North Star M1578111F User manual

2006 Northern Tool + Equipment
TM
M1578111F
ITEM NUMBERS:1578111, 1578171
1578131, 1578181
1578151, 1578201
Owner’s Manual
Pressure Washer: Machine that cleans dirty
surfaces with high pressure water.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Customer Service 1-800-270-0810
Engine is shipped without oil.
- Before starting engine, fill engine oil.
- See engine manual for engine oil requirements.
Pump is shipped with oil.
- Remove shipping plug and install vented fill cap. (Comet Pumps)
- Remove shipping tape from pump oil fill cap. (Cat Pumps)
- See pump oil cap section of this manual.
Closely inspect all components.
-If you have damaged components then: Contact the freight company that
delivered the unit and file a claim.
-If you have missing components then: Contact Customer Service at
1-800-270-0810.
Read this manual.
Serious injury or death can result if safety instructions are not followed.
WARNING

2
Hazard Signal Word Definitions

3
Table of Contents
Important Safety Rules .......................................... 4,5
Warning Label Locations ....................................... 6
Assembly Instructions………………………………….. 7-9
Machine Component Identification…………………….10
Pump Oil Cap and Pump Component Identification…11
Operation Instructions ........................................…12-16
Water Supply……………….………………………..12
Start-Up/Shut-Down Instructions…………………..13
Spray Gun Safety Lock and Attaching the Lance..14
Installing Nozzles and Quick Connect hoses…….15
Applying Chemicals..………………………………..16
Maintenance and Storage..................................….17-19
Maintenance Mode and Maintenance Schedule…17
Pump Oil Change….………………………………...18
Long Term Storage………………………………….19
Winter Storage……………………………………….19
Troubleshooting ...................................……...........….20
Specifications .....................….................................…21
Parts Explosions ....................................................… 22,23

4
Important Safety Rules
Save These Instructions
1.) Read owner's manual completely.
Serious injury or death can result if safety instructions are not followed. You must be
16 or older to operate this machine. Keep untrained people away.
2.) Skin puncture hazard.
High pressure fluid can inject under skin resulting in serious injury including
amputation. Do not direct spray at people or animals.
-If skin injection happens, seek IMMEDIATE surgical treatment.
-Do not check for leaks with hand. Instead, use a piece of cardboard to check for
leaks.
-Do not use unit if exterior hose damage is evident. Make sure all fittings are tight
before starting. Relieve system pressure before servicing.
-Know how to stop engine and bleed pressures quickly. Be thoroughly familiar with
the controls.
-Make sure accessories meet the unit's temperature and pressure limits.
-Stop engine, bleed pressure, and engage spray gun safety lock before leaving unit
unattended.
3.) Risk of fire and explosion.
Hot exhaust fumes from engine can cause fire. Gasoline is highly flammable and
explosive. You can be burned or seriously injured when handling fuel.
-Position muffler at least 7 feet from combustible objects.
-Before adding fuel, stop the engine and keep heat, sparks, and flame away. Do not
add fuel when engine is running or still hot. No smoking near engine.
-Do not pump fuel directly into engine at gas station. Static charge can build and
ignite fuel. Use a UL approved fuel container to transfer gas to the engine. Wipe up
fuel spills immediately.
-Only store and handle fuel outdoors. Gasoline vapors can ignite if they collect
inside an enclosure. Explosion can result.
-Do not change or add to exhaust system. Fire can result.
-Do not change or add fuel tanks or fuel lines. Fire can result.
-Before each use, check fuel tank and fuel lines for leaks. Any fuel leak is a fire
hazard. Fix any fuel leaks before starting engine.
-During transportation take precautions to make sure pressure washer will not tip
over and cause a fuel leak fire hazard.
4.) Poisonous gas.
This machine gives off carbon monoxide, a poisonous gas that can kill you. You
CANNOT smell it, see it, or taste it.
-ONLY run machine outdoors and away from air intakes.
-NEVER run machine inside homes, garages, sheds, or other semi-enclosed spaces.
These spaces can trap poisonous gases, EVEN IF you run a fan or open doors and
windows.
If you start to feel sick, dizzy, or weak while using this machine, shut it off and get to
fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING

5
Important Safety Rules
5.) Risk of exposure to dangerous chemicals.
Serious injury or death can result if chemical manufacturer instructions are not
followed.
-Wear protective gloves when handling and cleaning with chemicals.
-Understand all safety hazards and first aid for all chemicals being used.
-When cleaning filters, check if chemicals have been used and take any
precautions that are recommended by the chemical manufacturer.
-Different chemicals may interact dangerously with each other, always follow
chemical manufacturer directions before switching chemicals.
-Calculate the correct amount of chemical to mix, dispose of excess chemical
per the manufacturer instructions.
-Never spray flammable liquids.
6.) Risk of electrocution.
Electricity can kill you. Keep water away from electrical outlets and electrical
devices.
7.) Flying objects.
Small particles may fly out while spraying. Wear safety glasses. Serious eye
injury can occur.
Make sure nozzle is secure before squeezing trigger. If nozzle is not secure it
will become a projectile.
8.) Fall hazard.
Pressure washer creates puddles and slippery surfaces. Keep good footing
and balance. Serious injury can occur.
-Wear footwear cabable of maintaining a good grip on wet surfaces.
-Gun kicks back. Hold with both hands.
-Do not overreach or stand on unstable supports.
-Do not stand on ladders or scaffolding.
-Do not place pressure washer on soft or unstable ground.
CAUTION
1.) Hot muffler.
You can be burned by muffler. Do not touch.
WARNING
Save These Instructions

6
Warning Label Locations
2003 K-Bar Industries 800-270-0810
WARNING
1.) Skin puncture hazard. Do
not direct spray at people or
animals. Seek IMMEDIATE
surgical treatment.
2.) Risk of fire and explosion.
Do not add fuel when engine is
running or still hot.
3.) Breathing hazard.
Poisonous fumes from engine
can kill you. Do not operate
indoors even if ventilated.
4.) Risk of electrocution.
Keep water away from electric
outlets and electric devices.
5.) Read owner's manual.
Serious injury or death can
result if safety instructions are
not followed. Part No. 38570
SHUT-DOWN INSTRUCTIONS
1. Turn engine OFF.
2. Turn water supply OFF.
3. Squeeze trigger to
relieve system pressure.
4. Remove garden hose.
5. Remove pressure hose.
6. Turn fuel valve OFF
(if equipped).
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. Start engine.
Engine and pump not
shown for clarity.
Call 1-800-270-0810 to order new labels.
Instruction Label: Part No. 32538
Warning Label: Part No. 38570 (includes hot
muffler caution located on engine)
NOTE:
Only one set of
labels is used per
machine.
Labels may be
placed on right or left
side of machine.
Both locations are
shown.
Use the location that
does not obstruct
viewing labels.

7
Assembly Instructions
I.) Unpack
Your pressure washer is shipped in two boxes. Separate and identify the components found in both
boxes.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Customer Service 1-800-270-0810
Base Handle Pressure Hose
Lance Spray Gun Hardware Bag

8
Assembly Instructions
II.) Hardware Bag
Hose Hook – Qty 1
Part # 38510
Flange Nut – Qty 6
Part # 82019
Carriage Bolt – Qty 2
Part # 82233
Vented fill cap
1578111, 1578131
Vented dipstick
1578151 only
Gun Hook – Qty 2
Part # 38509
T- Handle Knob – Qty 2
Part # 38578
Nozzle – Qty 5
Part # 38531 Grommet – Qty 5 Part # 35198

9
nozzles
grommets
gun hooks
flange
nuts
hose hook
handle
t-handle
knob
Hook Detail
flange nut
carriage bolt
Assembly Instructions
III.) Handle Assembly
1.) Attach handle to base with two carriage bolts and t-handle knobs.
2.) Spin a flange nut backwards onto the hose hook and each gun hook. (see hook detail)
3.) Mount the hose hook and gun hooks onto the handle as shown.
4.) Make sure the top gun hook points back and the bottom gun hook points forward.
5.) Insert grommets into the holes on the handle nameplate.
6.) Press nozzles into grommets according to the colors indicated on the handle decal.

10
Machine 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.) Engine. Honda engine provides
years of reliable use.
7.) Gun Hook. Store gun on hook.
8.) Nozzles. Change nozzles for
different spray patterns
9.) Spray Gun. Always use two hands
for safe operation.
10.)Trigger. Actuate to allow
pressurized water to flow out of
spray gun.
*Note: Item 1578131 shown, location of components on other models vary slightly.

11
Pump Oil Cap and Pump Component Identification

12
Operation Instructions
Water Supply
1.) Make sure the water supply is clean. Debris can cause excess pump wear and reduce
performance.
2.) An insufficient water supply will damage your pump. Make sure the water supply is steady and is
20% over the rated flow of your pump. Use a stopwatch to time how long it takes to fill a 5 gallon
bucket with your garden hose. The bucket must fill faster than the times listed in the table below.
Model Time to fill 5 gallon bucket
1578111 100 seconds
1578131 84 seconds
1578151 72 seconds
1578171 100 seconds
1578181 84 seconds
1578201 72 seconds
3.) The water supply garden hose must have an inside diameter of at least 5/8”. If the hose is more
than 100 ft. long, the diameter must be at least 3/4”.
4.) Never use a reservoir tank as a water source. Drawing water out of a tank may cause pump
cavitation and damage to your pump. This pressure washer is designed for a pressurized water
source such as a city water faucet. However, the water source pressure must not exceed 115 psi
(8 bar).
5.) Always use a flexible rubber hose for your water supply. Do not use rigid piping.

13
Operation Instructions
Start-Up Instructions
1. Attach garden hose to water inlet.
2. Attach pressure hose to water outlet and gun.
3. Attach spray gun to lance.
4. Turn water supply ON.
5. Squeeze trigger to purge air from pump.
6. Insert nozzle.
7. Start engine.
Shut-Down Instructions
1. Turn engine OFF.
2. Turn water supply OFF.
3. Squeeze trigger to relieve system pressure.
4. Remove garden hose.
5. Remove pressure hose.
6. Turn fuel valve OFF (if equipped).
Skin puncture hazard.
High pressure fluid can inject under skin resulting in serious injury including
amputation. Do not direct spray at people or animals.
-If skin injection happens, seek IMMEDIATE surgical treatment.
-Do not check for leaks with hand. Instead, use a piece of cardboard to check for
leaks.
-Do not use unit if exterior hose damage is evident. Make sure all fittings are tight
before starting. Relieve system pressure before servicing.
-Know how to stop engine and bleed pressures quickly. Be thoroughly familiar with
the controls.
-Make sure accessories meet the unit's temperature and pressure limits.
-Stop engine and bleed pressures before leaving unit unattended.
WARNING

14
Operation Instructions
Spray Gun Safety Lock
When not spraying, use the spray gun safety lock to prevent accidental high pressure discharge.
Attaching the Lance
Tighten spin-on coupler hand tight.
Note: The o-rings make the seal so there is no need to tighten with a wrench.
spray gun
spray gun safety loc
k
lance spin-on coupler

15
Flying objects.
Make sure nozzle is secure before squeezing trigger. If nozzle is not secure it will become a
projectile. Serious injury can occur.
WARNING
Operation Instructions
Installing Nozzles
To install a nozzle pull back the collar and push the nozzle into the coupler. Once the connection
is made, pull on the nozzle to make sure it is secure.
Attach Quick Connect Couplers
-To install the hose onto the pump, pull back the collar and push the hose into the coupler on the
pump.
-To install the hose onto the spray gun, pull back the collar on the spray gun and push the hose
into the coupler on the spray gun.
Once the connections are made, pull on the hose to make sure it is secure.
CORRECT INCORRECT
nozzle colla
r
cou
p
le
r
lance
collar completely
pushed out. collar NOT completely
pushed out.
pump hose
spray gun

16
Operation Instructions
Applying Chemicals
1.) Install the black nozzle to spray chemicals onto the cleaning surface.
2.) Start the pressure washer according to the start-up instructions.
3.) Submerge the chemical hose in cleaning solution.
4.) Squeeze the spray gun trigger. The chemical injector will draw the chemical into the water
stream.
5.) Apply chemicals evenly onto the cleaning surface. Allow the chemicals to react with the dirt, then
clean at high pressure with green nozzle.
6.) Never use more chemical than is necessary to clean the surface.
7.) To clean the chemical injector, draw water through the strainer until all the chemical is purged
from the system.
Risk of exposure to dangerous chemicals.
Serious injury or death can result if chemical manufacturer instructions are not
followed.
-Wear protective gloves when handling and cleaning with chemicals.
-Understand all safety hazards and first aid for all chemicals being used.
-When cleaning filters, check if chemicals have been used and take any
precautions that are recommended by the chemical manufacturer.
-Different chemicals may interact dangerously with each other, always follow
chemical manufacturer directions before switching chemicals.
-Calculate the correct amount of chemical to mix, dispose of excess chemical
per the manufacturer instructions.
-Never spray flammable liquids.
WARNING
straine
r
diluted
chemical
pump inlet
pump outlet
p
um
p

17
Maintenance and Storage
Maintenance Mode
Before performing any maintenance on the pressure washer, it must be placed in maintenance mode.
1.) Turn off engine.
2.) Turn off water supply.
3.) Squeeze trigger to relieve system pressure.
4.) Shut off fuel valve.
5.) Unplug spark plug wire from spark plug, (see engine owners’ manual).
Maintenance Schedule
What to Check When To Check What to Do
Inlet Filter Each Use Visually inspect and clean inlet filter with clear water.
Pressure Hose Each Use Visually inspect pressure hose and hose couplings. Replace hose if any of the following is evident:
hose coupling is damaged, wire mesh is exposed or
damaged, hose is permanently kinked or flattened, outer
hose cover is blistered or loose.
Bolts Each Use Tighten any loose bolts.
Engine Oil See engine manual See engine manual for oil change instructions
Pump Oil After 1st 50hrs,
then 3mo/500hr Change pump oil. See pump oil change instructions on next page.

18
drain plug
sight glass
(other side)
fill cap fill cap
fill cap
fill cap
drain plug drain plug
drain plug drain plug
sight glass sight glass
sight glass
sight glass
Oil capacity: 8.5 oz. (.25L)
Cat 3DX25GSI Pump
Oil capacity: 22.6 oz. (.62L)Oil capacity: 10.2 oz. (.30L)
sight glass
drain plug
Cat 3SP30G1I Pump
fill cap Cat 66DX35G1I Pump
Oil capacity: 4.3 oz. (.13L)
Comet BXD 2527 Pump
Oil capacity: 10.3 oz. (.30L)Oil capacity: 5.7 oz. (.17L)
Comet AXD 3030 Pump Comet ZWD3540 Pump
fill cap
Maintenance and Storage
Pump Oil Change
1) Place a suitable container below the pump to catch used oil, then remove the oil fill cap and oil
drain plug.
2) Allow the used oil to drain completely, then reinstall the drain plug and tighten securely.
3) Please dispose of used oil in a sealed container to your local recycling center or service station for
reclamation. Do not throw it in the trash, pour it on the ground or down the drain.
4) With the pump in a level position, fill to the half way point on the oil sight glass (see pump oil
capacities below). For Comet pumps use Universal Tractor Transmission Oil or Mobil1 15W50
synthetic oil. For Cat pumps use SAE30 non-detergent oil or Cat Pump Oil Item # 22158.

19
Maintenance and Storage
Long Term Storage
Follow the engine owner’s manual for storing the engine.
Winter Storage
Protect your pump, hose, and gun from freezing.
Items needed: 12” piece of garden hose or equivalent, funnel and RV antifreeze (approximately 6 oz.)
1.) Follow the storage instructions listed above.
2.) Disconnect spark plug cable. Make sure the engine start switch is OFF and the fuel valve is OFF.
3.) Attach the garden hose with funnel to the pump inlet (see illustration).
4.) Pour RV antifreeze into the funnel, pull the engine recoil until antifreeze comes out the pump
outlet.
5.) Drain all water from the high pressure hose. Depress trigger on gun and drain all water out of
gun/lance.
RV Antifreeze
Funnel
Hose
Water Inlet

20
Troubleshooting
Problem
Engine will not start SOLUTION: A,B
Low/Surging pressure or no water flow SOLUTION: C,D,E,F,G,H
No chemical injection SOLUTION: I,J,K,L
Cause Solution
A- Low oil shutdown See engine manual for oil requirements
B- Engine starting instructions not followed See engine manual for starting instructions
C- Insufficient water supply See water supply section of this manual
D- Plugged pump inlet filter See maintenance section of this manual
E- Wrong nozzle Make sure high pressure nozzle is being used
F- Plugged nozzle Remove nozzle, check for blockage
G- Worn nozzle Replace nozzle
H- Leak in pressure hose Replace pressure hose
I- Wrong nozzle Make sure chemical nozzle is being used
J- Back pressure from extra long discharge hose Try shorter hose
K- Leak in chemical siphon hose Replace hose – use hose clamps if necessary
L- Chemical strainer not submerged Make sure strainer is completely submerged
Any Questions, Comments, Problems or Parts Orders
Call Northstar Customer Service 1-800-270-0810