North Star M109161E.4 User manual

Owner’s Manual
Original Instructions for
Assembly, Testing, Operation, Servicing, and Storage
Water Pump: Outdoor agricultural product used for general
purpose water pumping, field irrigation and trash
applications.**
WARNING
READ and UNDERSTAND the Owner’s Manual completely before using this water pump. Assemble,
test, and use only in accordance with the Owner’s Manual instructions.
WEAR personal protective gear when filling, using, cleaning, and servicing the water pump.
DO NOT START water pump until ready to spray in order to avoid unintentional spray release.
Improper use of the water pump could result in serious injury or illness to the operator or nearby
persons/animals, or could cause damage to the environment.
** This water pump is recommended for use in spraying non-flammable liquids such as water.
Solids capacity will depend on model.
Any Questions, Comments, Problems, or Parts Orders
Call NorthStar Product Support 1-800-270-0810
ITEM NUMBER: 109161, 109171
SERIAL NUMBER: _______________
M109161E.4

Hazard Signal Word Definitions
2

Table of Contents
3
About Your Water Pump ............................................................................................................ 4
Summary of Important Safety Information................................................................................5
During Assembly
During Operation
During Storage / Troubleshooting
Warning Label Locations..............................................................................................................6
Unpacking..................................................................................................................................................7
Assembly.................................................................................................................................................................. 8
Machine Components....................................................................................................................9
Operation
Operation - Preparing the Water Pump for Each Use
Step One: Inspect/Repair ...............................................................................................................10
Step Two: Fueling.....................................................................................................................................12
Step Three: Attach a suction strainer......................................................................................................13
Step Four: Place the water pump.............................................................................................................13
Operation - Using the Water Pump......................................................................................................14
Storage ..........................................................................................................................................15
Troubleshooting ...........................................................................................................................16
Specifications................................................................................................................................17
Water Pump Exploded View.......................................................................................................18
780969 Pump Exploded View .....................................................................................................19
780970 Pump Exploded View .....................................................................................................20
Limited Warranty........................................................................................................................21

About Your Water Pump
4
Thank you for purchasing your NorthStar water pump!
About Your Water Pump
This water pump is a machine designed for outdoor, agricultural, general purpose water
pumping, field irrigation and trash pumping applications.
This water pump is capable of handling suspended soft solids, up to a capacity determined by the
model.
Up to 5/8” solids (Model #109161).
Up to 3/4” solids (Model #109171).
This water pump has an optional wheel kit (Part #109172), which includes:
Axles
Wheels
Handle and Handle Mount
The technical specifications for your water pump are provided in the “Specifications” section of
this manual.
Follow all safety precautions presented throughout this manual. A summary of important safety
information can be found at the end of the manual.
Contact NorthStar Product Support at 1-800-270-0810 for any questions
about the appropriate use of this water pump and/or optional accessories.
Warranty Registration:
Please fill in the warranty registration information and have it on hand when you call in on a
warranty claim.
Attention: All Rental Companies and Private Owners who loan this
equipment to others!
All persons to whom you rent/loan this water pump must have access to and read this manual.
Keep this owner’s manual with the water pump at all times and advise all persons who will
operate the machine to read it. You must also provide personal instruction on how to safely
operate the water pump and be available to answer any questions a renter/borrower might have.

Summary of Important Safety Information
5
WARNING
Read and understand this owner’s manual completely before using the water pump.
Improper use of the water pump could result in serious injury or illness for the operator
or nearby persons/animals, or cause damage to the environment.
LISTED BELOW is a summary of safety information of particular importance. See individual
sections of this owner’s manual for more details.
------------------------------------- BEFORE OPERATION-------------------------------
Read manual. Do not allow anyone to operate the water pump who has not read the Owner’s Manual or has not
been instructed on the safe use of the water pump.
Review safety rules. Before starting this water pump, review the instructions for safe operation.
Know how to stop. Be thoroughly familiar with all controls and with the proper use of the equipment. Know how
to stop the water pump.
-------------------------------------- DURING ASSEMBLY -------------------------------
CHECK and TEST completed assembly as directed in this manual. Serious injury could result from water leaks if
water pump is improperly assembled.
DO NOT MODIFY water pump design.
---------------------------- DURING FUELING/REFUELING ------------------------
Fuel outdoors. Fill fuel tank outdoors –never indoors. Gasoline vapors can ignite if they collect inside an
enclosure. Explosion can result.
Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite
fuel. Use an UL approved fuel container to transfer gas to the engine.
Running / hot engine. A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if engine is
running or still hot. Stop the engine and allow it to cool, at least two minutes before adding fuel.
Heat / flames / sparks. Stay away from sources of heat, flame, or sparks while adding fuel.
Don’t overfill. DO NOT overfill the gas tank.
With the engine stopped and on a level surface, remove the fuel filler cap and check the fuel level. Refill
the tank if the fuel level is low.
Add fuel to the bottom of the fuel level limit of the fuel tank. Wipe up spilled fuel before starting the
engine.
Refuel carefully to avoid spilling fuel. Do not fill the fuel tank completely. It may be necessary to lower
the fuel level depending on operating conditions.
Replace cap. Replace gas cap securely before starting engine.
Spills. Clean up fuel spills immediately. Move water pump away from spilled fuel on the ground. Wipe fuel
off engine and wait 5 minutes for excess fuel to evaporate before starting engine. Gas soaked rags should be
disposed of properly.
On skin / clothes. If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately.
Gasoline storage. Store gasoline in a cool, dry place in an UL approved, tightly sealed container.

Summary of Important Safety Information
6
------------------------------------- DURING OPERATION ------------------------------
INSPECT and PREPARE water pump before each use as directed in this manual.
DO NOT USE flammable or corrosive chemicals in the water pump.
DO NOT RUN water pump while unattended.
FOLLOW INSTRUCTIONS for SAFELY FUELING/REFUELING THE ENGINE. Gasoline is
flammable and can explode. Always use caution when handling gasoline.
DO NOT START water pump until ready to spray in order to avoid unintentional release.
SEE Troubleshooting section of this manual before attempting any repairs. Wear personal protective
equipment and follow safety instructions.
Hot muffler. If you are starting a warm engine, stay clear of muffler. It may still be hot enough to burn you.
Unattended. Never leave the machine unattended while the engine is running.
Under the influence. Never operate, or let anyone else operate, the water pump while under the influence of
alcohol, drugs, or medication.
Adjusting/Repairing. Turn off engine and remove spark plug cap before cleaning, inspecting, or servicing the
water pump.
Carbon monoxide. The running engine gives off carbon monoxide, a poisonous gas that can kill you. You
CANNOT smell it, see it, or taste it. If you start to feel sick, dizzy, or weak while using the water pump, shut
off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
Other exhaust dangers. Engine exhaust, some of its constituents, and certain vehicle components contain or
emit chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Avoid inhalation of exhaust.
------------------------------------- AFTER OPERATION ------------------------------
Let engine cool before storing. Let engine cool for at least five minutes before storing. A hot engine can be a
fire hazard.
Storage location. Store the water pump in a location away from sources of heat, open flames, sparks or pilot
lights –such as water heaters, space heaters, furnaces, clothes dryers, or other gas appliances. Even if the water
pump’s gas tank is empty, residual gasoline vapors could ignite.
Gasoline storage. Store extra gasoline in a cool, dry place in an UL approved, tightly sealed container.
Gasoline vapors can ignite if they collect inside an enclosure.
Periodic maintenance. Perform periodic maintenance as directed in this manual to keep the water pump in safe
working condition.
------------------- DURING STORAGE / TROUBLESHOOTING ------------------
PREPARE THE WATER PUMP FOR STORAGE according to the instructions in this manual.
SELECT a well-ventilated STORAGE AREA away from sources of heat, flame, or sparks. Gasoline
vapors can ignite and cause a fire.
READ and FOLLOW the safety rules for troubleshooting / servicing the water pump to avoid accidental
exposure to chemical and risk of electric shock.

Warning Label Locations
7
Call North Star Product Support at 1-800-270-0810 to order new labels.
Order Part No. 782133 - Warning decal
785261 - Warning, priming port plug

Unpacking
8
Closely inspect all contents in the shipping carton.
Note that some parts are shipped inside the manual bag.
If you have damaged components: Contact the freight company that delivered the unit and file a claim.
If you have missing components: Contact NorthStar Product Support at 1-800-270-0810.
The following items are found in the manual bag.

Assembly
9
Attach rubber feet to the base.
1. Using a 3/8” and 7/16” socket, attach the rubber feet to the base with the screw and nut.
Axle Pin (2)
Base
Nut
Rubber Foot
Bolt

Machine Components
10
1. Prime Port: Fill the priming port to prime the pump.
2. Discharge Fitting: Connect the discharge hose to the discharge fitting.
3. Suction Fitting: Connect the suction hose to the suction fitting.
4. Drain Port: Drain the liquid in the pump through the drain port.
5. Pump: The pump moves the liquid.
6. Engine: The air-cooled engine powers the pump.
7. Lifting Points: Lift the machine from these points when transporting.
7

Operation –Preparing the Water Pump for Each Use
11
Step One: Inspect/Repair
If the water pump has been used previously, it must be prepared BEFORE EACH SUBSEQUENT USE.
WARNING
Read instructions below carefully for inspecting and preparing the water pump.
Damaged or clogged equipment could result in leaks or uncontrolled spray.
Important safety rules:
Turn off engine. Turn off engine and remove spark plug cap before cleaning, inspecting, or
servicing the water pump.
Guards / shields. Make sure all guards and shields are replaced after servicing the water pump.
Replacement parts. If a part needs replacement, only use parts that meet the manufacturer’s
specifications. Replacement parts that do not meet specifications may result in a safety hazard or
poor operation of the water pump.
1. Ensure water pump
casing is empty
Ensure the water pump has been thoroughly flushed with clean
water and drained from prior use.
2. Clean suction strainer
Clean the suction strainer of any material residue.
It is important to clean the suction strainer of debris before each use, to
ensure it is not clogged.
3. Inspect & repair
Inspect and test the water pump thoroughly
a. Inspect fittings for cracks and leaks. Replace all damaged fittings
with original NorthStar parts.
b. Check to be sure all nuts, bolts, and screws are tight.
c. Check oil level in engine. See engine owner’s manual.
d. Check for fuel leaks. Any fuel leak is a fire hazard. Fix any fuel
leaks before starting engine.
Step Two: Fueling
WARNING
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use
extreme care when handling gasoline.
1. Engine off / cool
The engine must be off and allowed to cool at least two minutes before adding
fuel.
WARNING: A running engine is hot enough to ignite fuel. Never add fuel or
remove gas cap if engine is running or still hot.
2. Outdoor location
Fill fuel tank outdoors –never indoors.
WARNING: Gasoline vapors can ignite if they collect inside an enclosure.
Explosion can result.

Operation –Preparing the Water Pump for Each Use
12
3. Check engine oil
level
Check engine oil level as specified in the engine manual.
4. Remove gas cap
Remove gas cap.
5. Add gasoline
Add gasoline through fill opening from a UL-approved container.
Important Safety Instructions:
Use approved container. NEVER 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.
With the engine stopped and on a level surface, remove the fuel filler cap and check
the fuel level. Refill the tank if the fuel level is low.
Don’t overfill. DO NOT overfill the gas tank. Add fuel to the bottom of the fuel
level limit of the fuel tank. Wipe up spilled fuel before starting the engine.
Heat / flames / sparks. Stay away from sources of heat, flame, or sparks while
adding fuel.
6. Spills / splashes
Clean up fuel spills /splashes immediately.
Move water pump away from spilled fuel on the ground.
1. Wipe fuel off engine and wait 5 minutes for excess fuel to evaporate before
starting engine.
2. Gas soaked rags are flammable and should be disposed of properly.
3. If gasoline is spilled on your skin or clothes, change clothes and wash skin
immediately.
7. Replace gas cap
Replace gas cap securely before starting engine.
8. Gasoline storage
Store gasoline in a cool, dry place in a UL approved, tightly sealed container.
Step Three: Attach a suction strainer

Operation –Preparing the Water Pump for Each Use
13
WARNING
This pump is design to pump water only. Never use the water pump to pump flammable liquids.
1. Attach suction
strainer
A suction strainer should be attached to the suction hose. A suction strainer has
holes or slots small enough to prevent large debris from working through and
damaging the pump.
2. Keep the strainer
clean
Keep the strainer clean.
If possible, suspend the strainer to keep it from working into sediment.
-OR-
A) Prepare a bed of large stones on which the strainer will rest.
B) Tie the strainer inside a basket or pail.
Step Four: Place the water pump
1. Place the water
pump near liquid
surface
Place the water pump on a level surface in a location as near to the liquid surface as
possible, this will ensure proper pump suction. Refer to Lifting Points on Machine
Components diagram when placing or transporting unit.
All hoses must be kept as straight as possible, avoid sharp bends.
NOTE: 23ft is the maximum height of suction head.
2. Environment
conditions
Ambient Operating Temperature Range. +5 °F to +104 °F (-15 °C to +40 °C). If
operating pump below +32 °F (0 °C) drain pump after use to prevent damage from
freezing.
Humidity. 95% max. If possible, avoid any area with high humidity. Humidity
promotes rust and corrosion.
Altitude. If operation of the engine is always at altitudes HIGHER than 6,000 feet
above sea level, have an authorized Honda Engine dealer perform carburetor
modifications. At high altitude, the standard carburetor air/fuel mixture will be
excessively rich. Performance will decrease while fuel consumption will increase.
NOTICE: Operation of the engine at an altitude LOWER than the carburetor is
modified for may result in reduced performance, overheating, and serious engine
damage caused by an excessively lean air/fuel mixture.

Operation –Preparing the Water Pump for Each Use
14
3. Use flexible hose
Use at least 12” of flexible hose to make plumbing connections to the pump body.
Rigid piping may put stresses on the pump, causing damage.
4. Place unit on
secure footing
Always be sure the unit is on a secure footing. Keep the immediate pump area free
of all unauthorized personnel. If the water pump is sitting beside a pit, be sure it is
well anchored so that it does not fall in.
5. Do not run the
pump dry
Do not run the pump dry. Always fill the pump body with water before starting. It
is not necessary to drain the pump body after each use, unless there is danger of
freezing, settling of solids, or crystallization.
6. Fill the pump
with water
Fill the pump with water utilizing the priming port on the top of the pump.
(The pump self primes only when it is first filled with priming water.)
All hoses and pipe connections must be airtight.

Operation –Using the Water Pump
15
Operate the water pump
WARNING
Do not run the water pump unattended.
1. Review safety
information
Review the “Operation – Important Safety Information” provided in this manual.
2. Priming
Using the priming port on the top of the pump, completely fill the pump chamber
with water before starting the engine.
3. Engine operation
precautions
Heed the following safety rules with regard to running the water pump engine:
Hot muffler. If you are starting a warm engine, stay clear of muffler. It may still
be hot enough to burn you.
Hot exhaust. Hot exhaust fumes from engine can cause fire. Position muffler at
least 7’ from combustible objects during operation.
Fire extinguisher. Have a Class B fire extinguisher available as a precautionary
measure when operating the water pump engine in dry areas.
Carbon monoxide. The running engine gives off carbon monoxide, a poisonous
gas that can kill you. You CANNOT smell it, see it, or taste it. ONLY run the
water pump engine OUTDOORS and at least 20 feet from the home, away from
windows, vents and air intakes, to allow proper ventilation. NEVER run the
water pump engine inside homes, garages, sheds, or other semi-enclosed spaces.
These spaces can trap poisonous gases, EVEN if you run a fan or open windows.
If you start to feel sick, dizzy, or weak while using the water pump, shut off the
engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon
monoxide poisoning.
4. Start engine
Consult the engine Owner’s Manual for starting the engine.
5. Throttle control
When operating the water pump much higher than the water surface, you may need
to speed up the engine, using the throttle. When the pump is near the water surface,
a slower engine speed can be used. This will save engine fuel and life.
Consult the engine Owner’s Manual for throttle location.
6. Secure flexible
hose
Never allow a vehicle to run over the flexible hose. This sudden shut off pressure
can cause “hydraulic shock”.
If your flexible hose must be laid across a high traffic area, it is advised to protect the
flexible hose with planking.
7. Keep pump
from freezing
Never allow water to freeze in the pump. Freezing water can be extremely
dangerous to the pump, always drain the water from the pump if freezing
temperatures are a factor.
8. Flush the pump
Flush the pump with clean water after each use is advised. Some liquids being
pumped may leave a solid or sticky residue. This may shorten the life of your pump.

Storage
16
Prepare the water pump for end-of-season storage by running clean water through the system. This will
flush out any contaminants and clean the water pump internals. After the water pump has been flushed
with clean water, completely drain the water pump of all water to protect from freezing.
WARNING
Gasoline vapors can ignite and cause a fire. Select a well-ventilated storage area away
from sources of heat, flame, or sparks.
CAUTION
The water pump will be damaged if it freezes.
Protect the water pump from freezing during storage by following the instructions below.
Preparing for storage:
1. Flush the
pump
Flush the pump with clean water after each use is advised. Some liquids being
pumped may leave a solid or sticky residue. This may shorten the life of your pump.
2. Drain the
water pump
Using the water pump drain plug, drain the water pump completely of water to
prevent freezing.
3. Engine
storage
Refer to the engine manual for proper engine storage instructions.
- Always disable the engine for storage by unplugging the spark plug wire.
CAUTION: Gasoline will oxidize and deteriorate in storage. Old gasoline in the
engine will cause hard starting and leave gum deposits that can clog the fuel
system. Deterioration problems may occur within a few months, or even less if
gasoline was not fresh when you filled the fuel tank.
Short-Term Storage:
Consider adding a fuel stabilizer to extend fuel storage life.
Long Term Storage: (between infrequent uses and at end of season)
Drain the fuel tank and carburetor as instructed in the engine owner’s manual.
Important Safety Instructions:
Always drain fuel from tank in outdoor, well-ventilated area.
Stay away from sources of heat, flame, or sparks while handling fuel.
Clean up fuel spills/splashes immediately.
4. Water pump
storage
location
Store the water pump in a location away from corrosive material, sources of
heat, open flames, sparks or pilot lights.
WARNING: Never store water pump inside where there is a source of heat or
an open flame, spark, or pilot light as on water heaters, space heaters, furnaces,
clothes dryers, or other gas appliances EVEN IF the water pump’s gas tank is
empty.
5. Gasoline
storage
Store gasoline in a cool, dry place in a UL approved, tightly sealed container.
WARNING:Gasoline vapors can ignite if they collect inside an enclosure and
an explosion can result.

Troubleshooting
17
Before attempting to service the water pump:
1. Review
troubleshooting
table
Review the Troubleshooting Table below for the type of problem you are
experiencing. However, DO NOT attempt to repair until the steps listed below are
followed.
2. Flush the pump
Pump clean water briefly through the pump to removed any debris/solids..
3. Drain the water
pump
Drain the water pump completely of water using the water pump drain plug, to
prevent freezing.
4. Disconnect
power
Switch off the engine and unplug the spark plug wire.
5. Perform repairs
Follow the directions provided in the troubleshooting table to repair the water
pump.
WARNING
Before troubleshooting or attempting to service, read the following safety rules.
PROBLEM
CAUSE
SOLUTION
Pump doesn’t revolve
1. Engine will not turn over
See engine owner’s manual
2. Rusting/Sticking of impeller
Disassemble and clean
Pump fails to prime
1. Priming chamber not full enough
Add more water to priming chamber
2. Air leaks on suction line joints
Check for loose screws or broken hoses
3. Quick coupling gaskets worn
Replace gaskets
4. Loose or broken hose clamps
Tighten or replace hose clamps
5. Priming chamber is over heated
Pour cold water in chamber or let cool
6. Engine speed is too slow
Increase engine speed
7. Worn or broken volute or impeller
Replace worn or broken component
8. Worn or broken mechanical seal
Replace mechanical seal
Low capacity
1. Clogged suction hose
Clear obstruction
2. Dirty suction strainer
Clear suction strainer
3. Flow restriction due to hose kinks
Straighten suction and discharge hoses
4. Suction lift too high
Move pump closer to water surface
5. Engine speed too low
Increase engine speed
6. Worn or broken mechanical seal
Replace mechanical seal
7. Reduced engine performance
See engine owner’s manual
8. Clogged impeller
Remove clog
9. Worn impeller
Replace impeller

Specifications
18
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
109161 –2” Semi-Trash
Engine
Honda GX200
Suction & Discharge Size
2” NPT
Maximum Flow
10,010 GPH
Maximum Suction Head
23 FT
Maximum Total Head
98 FT
Maximum Pressure
43.5 PSI
Passable Solid Size
5/8”
Mechanical Seal
Silicon Carbide
Overall Dimensions (L x W x H)
22" x 19" x 22"
Dry Weight
73 lbs
109171 –3” Semi-Trash
Engine
Honda GX200
Suction & Discharge Size
3” NPT
Maximum Flow
15,850 GPH
Maximum Suction Head
23 FT
Maximum Total Head
98 FT
Maximum Pressure
43.5 PSI
Passable Solid Size
3/4”
Mechanical Seal
Silicon Carbide
Overall Dimensions (L x W x H)
22" x 19" x 22"
Dry Weight
79 lbs

109161/109171 Exploded View- Rev. E.4
19
*109161 shown
*109161 Shown
Ref#
Part #
Description
Model
Qty
1
787770
Tethered fuel cap &
insert
All
1
2
782066
Tank Iso Grommet
All
4
3
786836
Fuel Vent Fitting
All
1
4
N/A
Fuel Tank
All
1
5
787714
Outlet Fuel Tank
Fitting
All
1
6
787884
GX200 Honda Engine
(w/o tank)
All
1
7
787353
Water Pump Iso Plate
All
1
8
32567
Rubber Iso Mount
All
4
9
787672
787671
Billboard Decal
109161
109171
1
10
787413
X-Run Roll Cage
All
1
11
2215
Bumper (Rubber Foot)
All
4
12
780969
780970
Semi -Trash Water
Pump
109161
109171
1
13
777834
¼” Hose Clamp
All
1
15
788718
Fuel Tank Assembly
All
1
16
31881
Heat Reflective
Sleeve
All
10”
17
777345
¼” Fuel Line Hose
All
9.5”
18
785767
¼ x 3/16 Hose
Mender
All
1
19
787403
5/8 Id Sym Grommet
All
4
20
777345
¼” Fuel Line
All
31“
21
782309
9/16 1-Ear Clamp
All
1
22
787396
Fuel Line Guide
All
1

780969 Pump Exploded View
20
Item
Description
Part #
Qty.
Item
Description
Part #
Qty.
1
Pump Cover
781234
1
18
Outlet Flange
782566
1
2
Large O-ring
781235
1
19
Inlet Flange
782565
1
3
Sealing Washer
781236
5
20
Inlet Check Valve
781250
1
4
Mount Bolt
781237
4
21
Inlet Connection Bolt
788866
3
5
Mechanical Seal
781238
1
22
Pump Body Bolt
788865
4
6
Impeller
781239
1
24
Inlet Hose Clamp
781254
1
7
Volute
781240
1
25
Suction Strainer
781255
1
8
Small O-ring
781241
1
26
Shaft Bolt
781256
1
9
Pump Body
781242
1
27
Shaft Bolt Washer
788988
1
10
Outlet Seal
781243
1
28
Key
788989
1
12
Outlet Connection Bolt
788864
4
13
Plug O-ring
782854
2
14
Drain/Prime Plug
2