North Star MA 1578111D User manual

©2006 Northern Tool + Equipment
TM
MA1578111D
ITEM NUMBERS:
A1573701, A1573981, A1577541,
A1578111, A1578171, A1578131,
A1578181, A1578151, A1578201
Owner’s Manual
Pressure Washer Pump: For high pressure
cleaning machines.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Customer Service 1-800-270-0810
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)
- Remove shipping plug and install dipstick. (General 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
Pump Oil Cap and Pump Component Identification…6
Operation Instructions ........................................….7-9
Water Supply……………….………………………...7
Start-Up/Shut-Down Instructions…………………..8
Applying Chemicals..………………………………...9
Maintenance and Storage...................................…10-12
Maintenance Mode and Maintenance Schedule…10
Pump Oil Change….…………………………...……11
Long Term Storage………………………………….12
Winter Storage……………………………………….12
Troubleshooting ...................................……............... 13
Specifications .....................….................................…14
Parts Explosions ........................................................ 15

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
Pump Oil Cap and Pump Component Identification

7
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
A1577541 100 seconds
A1573981 84 seconds
A1573981 58 seconds
A1578111 100 seconds
A1578131 84 seconds
A1578151 72 seconds
A1578171 100 seconds
A1578181 84 seconds
A1578201 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.

8
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

9
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

10
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.

11
sight glass
drain plug
fill cap
A1578171
fill cap
drain plug
sight glass
fill cap
drain plug
A1578181
A1578131 A1578151
sight glass
fill cap
drain plug sight glass
A1577541 A1573701 A1573981
sight glass
drain plug
fill cap
fill cap
sight glass
drain plug
fill cap
A1578201
Oil capacity: 8.5 oz. (.25L) Oil capacity: 10.2 oz. (.30L)
Oil capacity: 5.7 oz. (.17L) Oil capacity: 10.3 oz. (.30L)
Oil capacity: 22.6 oz. (.62L)
02444
fill cap
sight glass
drain plug
drain plug sight glass
fill cap
drain plug
Oil capacity: 3.4 oz. (.10 L) Oil capacity: 11 oz. (.33 L) Oil capacity: 14 oz. (.41 L)
A1578111
Oil capacity: 4.3 oz. (.13L)
Maintenance and Storage
Pump Oil Change
1.) Place a suitable container below the pump to catch the 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 manner that is compatible with the environment. We suggest you
take 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 synthetic
oil (15W50). For Cat pumps use SAE30 non-detergent oil or Cat Pump Oil Item# 22158.

12
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

13
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

14
Specifications
A1577541 A1573701
PSI 2700 PSI 2000
GPM 2.5 GPM 3.0
Max Water Temp 140°F Max Water Temp 140°F
Power 5-6.5hp Gas engine Power 5-6.5 hp Gas engine
Shaft size ¾” keyed Shaft size ¾” keyed
Nozzle size #3.0 Nozzle size #4.0
A1573981 A1578111
PSI 3000 PSI 2700
GPM 4.0 GPM 2.5
Max Water Temp 140°F Max Water Temp 140°F
Power 11-13 hp Gas engine Power 5-6.5hp Gas engine
Shaft size 1” keyed Shaft size ¾” keyed
Nozzle size #4.5 Nozzle size #3.0
A1578171 A1578131
PSI 2750 PSI 3000
GPM 2.5 GPM 3.0
Max Water Temp 140°F Max Water Temp 140°F
Power 5-6.5hp Gas engine Power 8-9hp Gas engine
Shaft size ¾” keyed Shaft size 1” keyed
Nozzle size #3.0 Nozzle size #3.5
A1578181 A1578151
PSI 3200 PSI 4000
GPM 3.0 GPM 3.5
Max Water Temp 140°F Max Water Temp 140°F
Power 8-9hp Gas engine Power 11-13hp Gas engine
Shaft size 1” keyed Shaft size 1” keyed
Nozzle size #3.5 Nozzle size #3.5
A1578201
PSI 4000
GPM 3.5
Max Water Temp 140°F
Power 11-13hp Gas engine
Shaft size 1” keyed
Nozzle size #3.5
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.

15
Parts Explosion Rev. D
Item Part# Description Qty Model
1 38514
35811
35812
779404
38518
38516
777654
38517
38520
Comet VRX Pump
General TP 2530
General EZ3040
Comet BXD Pump
Cat 3DX Pump
Comet AXD Pump
Cat 3SP Pump
Comet ZWD Pump
Cat 66DX Pump
1
1
1
1
1
1
1
1
1
A1577541
A1573701
A1573981
A1578111
A1578171
A1578131
A1578181
A1578151
A1578201
2 777915 Quick Connect
Outlet Plug 1 all
3 4027
38596
35169
Inlet Filter
Inlet Filter
Inlet Filter
1
1
A1577541, 3701,
3981,8111,8131
,8151
a1578171,818
A1578201
4 777340 ¼” x ¼” Hose Barb
Fitting 1 A1578171,8181, 8201
5 777834 ¼” Hose Clamp 2 A1578171,8181,
8201
Item Part# Description Qty Model
6 777165 ¼” PVC Hose 14” A1578171,8181
,
8201
7 38584 Easy Start Valve 1 A1578171,8181
,
8201
8 777347 3/8” Street Tee 1 A1578171,8181
8201
9 35918
777836
Thermal Valve
Thermal Valve
1
1
A1578171,8181
A1578201,3701
,3981
10 22393
35814
22392
Pop Off Valve
Pop Off Valve
Pop Off Valve
1
1
1
A1578181,8201
A1573701
A1573981
18 35813 Manifold Inlet 1 A1573701,3981
19 82141
82142
82143
3/16” x 1.5” Shaft Key
3/16” x 2” Shaft Key
¼” x 1 ¾” Shaft key
1
1
1
A1578111,8171
A1573701
A1578181,8131
,3981,8151,820
1
20 2212 Chemical Strainer 1 all
21 777165 ¼” Chemical Hose 3ft all
22 777837 3/8” plug 1 A1578181