Operation ....................................................................................................................................... 14
Preparing for Operation ........................................................................................................................................................ 15
Check/Add Oil to Pump....................................................................................................................................................... 15
Connect Hoses, Water Supply, and Spray Nozzle .............................................................................................................. 16
Prime the Water Supply......................................................................................................................................................... 17
Set Up for Chemical Spray (if desired)................................................................................................................................. 18
Start-Up Procedures.............................................................................................................................................................. 19
Start the Motor to Power the Pump..................................................................................................................................... 19
Apply Cleaning Chemical (if desired) .................................................................................................................................. 19
Begin High Pressure Spray................................................................................................................................................. 19
Shutdown ............................................................................................................................................................................... 20
STORAGE...................................................................................................................................................................21
Between Use Storage............................................................................................................................................................ 21
Prepare Pressure Washer for Freezing Conditions............................................................................................................ 21
Prepare Pressure Washer for Storage ................................................................................................................................. 21
MAINTENANCE & REPAIR........................................................................................................................................22
MAINTENANCE SCHEDULE SUMMARY..................................................................................................................22
DETAILED INSTRUCTIONS –MAINTENANCE & REPAIR ......................................................................................22
Follow Safety Rules ............................................................................................................................................................ 22
Keep Pressure Washer Clean............................................................................................................................................. 22
Inspect Spray System ......................................................................................................................................................... 22
Clean Inlet Filter.................................................................................................................................................................. 23
Change Pump Oil................................................................................................................................................................ 24

3
TROUBLESHOOTING................................................................................................................................................25
PARTS EXPLOSION- MODEL #990990, 990991 REV-A ..........................................................................................26
PARTS LIST - MODEL #990990, 990991...................................................................................................................27
PUMP ASSEMBLIES –4DX, 4DNX ...........................................................................................................................28
PUMP EXPLODED VIEW –CAT 4DX ........................................................................................................................29
PUMP PARTS LIST –CAT 4DX.................................................................................................................................30
PUMP EXPLODED VIEW –CAT 4DNX .....................................................................................................................31
WIRING DIAGRAM.....................................................................................................................................................32
LIMITED WARRANTY ................................................................................................................................................33
CALIFORNIA PROPOSITION 65 INFORMATION .....................................................................................................34

4
About Your Pressure Washer
Thank you for purchasing a NorthStar Pressure Washer!
It is designed for long life, dependability, and top
performance.
Intended Use. Produce a high-pressure water spray.
Incorporate cleaning chemicals into a low-pressure
water spray.
Note: Do not use for other purposes, as unforeseen
hazards or equipment damage may result.
Power Source. The pressure washer is powered by an
electric motor.
Supplies Required. Normal operation will require you
to supply:
•Pressure Washer pump oil
•Electric supply
•Personal Protection Equipment
See “Specifications”section of this manual for more
detail.
Personal Protection. Wear safety apparel during
operation, including safety glasses with side and top
protection. Ear protection is also recommended if
working near any operating machine. Other safety
apparel includes waterproof, insulated gloves and non-
slip protective footwear. Cleaning chemicals may require
the use of respiration mask; refer to the chemical label
for further instruction.
Adult Control only. Only trained adults should set up
and operate the pressure washer. Do not let children
operate the pressure washer.
Under The Influence. Never operate, or let anyone else
operate, the pressure washer while fatigued or under
the influence of alcohol, drugs, or medication.
Keep this manual for reference and review.
ATTENTION: Rental Companies and Private
Owners who loan this equipment to others!
All persons to whom you rent/loan this pressure washer
to must have access to and read this manual. Keep this
owner’s manual with the pressure washer at all times
and advise all persons who will operate the pressure
washer to read it. You must also provide personal
instruction on how to safely set-up and operate the
pressure washer and remain available to answer any
questions a renter/borrower might have. Owner’s
Manuals are available from NorthStar at 1-800-270-
0810.

5
Specifications
990990
990991
FLOW OUTPUT
FLOW OUTPUT
PSI (bar)
2000 (138)
PSI (bar)
3000 (207)
GPM (I/min)
1.5 (5.7)
GPM (I/min)
2.5 (9.4)
Max Water Temp
140° F (60°C)
Max Water Temp
140°F (60°C)
MOTOR
MOTOR
Motor Horsepower
2.0 HP
Motor Horsepower
5.0 HP
Ampere
20A
Ampere
30A
Voltage
120V
Voltage
230V
DIMENSIONS/COMPONENTS
DIMENSIONS/COMPONENTS
Length
34.00″
Length
34.00″
Width
21.00″
Width
21.00″
Height
38.00″
Height
38.00″
Pump Model
Cat 4DX
Pump Model
Cat 4DNX
Pump Oil Capacity
8.5 oz
Pump Oil Capacity
8.5 oz
Nozzle orifice Size
#2.0
Nozzle orifice Size
#3.0
SUPPLIES REQUIRED (not included)
SUPPLIES REQUIRED (not included)
Pump Oil (Shipped
with oil but refills
required)
SAE 30 Non-Detergent Oil or Cat
Pump Oil (Part# 22158)
Pump Oil (Shipped
with oil but refills
required)
SAE 30 Non-Detergent Oil or Cat
Pump Oil (Part# 22158)

6
Component Identification
1. Handle: Designed for easy cart movement.
2. Hose Hook: Store hose on hook.
3. Pressure Hose: Attach quick couplers to gun and water outlet.
4. Chemical Hose: Submerge in cleaning solution.
5. Water Pump: Inspect for loose/broken parts prior to each use.
6. Motor: Leeson motor provides years of reliable use.
7. Gun Hook: Store gun on hook.
8. Nozzle: Change nozzles for different spray pattern or cleaning chemical application.
9. Spray Gun: Always use two hands for safe operation.
10. Trigger: Actuate to allow pressurized water to flow out of spray gun.
11. Cord Hook: Store electrical cord on hook.
12. Garden Hose Inlet: Connect water supply for pump.
13. High Pressure Outlet: Connect your high-pressure hose.
14. Lifting Points: Lift the pressure washer from these points when transporting.
15. GFCI cord: For protected power supply.
16. On Demand Flow Switch: Automatically shuts motor off when not spraying
See “Parts Explosion” for more details
Fig990990-1
12
13
16
9
11
10
7
1
14
15
3
2
6
5
4
8

7
Safety
Hazard Signal Word Definitions
DANGER
WARNING
CAUTION
CAUTION
NOTICE
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 or serious injury.
WARNING (orange) indicates a hazardous situation,
which if not avoided, could result in death or serious
injury.
CAUTION (yellow) used with the safety alert symbol,
indicates a hazardous situation, which if not avoided,
could result in minor or moderate injury.
CAUTION (yellow) without the safety alert symbol, is
used to address practices not related to personal injury.
NOTICE is used to address practices not related to
personal injury.

8
Safety Labeling
Safety Decal Locations
WARNING
ALWAYS make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels
from NorthStar Product Support at 1-800-270-0810.
On-Product Warning Labels
Location
Part Numbers
Description
1
802050
Instruction Label
2
802049
Warning Label
1
2

9
Safety Labeling
Safety Decals
To order replacement safety labels, call NorthStar Product Support
at 1-800-270-0810.
START-UP INSTRUCTIONS
1. Attach garden hose.
2. Attach pressure hose.
3. Attach gun and lance.
4. Turn water supply ON.
5. Squeeze trigger to
purge air from pump.
6. Insert nozzle.
7. Plug in power cord,
reset the GFCI, start motor.
Gun kicks back. Hold with both hands.
Risk of injection or injury to persons. Do
not direct discharge stream at persons.
Risk of fire and explosion. Do not spray
flammable liquids.
To reduce the risk of injury, read
owner's manual carefully before using.
©2008 NT+E Co. 800-270-0810
SHUT-DOWN INSTRUCTIONS
1. Turn motor OFF.
2. Unplug the power cord.
3. Turn water supply OFF.
4. Squeeze trigger to
relieve system pressure.
5. Remove garden hose.
6. Remove pressure hose.
Part No. 802049
WARNING
FIG990990-10

10
Initial Set-Up
Step 1. Inspect & Unpack
Upon receiving your item check for missing or damaged parts.
See “Component Identification” section of this manual for a diagram of the pressure washer and its components.
•For missing or damaged components, contact Product Support at 1-800-270-0810.
•If complete, fill out product serial number information. See “Limited Warranty” section of this manual.
Any Questions, Comments, Problems or Parts Orders call NorthStar Product Support
at 1-800-270-0810.
Fig.990990-2
Motor/Pump/Base Assembly
Handle
Pressure Hose
Lance
Spray Gun
Hardware Bag