North Star PROVEN PERFORMANCE M1578112G User manual

TM
M1578112K
Owner’s Manual
Pressure Washer: Machine that cleans dirty
surfaces with high pressure water.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Product Support 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
ITEM NUMBERS: 1578112, 1578172
1578182, 1578152,
1578202, 1578203,
1578173, 1577543,
1577544

Hazard Signal Word Definitions
2

Table of Contents
3
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 Exploded View ..................................................
22,23
Pump Exploded Views…………………………………..
24,25
Pump Breakdowns………………………………………
26-38

Important Safety Rules
4
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

Important Safety Rules
5
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

Warning Label Locations
6
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.
2008 Northern Tool + Equipment 800-270-0810
WARNING
Part No. 38570
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.
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).
Call 1-800-270-0810 to order new labels.
Instruction Label: Part No. 32538
Warning Label: Part No. 781026 (includes
hot muffler caution located on engine)

Assembly Instructions
7
I.) Unpack
Your pressure washer is shipped in two boxes except for models 1577543 and 1577544 which are
shipped in one box. Separate and identify the components found in the box/boxes.
* Depending in model, components may appear differently than illustrated
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Product Support 1-800-270-0810
Pressure Hose
Hardware Bag
Spray Gun
Handle
Engine/Pump/Base Assembly
Lance

Assembly Instructions
8
II.) Hardware Bag
Hose Hook –Qty 1
Part # 779761
Flange Nut –Qty 2
Part # 82019
Carriage Bolt –Qty 2
Part # 82233
Vented fill cap
1578112,
1577543,1577544
Vented dipstick
1578152,
1578173, 1578203
Gun Hook –Qty 1
Part # 38509
T- Handle Knob –Qty 2
Part # 38578
Nozzle –Qty 2 or 5
Varies by model
Part # 38531
Grommet –Qty 5
Part # 35198
Nylock Nut –Qty 2
Part # 777495

Assembly Instructions
9
III.) Handle Assembly
1.) Attach handle to base with two carriage bolts and t-handle knobs.
2.) Spin a flange nut backwards onto the gun hook. (see hook detail)
3.) Mount the hose hook onto the handle and gun hook onto base as shown.
4.) Insert grommets into the holes on the handle nameplate.
5.) Press nozzles into grommets according to the colors indicated on the handle decal.
Gun Hook
Flange nut
Hose hook
(Position A)
T-handle knob
Carriage bolts
Gun Hook Detail
Flange nut
Nozzles
(Quantities vary
by model)
Grommets
Handle
Hose hook
(Position B)
GC models only
Nylock nut

Machine Component Identification
10
1.) Handle. Designed for easy cart
movement.
2.) Hose Hook. Store hose on hook.
(Position depends on model, see
Assembly Instructions section.)
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: Components on models vary slightly

Pump Oil Cap and Pump Component Identification
11

Operation Instructions
12
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
1577543
100 seconds
1577544
100 seconds
1578112
100 seconds
1578203
72 seconds
1578152
72 seconds
1578172
100 seconds
1578182
84 seconds
1578202
72 seconds
1578173
100 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.

Operation Instructions
13
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

Operation Instructions
14
Spray Gun Safety Lock
When not spraying, use the spray gun safety lock to prevent accidental high pressure discharge.
* Note: Depending on model, gun may appear differently.
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 lock
lance
spin-on coupler

Operation Instructions
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
pump
hose
spray gun
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
collar
coupler
lance
collar completely
pushed out.
collar NOT completely
pushed out.

Operation Instructions
16
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
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. (See Pump Component Identification section
for chemical injector location.)
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.
Pump
Pump Outlet
Pump Inlet
Chemical Hose
Cleaning Solution
Strainer

Maintenance and Storage
17
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.

Maintenance and Storage
18
Pump Oil Change
1) Place a suitable container below the pump to catch the used oil.
VRX:
Remove the bolts that connect the pump to the engine. Remove fill
cap and rotate pump upside down.
All other pumps:
Remove drain plug.
2) Allow the used oil to drain completely.
VRX:
Rotate pump to the upright position, and reinstall mounting bolts.
All other pumps:
Reinstall drain plug.
3) Please dispose of used oil in a manner that is compatible with the environment. We suggest you
take used oil in a sealed container to you 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 add oil to the pump (see capacities below). For Comet and
NorthStar pumps: Use Universal Tractor Transmission Oil (part# COCP2101) or Mobil1 15W50
synthetic oil. For Cat pumps: Use SAE 30 non-detergent oil or Cat pump oil item # 22158.
VRX:
Add specified capacity.
All other pumps:
Fill to middle of sight glass.
fill cap
Oil capacity: 8.5 oz. (.25L)
Cat 3DNX25GSI Pump
Oil capacity: 18 oz. (.53L)Oil capacity: 10.2 oz. (.30L)
sight glass
drain plug
Cat 3SPX30G1I Pump
fill cap Cat 66DX35G1I Pump
Oil capacity: 4.3 oz. (.13L)
Comet BXD 2530 Pump
fill cap
drain plug
Oil capacity: 10 oz. (.29L)
drain plug
fill cap
Comet AWD4040 Pump
fill cap fill cap
drain plug drain plug
sight glass sight glass
drain plug
sight glass
(other side)
Oil capacity: 3.4 oz. (.10 L)
Comet VRX 2528G Pump
fill cap
fill cap
NorthStar NSZW3540 Pump
Oil capacity: 10.3 oz. (.30L)
sight glass drain plug
NorthStar NSLW2530 Pump
Oil capacity: 11 oz. (.32L)
sight glass

Maintenance and Storage
19
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

Troubleshooting
20
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
The manufacturer reserves the right to make improvements in design and/or
changes in specifications at any time without incurring any obligation to install
them on units previously sold.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Product Support 1-800-270-0810