NorthStar 157495 User manual

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M157495U
Owner’s Manual
Industrial Water Heater
Instructions for Set-up, Operation, Maintenance & Storage
Thank you for purchasing a NorthStar water heater. Your machine is designed for long life, dependability, and the
top performance you demand! Take time now to read through this manual so you better understand the machine’s
operation, maintenance and safety precautions. Everyone who operates this machine must read and understand this
manual. The time you take now will prolong your machine’s life and prepare you for its safe operation. Enjoy the
exceptional performance of your NorthStar water heater, the industry leader! 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.
WARNING: SPECIAL HAZARDS
Burns: Hot spray can scald and burn skin. Hot surfaces of wand and burner, as well as hot exhaust from the burner can
cause burns.
Fire/Explosion: Burner sparking can ignite fuel or other flammable liquids or vapors in the vicinity. Hot exhaust from burner
can ignite combustible materials. Keep a fire extinguisher rated “ABC” nearby during operation.
Electrocution: Improper connection of the equipment or grounding conductor can result in a risk of electrocution.
CO Poisoning: Exhaust from burner contains carbon monoxide, a poisonous gas that can cause carbon monoxide poisoning
and possible death if inhaled.
Equipment Protection Quick Facts
Inspect Upon Delivery: STOP! Closely inspect to make sure no components are missing or damaged. Contact
NorthStar Product Support to report missing or damaged parts.
Maintenance Schedule: Burner fuel filter, burner coil and electrodes require periodic checking and servicing to keep
pressure washer functioning efficiently. See “Maintenance & Repair”for frequency of servicing.
Any Questions, Comments, Problems or Parts Orders
Call NorthStar Product Support 1-800-270-0810
ITEM NUMBER: 157495
SERIAL NUMBER: _____________

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Table of Contents
Equipment Protection Quick Facts ........................................................................................................................................ 1
TABLE OF CONTENTS................................................................................................................................................2
ABOUT YOUR PRESSURE WASHER.........................................................................................................................4
SPECIFICATIONS ........................................................................................................................................................5
COMPONENT IDENTIFICATION..................................................................................................................................6
SPECIAL EQUIPMENT SAFETY FEATURES .............................................................................................................7
1. High Pressure Safety Device .............................................................................................................................................. 7
2. Thermostat ........................................................................................................................................................................... 7
IMPORTANT SAFETY INFORMATION........................................................................................................................8
GROUNDING INSTRUCTIONS ....................................................................................................................................9
EXTENSION CORDS....................................................................................................................................................9
SAFETY ......................................................................................................................................................................10
Hazard Signal Word Definitions .......................................................................................................................................... 10
SAFETY DECAL LOCATIONS...................................................................................................................................11
UN-PACKING INSTRUCTIONS..................................................................................................................................12
HARDWARE BAG ......................................................................................................................................................13
ASSEMBLY ................................................................................................................................................................14
BEFORE EACH USE..................................................................................................................................................15
Step 1: Inspect Equipment................................................................................................................................................... 15
Electrical ............................................................................................................................................................................. 15
Burner Fuel System ............................................................................................................................................................ 15
Periodic Maintenance.......................................................................................................................................................... 15
Step 2. Check and Fill Burner Fuel Tank ............................................................................................................................ 15
Filling Burner Fuel Tank...................................................................................................................................................... 15
Step 3. Select Suitable Worksite Guidelines ...................................................................................................................... 15
For Indoor and Outdoor Uses ............................................................................................................................................. 16
Step 4. Oil Burner Adjustment.............................................................................................................................................. 16
Step 5. Verify Electrical Connection .................................................................................................................................... 16
Grounding ........................................................................................................................................................................... 16
Ground Fault Circuit Interrupter Protection ......................................................................................................................... 16
Extension Cord and Usage ................................................................................................................................................. 17
Electric Shock Accident....................................................................................................................................................... 17
OPERATION INSTRUCTIONS ...................................................................................................................................18
1. Pre-Operation.................................................................................................................................................................... 18
2. Check Your Water Supply................................................................................................................................................. 18
3. Connect Your Pressure Washer....................................................................................................................................... 18
4. To Start ............................................................................................................................................................................... 19
5. Turn Your Pressure Washer ON....................................................................................................................................... 19
6. Turn Water Heater ON ....................................................................................................................................................... 19
7. To Clean.............................................................................................................................................................................. 19
8. To Stop ............................................................................................................................................................................... 19
MAINTENANCE & REPAIR........................................................................................................................................20

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1. Recommended Service Parts List.................................................................................................................................... 20
2. Maintenance Mode............................................................................................................................................................. 20
3. Maintenance Schedule ...................................................................................................................................................... 20
4. Checking the Tire Air Pressure ........................................................................................................................................ 20
5. Burner Fuel Filter............................................................................................................................................................... 20
6. Checking the Hoses........................................................................................................................................................... 20
7. Coil Descaling.................................................................................................................................................................... 21
8. Coil Desooting.................................................................................................................................................................... 21
9. Electrodes .......................................................................................................................................................................... 22
10. Flow Switch ...................................................................................................................................................................... 22
MOVING AND HANDLING INSTRUCTIONS..............................................................................................................25
1. Maneuvering Your Water Heater ..................................................................................................................................... 25
2. Lifting Your Water Heater.................................................................................................................................................. 25
MAINTENANCE INSTRUCTIONS ..............................................................................................................................25
TROUBLESHOOTING GUIDE....................................................................................................................................26
PARTS EXPLOSION- 157495- REV U .......................................................................................................................27
PARTS LIST–157495- REV U.....................................................................................................................................28
WIRING DIAGRAMS...................................................................................................................................................29
LIMITED WARRANTY ................................................................................................................................................31
CALIFORNIA PROPOSITION 65 INFORMATION .....................................................................................................32

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About Your Pressure Washer
Thank you for purchasing a NorthStar Industrial Water
Heater! It is designed for long life, dependability, and top
performance.
Intended Use. Add-on to cold water pressure washer
that will allow for hot water cleaning to aid in washing
siding, windows, walkways, driveways, patios, decks,
fences, vehicles, boats, lawnmowers, ATVs and other
equipment.
Note: Do not use for other purposes, as unforeseen
hazards or equipment damage may result.
Water Supply. The pump requires a clean, standard tap
water supply provided through a garden hose at a flow
rate of at least 3 gallons per minute. Use of a backflow
preventer on the water supply hose is recommended
and may be required by local code.
Chemical Usage. Any cleaning chemicals that are used
must be specifically approved for use in pressure
washers.
Power Source. The water heater is powered by
electricity and a diesel fired burner.
Supplies Required. Normal operation will require you
to supply:
Fuel
Electricity
Cold water pressure washer
See “Specifications”section of this manual for more
detail.
Site Selection. This unit is made for OUTDOOR USE
ONLY unless specific exhausting guidelines are met.
Read additional details in the “Before Each Use”section
of this manual.
Personal Protection. Wear safety apparel during
operation, including waterproof insulated gloves, safety
glasses with side and top protection, and non-slip
protective footwear. Some cleaning chemicals may
require the use of a respirator mask (as instructed on
chemical label).
Adult control only. Only trained adults should set up
and operate the water heater. Do not let children
operate. Water heaters can generate forces greater than
children can control and require judgment beyond what
can be expected of them.
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 water heater
must have access to and read this manual. Keep this
owner’s manual with the water heater all times and
advise all persons who will operate the machine to read
it. You must also provide personal instruction on how to
safely set-up and operate the water heater and remain
available to answer any questions a renter/borrower
might have. Owner’s Manuals are available from
NorthStar at 1-800-270-0810.

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Specifications
Item Number
157495
Max. Pressure Rating
4000 PSI
Max. Flow Output
4 GPM
BTU Output
353,700 BTU
Temperature Rise
190F @ 2GPM
190F @ 3GPM
140F @ 4GPM
Maximum Temperature
250F
Approved Fuels
#1 or 2 Diesel, Kerosene,
Fuel Oil
Fuel Capacity
4 gal.
Power Requirements
NEMA Receptacle
5-15R
Volts
115V
Amps
5A
Hertz
60Hz
Phase
single
Dimensions
Length
38.25”
Width
27”
Height
38.75”
Weight (dry)
286 lbs.
Weight (fueled)
334 lbs.
Ship Weight
310 lbs.

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Component Identification
1. Water Outlet: Attach your high pressure hose.
2. Control box: Box to house control switches.
3. Heat Switch: When turned to ON position water
heater will begin heating with proper water flow.
4. Thermostat: Controls power to fuel solenoid for
firing.
5. Fuel Fill Cap: Vented cover for fuel tank.
6. Fuel Tank: The Burner has a 4 gal. fuel tank-
kerosene, #1 or #2 diesel, or fuel oil may be
used. Do not mix fuel types.
7. Burner: The oil burner is preset and
performance tested at the factory. The Burner
may need initial adjustment for peak
performance. See “Oil Burner Adjustment”
section for instructions on initial adjustment of the
oil burner. Tip pressure washer using handle to
access burner from underneath unit.
8. Fuel Filter: Filter in fuel line that removes water
and screens out dirt and debris from fuel.
9. Exhaust Vent: Provides an exit for burner
exhaust gases.
10. Flow Switch: Water activated switch to control
on and off of burner.
11. Rupture Disc: Safety device for over pressure
protection
12. Heating Coil: Tubing in which water circulates
through to heat.
13. Water Inlet (pressure washer): Connect hose to
cold water pressure washer.
14. Power Cord (w/GFCI): Plug into outlet to power
unit.

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Special Equipment Safety Features
1. High Pressure Safety Device
The high pressure safety device (rupture disc) is a backup
safety feature. If the system’s pressure exceeds its limits,
the rupture disc will open and relieve system pressure.
WARNING: If the rupture disc ever discharges
water, turn the unit off and do not use the machine.
See a dealer or call Customer Service at 1-800-270-
0810.
2. Thermostat
The thermostat is another safety feature that keeps
the outlet water temperature below 250F.
Thermostat
Rupture Disc

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Important Safety Information
1.) Read all the instructions before using the product.
2.) Make sure that your existing hose, gun, and all accessories are rated for high temperatures and the
appropriate pressure.
3.) To reduce the risk of injury, close supervision is necessary when the product is used near children. Do not
allow irresponsible use by children. Always stop the product and bleed pressures before leaving
unattended, disconnecting hoses, or servicing.
4.) Know how to stop the product and bleed pressures quickly. Be thoroughly familiar with the controls.
5.) Stay alert - watch what you are doing.
6.) Do not operate the product when fatigued or under the influence of alcohol or drugs. Never smoke while
operating or fueling this machine.
7.) Keep operating area clear of all persons.
8.) Do not overreach or stand on unstable support. Keep good footing and balance at all times. Wear footwear
capable of maintaining a good grip on wet surfaces. Do not place the machine on soft or unstable ground.
9.) Follow the maintenance instructions specified in all manuals.
10.) Wear safety glasses, gloves, face protection and appropriate clothing when operating the machine.
11.) Do not operate this machine with broken or missing parts. Never alter the manufacturer’s original design or
deactivate any safety device on the machine.
12.) Risk of exposure to dangerous chemicals. Wear protective gloves when handling and cleaning with
chemicals. Follow the chemical manufacturer’s directions. Understand all safety hazards and first aid for all
chemicals being used. Do not pump highly abrasive fluids or use with incompatible chemicals or solvents.
13.) Know the pressure and temperature limits of your machine. Be sure all high pressure accessories meet or
exceed your machine’s limits. Do not set the rupture disc above the machine’s limit.
14.) Do not move this machine by pulling on the hose. Do not attempt to use this machine as a prop.
15.) Do not clean this machine with its own spray. Cleaning should be done with a damp sponge with the
machine OFF.
16.) NEVER attempt to immediately run or re-light the burner if it doesn’t ignite the first time. Unburned oil or
gas may have accumulated causing potential explosion or fire hazard.
17.) Always make sure all switches and controls are in the OFF position prior to plugging in the electrical cord.
Do not stand in water while plugging and unplugging electrical cord.
18.) This product is provided with a ground fault circuit interrupter built into the power cord plug. If replacement
of the plug or cord is needed, use only identical replacement parts. Failure to do so will void all warranties.
SAVE THESE INSTRUCTIONS

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Grounding Instructions
This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance
for electric current to reduce the risk of electrical shock. This product is equipped with a cord having an equipment-
grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly
installed and grounded in accordance with all local codes and ordinances.
DANGER - Improper connection of the equipment; grounding conductor can result in a risk of electrocution. Check
with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. Do
not modify the plug provided with the product. If it will not fit the outlet, have a proper outlet installed by a qualified
electrician. Do not use any type adapter with this product.
GROUND FAULT CIRCUIT INTERRUPTER PROTECTION
This water heater is provided with a ground fault circuit interrupter (GFCI) built into the plug of the power supply cord.
This device provides additional protection from the risk of electric shock. Should replacement of the plug or cord
become necessary, use only identical replacement parts that include GFCI protection.
Extension Cords
Use only 3-wire extension cords that have 3 prong grounding-type plugs and 3-pole cord connectors that accept the
plug from the product. Use only extension cords that are intended for outdoor use. These extension cords are
identified by a marking “Acceptable for use with outdoor appliances; store indoors while not in use.” Use only
extension cords having an electrical rating not less than the rating of the product. Do not abuse extension cord and
do not yank on any cord to disconnect. Keep cord away from heat and sharp edges. Always disconnect the extension
cord from the receptacle before disconnecting the product from the extension cord.
Warning - To reduce the risk of electrocution, keep all connections dry and off the ground. Do not touch plug with wet
hands.
SAVE THESE INSTRUCTIONS

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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.