NORTH STAR M157119J.1 Pressure Washer Owner’s Manual

NORTH STAR M157119J.1 Pressure Washer

Pressure Washer: Machine that cleans dirty surfaces with high-pressure water.

Instructions for Installation/Set-up, Operation, Maintenance, & Storage
This pressure washer produces cold water high-pressure spray. Cleaning chemicals may be incorporated into the spray if desired. The pressure pump for this equipment is powered by a gasoline internal combustion engine.

WARNING: SPECIAL HAZARDS

• CO Poisoning: Exhaust from the engine contains carbon monoxide, a poisonous gas that can cause carbon monoxide poisoning and possible death if inhaled. ONLY run pressure washer OUTDOORS and at least 20 feet from the home, away from windows, vents, and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT AWAY.
• Injection Injury: High-pressure spray can pierce skin and underlying tissues, leading to serious injury and possible amputation. Such an injection injury can result in blood poisoning and/or severe tissue damage.
• Flying Debris: High-pressure spray can cause flying debris and possible surface damage.
• Electric Shock: Spraying live electrical components or systems can cause electric shock.
• Chemical Exposure: Cleaning chemical vapors or contact with skin may be hazardous.
• Fire/Explosion: Engine sparking can ignite fuel or other flammable liquids or vapors in the vicinity. Hot exhaust from the engine can ignite combustible materials.
• Burns: Pressure washer pump and engine are hot surfaces that can cause burn injuries. Detailed safety information about these hazards appears throughout this manual.

Equipment Protection Quick Facts

• Inspect Upon Delivery : FIRST! Inspect for missing or damaged components. See the “Initial Set-Up” section for where to report missing or damaged parts.
• Add Engine Oil : The engine is shipped without oil. See the engine manual for instructions on capacity and viscosity recommendations. Pump: The pump is shipped with oil: Check the pump oil level before starting. Remove the shipping plug and install the vented fill cap. Water Flow Requirements: Make sure your supply water flow rate is 20% higher than the pressure washer’s flow rate (see “Operations” section for details) and that your water is clean and particle-free. Chemical Spraying: Use only approved pressure washer chemicals designed for high-pressure use.
• Storage : Do not allow water to freeze in the pump, hose, or spray gun(s). See “Storage” for more information. Maintenance Schedule: The engine and pump require periodic inspection and servicing to keep the pressure washer functioning efficiently. See “Maintenance Schedule Summary” for frequency of servicing.

For any Questions, Comments, Problems, or Parts Orders Call NorthStar Product Support at 1-800-270-0810

About Your Pressure Washer

Thank you for purchasing a NorthStar Pressure Washer! It is designed for long life, dependability, and top performance.

Intended Use
Produce a high-pressure water spray. Incorporate cleaning chemicals into a low-pressure water spray.

Note: Do not use it for other purposes, as unforeseen hazards or equipment damage may result.

• Power Source. The pressure washer is powered by a gasoline engine.
• Supplies Required. Normal operation will require you to supply:
  • Pressure Washer pump oil
  • Gasoline
  • Engine oil
  • Personal Protection Equipment
• See the “Specifications” section of this manual for more details.
• Site Location. Intended for outdoor use only. See suitable mounting location.
  Personal Protection. Wear safety apparel during operation, including safety glasses with side and top protection. Ear protection is also recommended if working near any operating engine. Other safety apparel includes waterproof, insulated gloves and non-slip protective footwear. Cleaning chemicals may require the use of a respiration mask; refer to the chemical label for further instructions.
  Adult Control Only. Only trained adults should set up and operate the pressure washer. Do not let children operate the pressure washer.
  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 pressure washer must have access to and read this manual. Keep this owner’s manual with the pressure washer 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 set up and operate the pressure washer and remain available to answer any questions a renter/borrower might have. Owner’s Manuals are available from NorthStar at 1-800-270-0810.

Specifications

Engine Owner’s Manual
Pump Oil (Shipped with oil but refills required)| SAE 30 Non-Detergent Oil or Cat Pump Oil (Part# 22158)| Pump Oil (Shipped with oil but refills required)| SAE 30 Non-Detergent Oil or Cat Pump Oil (Part# 22158)

Component Identification

1. Pressure Hose : Attach quick couplers to the gun and water outlet.
2. Chemical Hose : Submerge in cleaning solution.
3. Water Pump : Inspect for loose/broken parts before each use. A device that moves fluid through a combination of suction and displacement.
4. Engine : The Honda engine provides years of reliable use. The air-cooled engine that powers the pump.
5. Nozzles : Change nozzles for different spray patterns.
6. Spray Gun : Always use two hands for safe operation.
7. Trigger : Actuate to allow pressurized water to flow out of the spray gun.
8. HigHigh-Pressuretlet : Connect your high-pressure hose.
9. Garden Hose Inlet : Connect water supply for pump.

See “Parts Explosion” for more details

Safety

Hazard Signal Word Definitions

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.

Safety Labeling

Safety Decal Locations
WARNING: ALWAYS make sure safety labels are in place and good condition. If a safety label is missing or not legible, order new labels from NorthStar Product Support at 1-800-270-0810.

On-Product Warning Labels

Location| Part Numbers| Description
1| 801118| Poisonous Gas Decal
2| 788936| Burn Hazard Decal
3| 788935| Fuel Fire Explosion Hazard
4| 801049| Pressure Washer Warning + Instruction Decal

Safety Labeling

Safety Decals

For questions, replacement parts or labels contact product support at www.northerntool.com or call 1-800-270-0810.

To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.

Initial Set-Up

Step 1. Inspect & Unpack
Upon receiving your item check for missing or damaged parts. See the “Component Identification” section of this manual for a diagram of the pressure washer and its components.

• For missing or damaged components, contact Product Support at 1-800-270-0810.
• If complete, fill out the product serial number information. See the “Limited Warranty” section of this manual.

For any Questions, Comments, Problems, or Parts Orders call NorthStar Product Support at 1-800-270-0810.

Initial Set-Up

Hardware Bag

Step 2. Assembly

Note: Remove contents from packaging to begin assembly.

Spray Gun Assembly

1. Attach the Lance to the Spray Gun.
   • Tighten the spin-on coupler hand tight.

Note: The o-rings create a seal so there is no need to tighten it with a wrench.

Step 3. Select Suitable Location

Mounting Instructions

1. The pressure washer should be positioned on a firm, level (less than 3-degree slope), heat-resistant surface with good drainage and a nearby water supply.
2. The pressure washer should be placed within the garden hose distance of a continuous water supply. Ensure that the pressure washer sits level and will not slide or shift during operation. If applicable, block the pressure washer’s wheels to prevent movement.
3. Situate so there is adequate pulling room for starting the engine using the recoil starter. Attempting to pull at an odd angle could rip off the grip cord and/or cause muscular injuries to the operator.
4. Mounting dimensions and pattern are as shown below in fig06747.
   Supplied flange bolts (Part # 82625) and flange nuts (Part #82631) and secured to 23 ft-lbs. Torque.

WARNING: Lifting hazard
The pressure washer is heavy. It can crush and cause serious injury or tip over. Follow the instructions below for safely moving the pressure washer.

Outdoor Use Only

Select a suitable outdoor location.

1. Never run the pressure washer in an enclosed or partially enclosed location such as a building, garage, barn, shed, or house. These spaces can trap poisonous gases. Running a fan or opening windows will not provide adequate ventilation to prevent dangerous CO build-up.
2. Only use the pressure washer outdoors at least 20 feet from the home, away from windows, vents, and air intakes, to allow proper ventilation. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT AWAY.
3. Position the pressure washer so that the exhaust fumes will not be directed toward people or building air intakes.
4. Do not locate and use the pressure washer in the presence of flammable vapors, dust, gases, or other potentially combustible materials.
5. Ensure that working, battery-operated, or battery back-up carbon monoxide alarms are used in any dwelling/structure that is near the running pressure washer.
6. Note that this pressure washer is NOT designed or approved for use in vehicles or marine applications. Never run the pressure washer inside RVs or other vehicles, on boats, or pick-up truck beds.

WARNING: Location hazards
Choose a suitable site for operating your pressure washer to prevent possible death from carbon monoxide poisoning or injury from fire/explosion, hot surfaces, or equipment tip-over.

Airflow

1. Situate so there is adequate clearance around the pressure washer to allow for airflow – at least 7 feet from any non-combustible wall or obstruction.
2. Do not operate with a tarp, blanket, or cover surrounding the machine.
3. Do not place any objects against or on top of the unit.
4. The pressure washer needs an adequate, unobstructed flow of air to allow for proper combustion and adequate cooling. Proper combustion can only be obtained when there is a sufficient supply of oxygen available for the amount of fuel being burned. Cooling ventilation is required to prevent overheating of the pressure washer and possible fire.

Exhaust

WARNING: Exhaust Modification hazard
Never attempt to attach ductwork to the muffler system to allow for installation inside an enclosure. This could cause heat build-up and increased exhaust backpressure, resulting in possible exhaust leakage or damage to the pressure washer.

1. The exhaust gas from your pressure washer is extremely hot and can cause combustible materials to catch on fire.
2. Make sure the engine is at least 7 feet from all combustible materials and structures during operation.
3. Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged and be familiar with its use.
4. Place the unit so that the exhaust fumes will not be directed toward people or building air intakes.

DANGER: Carbon monoxide hazard
Exhaust fumes from the engine contain carbon monoxide (CO), a poisonous gas you cannot see, smell, or taste. The CO generated by the engine can rapidly accumulate, even in areas that appear to be well-ventilated, resulting in dangerous and fatal concentrations within minutes. NEVER run a pressure washer inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats. 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 pressure washer, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Install Spark Arrestor (if required)
Equip the engine with a spark arrestor if the machine will be used near any ignitable forest, brush, or grassland. (See engine Owner’s Manual provided to determine if the engine is already equipped.) Make sure you comply with applicable local, state, and federal codes.

Operation

Follow Safety Rules for Operation
After you have checked and fueled the equipment and positioned it in a suitable worksite, it is time to start your pressure washer. The following are the procedures necessary for the safe, successful operation of your pressure washer.

WARNING
Failure to follow safety rules may result in serious injury or death to the operator or bystanders.

Instruct Operators.
The owner must instruct all operators in safe set-up and operation. Do not allow anyone to operate the pressure washer who has not read the Owner’s Manual and been instructed on safe use practices.

Safety Equipment/Controls.
Always operate with all safety covers, guards, and barriers in place and good working order, and all controls properly adjusted for safe operation.

Moving Parts.
Keep hands, feet, hair, and apparel away from moving parts. Air vents may cover moving parts and should be avoided as well. Never remove any guards while the unit is operating.

Ear Protection.
Hearing can be damaged from prolonged, close-range exposure to the type of noise produced by this pressure washer. The use of ear plugs or other hearing protection devices is recommended for persons working within 15-20 feet of the running pressure washer for an extended period.

Eye Protection.
Wear ANSI/OSHA-required “Z87.1” safety glasses when operating or servicing the pressure washer. Pressurized spray from this unit can cause severe injury to the eyes. Small objects can become airborne as the spray contacts them.

NOTE!
Before starting the pressure washer, review the following general safety rules for operation:

Conditions for Use

• Know How to Stop. Be thoroughly familiar with the proper use of the equipment and all controls and connections. Know how to stop the pressure washer and depressurize the system quickly if needed.
• Instruct All Operators. The pressure washer’s owner must instruct all operators and potential renters in safe set-up and operation. Do not allow anyone to operate the pressure washer who has not read the Owner’s Manual and been instructed on its safe use.
• Adult Control Only. Only trained adults should set up and operate the pressure washer. Do not let children operate. Pressure washers can generate forces greater than children can control and require judgment beyond what can be expected of children.
• Under the Influence. Never operate, or let anyone else operate, the pressure washer while fatigued or under the influence of alcohol, drugs, or medication.
• Safety Equipment / Controls in Place. Do not operate the pressure washer unless all safety covers, guards, and barriers are in place and good working order, and all controls are properly adjusted for safe operation. Damaged. Do not operate the pressure washer with damaged, missing,
• or broken parts. Never attempt to repair a high-pressure hose or component. Always replace it with a part that is rated at or above the pressure rating of the machine.
• Modifications. Do not modify the pressure washer in any way or deactivate any safety device. Do not change or add to the fuel tank, fuel lines, or exhaust system. Modifications can result in hazards related to carbon monoxide poisoning, fuel leaks, fire, explosion, or other serious safety hazards, and will also void the warranty.

During Use

• Stay alert. Watch what you are doing at all times. Clear work area. Clear the work area of all bystanders. Keep children and pets away.
• Keep the spray away from electrical wiring. Spray contact with electrical wiring will likely result in severe electrical shock or electrocution.

WARNING
Do not spray live electrical components or systems.

• Hot exhaust/parts. Stay clear of engine exhaust. Never touch a hot engine muffler or other hot surfaces. All are very hot and will burn you.
• Do not direct the spray to this machine. Do not attempt to clean this machine with its spray. Engine damage will result. Cleaning should be done with a damp sponge with the engine OFF. Let the engine cool for at least two minutes before refueling.
• Avoid inhalation of exhaust. This product emits CO and chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
• Never pull by hose. Do not move this machine by pulling on the hose. Hose or connections could fail and result in catastrophic high-pressure release of fluid as well as hose whipping.
• Avoid sharp objects. Keep the hose away from sharp objects. Bursting hoses may cause injury.
• No load bearing. Do not use the pump to support other items of equipment that impose unacceptable loads on the pump. Do not attempt to use this machine as a prop.
• Lock trigger safety latch when not spraying. The spray gun is equipped with a built-in trigger safety latch to guard against accidental trigger release. Rotate the safety latch to the locked position when not spraying.
• Leaving unattended. Always turn off the pressure washer and relieve system pressure before leaving the sprayer unattended.

Prompt Emergency Response

• Seek medical aid for suspected injection injury. If injured by high-pressure fluid, no matter how small the wound is, see a doctor at once. A typical injection injury may be a small puncture wound that does not look serious. However, severe infection or reaction can result if proper medical treatment is not administered immediately by a doctor who is familiar with injection injuries.
• Seek medical aid for suspected carbon monoxide poisoning. The running engine gives off carbon monoxide, a poisonous gas that can kill you. If you start to feel sick, dizzy, or weak while using the pressure washer, shut off the engine and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Put on Personal Protective Gear

WARNING: Personal Protective Gear Use personal protective gear to prevent:

• Eye and skin injection injury from high-pressure spray
• Eye injury from flying debris

1. Wear waterproof gloves, safety glasses with side and top protection, face protection, and protective clothing when operating the machine. If spraying pressure washer-specific chemicals, wear a respirator mask to avoid inhalation of vapors if directed on the chemical label.
2. Wear non-slip, protective footwear. The use of a pressure washer can create puddles and slippery surfaces. Wear footwear capable of maintaining a good grip on wet surfaces.

Preparing for Operation

Make sure that any regular maintenance has been performed as prescribed in the “Maintenance & Repair” section.

Check/Add Oil to Pump

CAUTION
Never run the pump without sufficient lubrication!

1. Check the oil level. Verify that the oil level is halfway up the sight glass.
2. If the oil level is low, use the following:
   Pump| Model| Oil Type
   ---|---|---
   Cat 4DNX| 157119| SAE 30 Non- Detergent Oil or

Cat Pump Oil part # 22158

Cat 66DX| 157120
3. Replace the vented fill cap.

Check/Add Engine Oil
Use the recommended oil type for your engine and expected ambient conditions. (See engine Owner’s Manual for oil type and capacity, and more detailed oil check/fill instructions.)

WARNING: Burn Hazard
Never open the oil port while the engine is running. Hot oil be sprayed over the face and body.

Notes

• The low oil shutdown feature prevents the engine from starting without sufficient oil.
• The engine is shipped without oil. You must add oil before first use.

Add Fuel

WARNING: Fuel Fire/Explosion Hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite fuel vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Always use extreme care when handling fuel. Carefully follow all instructions to avoid the following conditions which could result in fuel ignition:

• gas vapor collection inside enclosures
• static electric sparks
• sparks from electric wiring, batteries, or running engines
• sources of heat (such as a hot engine exhaust)
• open flames, including pilot lights

Always follow these general safety rules when fueling:

1. Turn the pressure washer off and allow it to cool for at least two minutes before removing any fuel cap.
   Note: A running or still-hot engine is hot enough to ignite fuel.

2. Fill the fuel tank OUTDOORS – never indoors. Fuel vapors can ignite if they collect inside an enclosure and an explosion can result.

3. Stay away from all sources of heat, sparks, and flames. Do not smoke.

4. Never pump fuel directly into the gas tank at a gas station – it could cause a static electric spark. Follow these steps to avoid static electric sparking during fueling:

   • Use an approved portable container to transfer fuel to the pressure washer’s tank. (A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily.)
   • Always place the container on the ground to be filled. Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed.
   • Dissipate static charge from your body before beginning the fueling process by touching a grounded metal object at a safe distance from fuel sources.
   • Keep the nozzle in contact with the container while filling. Do not use a nozzle lock-open device.

5. Clean up fuel spills/splashes immediately.

   • If possible, move the pressure washer away from spilled fuel on the ground.
   • Wipe up spilled fuel and wait 5 minutes for excess fuel to evaporate before starting the engine.
   • Fuel-soaked rags are flammable and should be disposed of properly.
   • If fuel is spilled on your skin or clothes, change clothes and wash your skin immediately.

Fill the Engine Fuel Tank

Check the gasoline tank level. If needed, fill the tank with fresh unleaded gasoline from a portable container:

1. Remove the engine gas cap.
2. Add gasoline through the fill opening:
   • Use only a UL-approved portable gasoline container to transfer the gasoline to the engine’s tank.
   • Do NOT overfill the gasoline tank. Allow at least 1/2″ of space below the fill neck to allow for fuel expansion.
3. Replace the gas cap securely before starting the engine.
4. Store extra gasoline in a cool, dry place in a UL- approved tightly sealed container.

Inspect Fuel System/Check for Leaks
Inspect the engine fuel system and check for leaks before each use. Do not start pressure washer until all needed repairs have been completed.

WARNING: Fuel Leak Hazard
Gasoline fuel is highly explosive and fuel leaks can result in fire or explosions. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

Inspect the entire fuel system. Look for:

• signs of leaks or deterioration
• chafed or spongy fuel hose
• loose connections
• loose or missing fuel hose clamps
• damaged fuel tank or
• defective gasoline shut-off valve

Inspect Spray System

• Always inspect the spray system for damage and leaks before each use. Do not start pressure washer until all needed repairs have been completed.

WARNING: High-Pressure Fluid Injection Hazard

High-pressure fluid discharge from leaks (even pin-sized) or ruptured components can pierce the skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

• Never use a finger or skin to check for leaks.
• Never operate the machine with damaged or missing hoses/parts.
• Never attempt to repair a high-pressure hose or component – Always replace it with a part that is rated at or above the pressure rating of this machine.

Perform Scheduled Maintenance, As Needed
Make sure that any other regular maintenance has been performed as prescribed in this manual in the “Maintenance Schedule Summary” section. Refer to the Engine Owner’s Manual for engine maintenance instructions.

Connect Hoses, Water Supply, and Spray Nozzle

Position Pressure Washer for Use

• For detailed instructions on positioning your pressure washer for use, turn to the “Initial Set-Up” section of this manual and reference “Step 3: Select Suitable Location”.
• Where no flammable vapors, dust, and gases are present.
• Where there is adequate, unobstructed ventilation airflow.
• With adequate clearance from combustible materials.
• On a firm, level, heat-resistant surface with good drainage and nearby access to a continuous water supply.

Attach Garden Hose to Water Inlet

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
   ---|---
   157119| 100 sec
   157120| 72 sec
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:
   Model#| Max. Inlet psi
   ---|---
   157119| 60 psi
   157120| 75 psi
5. Always use a flexible rubber hose for your water supply. Do not use rigid piping.
   Attach a High-Pressure Hose to the Spray Gun and Water Outlet

WARNING: High Pressure
NEVER operate this pump with components (such as hose, connections, and spray gun) rated for lower pressure and/or temperature limits than the machine’s maximum rated pressure and temperature, or the component could rupture and cause serious personal injury from escaping high-pressure fluids.

1. See the “Component Identification” section of this manual for the location of the pressure washer’s water outlet.
2. Your pressure washer hose is equipped with quick couplers. Simply pull the collar back and push the coupler onto the water outlet nipple. The collar should slide over the ball bearings.
3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. Check the connection by pulling on the hose to ensure a positive connection.

Select Nozzle for Spray Gun
Your pressure washer is equipped with four high-pressure nozzles. Generally, the wider the spray angle of the nozzle, the lower the spray impact produced. Select the appropriate nozzle for the job based on the following table:

• You must use the low-pressure, black nozzle for spraying chemicals.

Attach Nozzle to Spray Gun

WARNING: Depressurize First
Any time you remove/install/change a nozzle, you must depressurize the hose line by squeezing the spray gun trigger while the engine is off. Even if the engine has been off for a long period, the hose may remain dangerously pressurized.

1. Make sure the engine is off and the hose line is depressurized.
2. To install the nozzle, pull the collar back and twist the nozzle firmly into the coupler on the end of the wand.
3. Release the collar, making sure it springs back and re-seats to its original (non-retracted) position. Check the connection by pulling on the nozzle to ensure a tight connection — if correctly inserted, the nozzle will rotate but not pull out.

Prime the Water Supply

Turn on Water Supply and Squeeze the Trigger

CAUTION: Water Pressure
Never run the pump without the water supply connected and turned on. Operating the pressure washer without a sufficient incoming flow of water will damage the pump.

• Turn on the water supply. Make sure the water supply is steady and flowing at a rate of 20% over the rated flow of your pump. (Reference the flow rate table under the Connect Hoses, Water Supply, and Nozzle” section.)
• Purge air from the water supply hose by squeezing the trigger until a steady stream of water flows out of the nozzle at low pressure. (Air in the hoses can cause damage to the pump, so always make sure all the air is out of the hoses before starting the pressure washer engine.)
• Make sure the water supply hose is not kinked. A kinked hose will provide insufficient water supply to the pump and reduce its life. Make sure the hose remains unkinked after moving the pressure washer.

Set Up for Chemical Spray (if desired)

Prepare for Chemical Spray (if planning to use) Using the proper cleaning chemical for the application can speed up cleaning jobs tremendously. Your pressure washer is equipped with a chemical injection point on the downstream side of the pump for introducing cleaning chemicals into the water stream. A braided chemical hose is provided to connect at this point. Suction pressure at this connection automatically draws the chemical solution in through the hose, mixing in 1 part chemical to 15 parts water. Adequate suction pressure is created only when the low-pressure (black) spray nozzle is used. The introduction of cleaning chemicals via the chemical injection point affords the following advantages:

• It protects the pump from damage because no chemical passes through the pump.
• It mixes the cleaning chemical into a low-pressure spray. Cleaning chemicals applied under low pressure adhere better to the surface being cleaned, allowing the formula time to react and remove dirt more effectively.

Note: An external upstream chemical injector is not recommended for use with this pressure washer, and if used would alter the 15-to-1 dilution ratio and may cause pump damage.

CAUTION: Chemicals Containing Muriatic Acid
Certain chemicals, such as bleach or those containing muriatic acid, will cause pump damage if introduced upstream through the pump’s water inlet.

WARNING: Chemical Spraying

• Never spray acids, corrosives, or abrasive or flammable liquids. Breathing hazards, surface burns/corrosion, or fire/explosion could result.
• Follow the chemical manufacturer’s label instructions for proper use and handling of the chemical. Understand all safety hazards and first aid for all chemicals being used. Always wear protective gloves when handling and cleaning with chemicals, and wear other protective gear as directed by the chemical manufacturer. Always dispose of hazardous fluids per local, state, and national guidelines.

Acquire Cleaning Chemical
Use only approved pressure washer chemicals or chemicals specifically formulated for use with pressure washers.

CAUTION: Non-approved Chemicals Non-approved chemicals can damage pressure washer components (seals, wand, hoses, pump, etc.) and be harmful to the environment.

Prepare for Chemical Spray (if planning to use)
Prepare the pressure washer for chemical spraying using the following steps:

1. Prepare (dilute) chemical cleaning solution as required for the job.
   Note: the chemical solution will be automatically mixed with the water at a ratio of 15 parts water to 1 part chemical solution.

2. Press the braided chemical hose over the chemical injector on the pump.

3. Submerge the suction strainer connected to the braided chemical hose into a bucket containing the chemical solution.

Start-Up Procedures

Start the Engine to Power the Pump

1. Make sure the water supply is connected and primed.
   CAUTION: Warranty Void Running the pump dry will cause damage and void the warranty.

2. To prevent accidental spraying, engage the safety latch on the spray gun trigger by rotating it to the locked position.

3. Follow the instructions in the Engine Owner’s Manual for starting the engine.

   • If the engine doesn’t start on the first try, pressure may build up in the pump. Relieve pressure by squeezing the spray gun trigger before attempting to start the engine again. This will make starting easier.
   • DANGER: Engine Exhaust Do not inhale engine exhaust. It contains dangerous carbon monoxide that can kill you.

Apply Cleaning Chemical (if desired)

1. Make sure the chemical injector is properly set up according to the instructions. Reference “Set Up for Chemical Spray” on the previous page.
2. Make sure the low-pressure BLACK nozzle is attached before beginning to spray chemicals. Only the low-pressure black nozzle will allow chemicals to be drawn through the chemical injector into the water stream.
3. Apply chemicals by squeezing the spray gun trigger. The chemical injector will draw the chemical into the water stream.
4. Apply chemicals evenly to the cleaning surface. Never use more chemicals than is necessary to clean the surface.
5. Allow the chemicals time to react with the dirt before rinsing.
6. Prepare to rinse by changing to a high-pressure nozzle. Changing the nozzle from the low-pressure black nozzle to a high-pressure nozzle will stop the flow of chemicals into the water stream. Instructions for selecting a nozzle can be referenced in the “Connect Hoses, Water Supply, and Spray Nozzle” section. See the subsection “Select Nozzle for Spray Gun”.
7. Rinse with high-pressure spray as instructed:

Begin High-Pressure Spray

WARNING: High-Pressure Spraying Safety

• Keep the spray away from people. Never direct discharge stream at or near any person. Do not allow any part of the body to come in contact with the fluid stream. High-pressure spray can cause serious skin, eye, or falling injuries. Injection injury will occur if high-pressure spray pierces the skin, injecting liquid under the skin. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation. Seek medical attention.
• Do not secure the trigger open. To reduce the risk of injury, do not attempt to secure the spray gun open by blocking or tying the spray gun in the open position.
• Prevent slips/loss of balance. High-pressure spray could cause you to lose balance from kickback forces, and wet surfaces can be slippery.
  • Keep good footing and balance at all times. Do not overreach.
  • Keep the hose tidy while in use.
  • Do not stand on unstable support when spraying.
  • If spraying from an elevated surface, use fall protection because spray gun kickback can propel you off the elevated surface. When spraying from a ladder or scaffolding, ensure it is firmly anchored from sway or tip-over.
  • Be aware of puddles and slippery surfaces. Ensure there is adequate drainage to prevent the pooling of water.
• Prevent surface damage & flying debris. Surfaces being sprayed must be strong enough to withstand high-pressure spray or damage may result. In addition, high-pressure spray will dislodge unsecured objects as well as surface chips and debris, resulting in hazardous flying objects that can cause personal injury or property damage. Do not spray brittle surfaces or breakable, fragile, or unsecured objects such as:
  • stucco or laminar flagstone
  • some painted surfaces
  • windows or glass doors (they may break)
  • light fixtures, flowerbeds, or mailboxes
  • unsecured, lightweight objects

Procedure

1. Put on one of the high-pressure spray nozzles (always relieve system pressure first and follow instructions for attaching a nozzle).

2. Clear the cleaning area of all persons. Keep children and pets away.

3. Hold the spray gun firmly with two hands and a sturdy stance the gun kicks back when triggered.

4. Wash from the bottom to the top, using side-to-side motions. This washes away heavy dirt and allows the detergent to soak as you work toward the top.

5. Use the width of the spray pattern to wash a wide path. Overlap spray paths for complete coverage.

6. The nozzle should be 12″ to 24″ from the work, closer for tough areas.

7. Small parts should be washed in a basket so the pressure does not push them away. Larger, lightweight parts should be clamped down.

8. The pressure washer is set and locked to the maximum rated pressure when it leaves the factory. To reduce the pressure, turn the unloader knob counterclockwise. To return to maximum pressure turn the unloader knob clockwise.
   WARNING: Warranty Void Do not attempt to alter the unloader valve’s maximum pressure. Excess pressure could cause serious injury from escaping high-pressure fluids and/or pump damage. Any alteration other than turning the adjustment knob will void your warranty.

9. If temporarily interrupting spraying, rotate the trigger safety latch downward to the locked position to guard against accidental trigger release.
   Spray Gun Safety Lock
   When not spraying, use the spray gun safety lock to prevent accidental high- pressure discharge.

10. Always turn off the engine and activate the spray gun trigger to relieve system pressure when:

    • the sprayer is unattended, or
    • disconnecting hoses, installing/cleaning nozzles, or servicing the pump.

WARNING: Injury
Always turn off the engine and relieve system pressure when finished spraying or when leaving the sprayer unattended. Serious injury could result from unintentional release of high-pressure spray.

Shutdown

WARNING: Injury
Never disconnect the high-pressure hose from the pump or spray gun while the system is pressurized. Relieve pressure by squeezing the spray gun trigger after the engine is turned OFF.

Stop the engine using the following steps:

1. Turn the engine OFF.
2. Turn the water supply OFF.
3. Actuate spray gun trigger to relieve system pressure.
4. Remove garden hose.
5. Remove the pressure hose.
6. Remove the nozzle from the spray gun.
7. Turn the gasoline line valve to the OFF position.
8. If chemicals were used, remove the chemical injector tube from the pump.
9. Cool the engine for at least five minutes before storing it; a hot engine is a fire hazard.

Storage
When you are finished using the pressure washer, you must prepare the sprayer for storage and store it in a proper location.

Between Use Storage
Perform periodic maintenance as directed in this manual to keep the pressure washer in safe working condition.

Choose a storage location that is:

• Clean and dry.
• Away from sources of heat, open flames, sparks, or pilot lights, even if the pressure washer’s engine fuel tank is empty. Residual fuel fumes from the tank can ignite. Away from extreme high or low temperatures. Do not store the pressure washer in freezing conditions unless it is prepared as directed below for those conditions.

Note

• If you will be storing the pressure washer in freezing conditions, follow the instructions for preparing the sprayer for storage in freezing conditions.
• If you will not be using the pressure washer again for 30 days or more, follow the instructions for preparing the engine for long-term storage.

WARNING: Flammable Materials

• Fuel and its vapors can ignite and cause a fire. Select a well-ventilated storage area away from sources of heat, flame, or sparks.
• A hot engine can ignite flammable materials. Always let the engine cool for at least five minutes before storing.

Prepare Pressure Washer for Freezing Conditions
If you will be storing the pressure washer in freezing temperatures, you must properly prepare the pressure washer to prevent water from freezing in the system.

WARNING: Freezing Conditions
Do not allow water to freeze in the pressure washer, high-pressure hose, or spray gun. Freezing water can cause damage to the equipment and cause the spray gun to fail in the open position. A spray gun that has failed in the open position can whip around and cause personal injury when the pressure washer is started.

1. Drain the water from the high-pressure hose and spray gun by depressing the trigger on the spray gun until all the water drains out.
2. Disconnect the plumbing that connects to the pump outlet.
3. Obtain the materials you will need:
   • 12″ piece of garden hose or equivalent, funnel, and
   • approximately 6 oz. of RV antifreeze.
4. Attach the 12″ garden hose piece with the funnel to the pump inlet.
5. Pour RV antifreeze into the funnel, then pull the recoil a few times until the antifreeze comes out of the pump outlet.

Prepare Engine for Long Term Storage
First, prepare the engine for long-term storage if you will not be using the pressure washer for more than 30 days. Fuel can become stale when stored over 30 days. Stale fuel causes acid and gum deposits to form in the fuel system which can cause malfunction of the engine.

1. Prepare fuel system for storage:

• Drain all gasoline from the tank and carburetor. This is most easily accomplished by running the pressure washer with the high-pressure hose until the engine stops from lack of fuel. Drain the carburetor bowl after the engine has stopped and has been allowed to cool for at least two minutes.
  OR

• Add fuel stabilizer to the gasoline (following manufacturer’s instructions)

Fuel stabilizer steps:

• Ensure the gas tank is full.
• Add fuel stabilizer to fuel tank.
• Run the pressure washer with a high-pressure hose for at least 5 minutes after adding the stabilizer to allow it to enter the fuel system.
• Shut off the engine.

Lubricate cylinder and piston:

• Disconnect the spark plug wire and remove the spark plug.
• Add one teaspoon of oil through a spark plug hole.
• Place a rag over the spark plug hole and slowly pull the recoil a few times to lubricate the combustion chamber.

Replace the spark plug, but do not reconnect the spark plug wire.

Prepare Pressure Washer for Storage

1. Make sure the engine start switch is OFF.
2. Disconnect the engine spark plug wire if you haven’t already done so.
3. Disconnect the high-pressure hose, garden hose, and spray gun.

Move Pressure Washer to Storage Location
Let the engine cool for 5 minutes before moving the pressure washer to its storage location.

Maintenance & Repair

WARNING: Maintenance Hazards
ALWAYS shut off the water supply, bleed water pressure, turn off the engine, and disconnect the spark plug wire before cleaning, adjusting, or servicing the pressure washer. After servicing, make sure all guards and cover shields are replaced before using.

Maintenance Schedule Summary

·    Every 3 months or 500 hours of use after that

See detailed instructions for each maintenance item below.
( Note: For end-of-the-season storage instructions, see the “Storage” section of this manual.)

Detailed Instructions – Maintenance & Repair

No modifications. Never modify or alter the pressure washer in any way. Modifications can create serious safety hazards and will also void the warranty.

Follow Safety Rules
Read and follow these safety rules whenever you will be servicing the pressure washer:

• Turn off / relieve pressure first. Always turn off the pressure washer and relieve system pressure before inspection or maintenance. Remove the spark plug or spark plug wire to prevent accidental starting.
• Fuel valve off. Turn the fuel shut-off valve to the OFF position before transporting or servicing the pressure washer.
• Replace guards. Make sure all guards and cover shields are replaced after servicing the pressure washer.
• Major repair. Major service, including the installation or replacement of parts, should be performed only by a qualified service technician. Obtain factory-approved parts from NorthStar Product Support at 1-800-270-0810.
• Replacement parts. If a part needs replacement, only use factory-approved repair parts. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the pressure washer and will void the warranty.

Keep the Pressure Washer Clean
If dust or debris accumulates on the pressure washer, clean the pressure washer with a damp cloth or soft bristle brush. Do not allow air intake to become blocked.

CAUTION
Do not spray the pressure washer with a garden hose or pressure washer. Water may enter the pressure washer and cause damage.

Inspect Spray System
Inspect the spray system for damage and leaks before each use. Do not start pressure washer until all needed repairs have been completed.

Maintenance & Repair

WARNING: High-Pressure Fluid Injection Hazard
High-pressure fluid discharge from leaks (even pin-sized) or ruptured components can pierce the skin and inject fluid into the body. Injection injury can result in blood poisoning and/or severe tissue damage leading to infection, gangrene, and possibly amputation.

• Never use a finger or skin to check for leaks.
• Never operate the machine with damaged or missing hoses/parts.
• Never attempt to repair a high-pressure hose or component – Always replace it with a part that is rated at or above the pressure rating of this machine.
  1. Check hoses, fittings, wand, trigger gun, and connections for signs of wear, cracks, looseness, or leaks. Replace as required.
  2. Check and clean the nozzle orifice.

Clean Inlet Filter Clean the inlet filter before each use.

WARNING: Filter Disposal
When cleaning filters, check whether dangerous chemicals have been used with the filter and take any precautions that may be recommended by the manufacturer of these chemicals. Always dispose of hazardous fluids per local, state, and national guidelines.

1. Unscrew the garden hose from the water inlet (if connected).
2. Use an Allen wrench to remove the garden hose coupler.
3. Remove the glass filter screen.
4. Remove the filter screen.
5. Run water through the filter screen to clean.
6. Reassemble.

Inspect Fuel System

• Inspect the engine fuel system and check for leaks before each use.
• Do not start pressure washer until all needed repairs have been completed.

WARNING: Filter Disposal
Gasoline fuel is highly explosive and fuel leaks can result in fire or explosions. You can be burned and seriously injured if the fuel system is not properly hooked up or there is a fuel leak when you start the engine.

Inspect the entire fuel system. Look for:

• signs of leaks or deterioration
• chafed or spongy fuel hose
• loose connections
• loose or missing fuel hose clamps
• damaged fuel tank
• defective gasoline shut-off valve

Perform Engine Maintenance As specified in the Engine Owner’s Manual.

Engine maintenance items include:

1. Changing oil
2. Air filter check/replacement
3. Spark plug cleaning and replacement
4. Fuel filter check/replacement
5. Inspecting and cleaning muffler (and spark arrestor if equipped)

Change Pump Oil
Change the pump oil after the first 50 hours of use, and then after every 3 months or 500 hours of use after that.

1. Remove the drain plug from the pump.

2. Drain pump oil into a suitable container and dispose of it responsibly.

3. Reinstall the l drain plug.

4. Make sure the unit is sitting level.

5. Reference the “Specifications” section of this manual to determine the oil type and quantity needed for your pump model.

6. Replace the oil fill cap.
   NOTICE:
   Dispose of used motor and pump oil in a manner that is compatible with the environment and with local, state, and federal laws and regulations.

   • 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 pour it down a drain.

NOTE TO COMMERCIAL USERS:
All mechanical equipment, no matter how well designed, will need maintenance and repairs. A NorthStar pressure washer is no exception. At times, a NorthStar pressure washer may become inoperable because repairs are required. NorthStar Product Support will assist in these repairs as needed, but if an inoperable pressure washer creates a major expense to your business, then we strongly recommend the following:

• Have a staff person become familiar with the mechanical operation of the pressure washer and be capable of making minor repairs and performing all preventative maintenance procedures.
• Keep a stock of recommended service parts for maintenance and minor repairs.

IMPORTANT: Replacement Parts
If a part needs replacement, only use parts that meet the manufacturer’s part number specifications. Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the pressure washer. Contact NorthStar Product Support at 1-800-270-0810 for any questions, problems, or parts orders.

Troubleshooting

This section provides a list of the more frequently encountered pressure washer malfunctions, their causes, and corrective actions. Some corrective actions can be performed by the operator or maintenance personnel, and others may require assistance of a qualified Service Center.

ENGINE WILL NOT START

Causes| Solutions
Low oil shutdown| Fill the engine with an adequate amount of oil
Cold engine| Choke engine to start
No fuel| Add gas to the fuel tank. Make sure the fuel shutoff valve is open
Pressure build-up from initial use| Trigger spray gun to relieve pressure
The engine is not turned ON| Place the ON/OFF switch in the ON position
The spark plug wire is not attached| Attach spark plug wire to spark plug
LOW/SURGING PRESSURE
Causes| Solutions
Insufficient water supply| Increase water flow. Check for kinked or pinched hose
Plugged inlet screen| Pull out and clean the screen carefully
Need to use a high-pressure nozzle| Change to the green, yellow, white
Plugged nozzle| Remove the nozzle, check for blockage
Worn nozzle| Replace nozzle
Leak in the high-pressure line| Fix leaks
NO CHEMICAL INJECTION
Causes| Solutions
Need to use different nozzle| Change to the black nozzle
Back pressure from extra-long hose| Try shorter high-pressure hose
Leak in clear chemical hose| Replace hose. Use hose clamps if necessary
The chemical strainer is not submerged| Make sure the strainer is completely submerged in the solution

Parts Explosion- Model #157119, 157120 – Rev J.1

Parts List – Model #157119, 157120 – Rev J.1

Pump Assemblies

FITTING

| 1| 157119, 157120

23

| 803642| FILTER, INLET, 3/8″ NPT X 3/4″ FGH|

1

| 157119
803643| FILTER, INLET, 1/2″ NPT X 3/4″ FGH| 157120
24| 777836| THERMAL VALVE| 1| 157119
35918| 157120
25| 777838| 1/4″ NPT PLUG| 1| 157119, 157120

Pump Exploded View – Cat 4DNX

Ref#| Part#| Description| Qty| | Ref#| Part#| Description| Qty
---|---|---|---|---|---|---|---|---
5| CA549360| SCREW| 3| 106| CA49816| SEAL| 3
8| CA547153| BEARING COVER| 1| 120| Not Available| SEAL CASE| 3
10| CA14041| O-RING, BEARING COVER| 1| 121| CA13976| O-RING FOR SEAL CASE| 3
11| CA55337| OIL SEAL| 1| 125| CA49824| SEAL| 3
15| CA14488| INNER BALL BEARING| 1| 160| CA17428| O-RING, INLET| 3
20| CA547048| CONNECTING ROD| 3| 161| CA547077| SEAT, INLET| 3
24| Not Available| OIL PLUG CAP| 1| 162| CA48361| BACK-UP RING| 3
25| CA49883| CRANKSHAFT| 1| 163| CA43358| O-RING| 3
27| CA15710| BALL BEARING| 1| 164| CA547076| SEAT, DISCHARGE| 3
32| CA547961| CAP| 1| 166| CA547098| VALVE| 6
33| CA14179| O-RING FOR OIL FILTER CAP| 1| 167| CA46865| SPRING| 6
37| CA92241| GAUGE, BUBBLE OIL W/GASKET| 1| 168| CA543988| RETAINER, SPRING, INLET| 3
38| CA44428| GASKET, FLAT FLEX OIL GAUGE| 1| 169| CA49764| RETAINER, SPRING, DISCHARGE| 3
48| CA44842| DRAIN PLUG| 1| 172| CA142807| O-RING FOR PLUG| 3
49| CA14179| O-RING FOR DRAIN PLUG| 1| 174| CA547104| PLUG, VALVE W/O-RING| 3
53| Not Available| CRANKCASE| 1| 185| Not Available| HEAD, MANIFOLD W/UNLOADER BODY| 1
64| CA46229| CROSSHEAD PIN| 3| 188| CA549357| SCREW| 6
65| CA542402| PLUNGER ROD| 3| 197| CA941516| INLET FITTING ASSEMBLY| 1
70| CA47215| OIL SEAL| 3| 249| CA30520| ADAPTER MOUNT ASSEMBLY| 1
90| CA547091| PLUNGER| 3| 255| CA30516| BOLT MOUNT ASSEMBLY| 1
98| CA46730| WASHER| 3| 300| CA76975| SEAL KIT INCLUDES: 98, 106, 121,

125

| 1

99

|

CA542405

|

RETAINER, PLUNGER

|

3

|

310

|

CA76976

| VALVE KIT INCLUDES: 160, 161,

162, 163, 164, 166, 167, 168, 169,

172

|

1

100| CA46233| RETAINER, SEAL| 3|

Pump Unloader Exploded View – Cat 4DNX

Ref#| Part#| Description| Qty| | Ref#| Part#| Description| Qty
---|---|---|---|---|---|---|---|---
402| CA547798| ADJUSTING CAP| 1| 438| CA46254| SEAT, CHECK VALVE| 1
403| CA45070| LOCK NUT| 1| 439| CA13963| O-RING, CHECK VALVE SEAT| 1
408| CA32094| PRESSURE SPRING| 1| 443| CA49765| VALVE, CHECK| 1
410| CA549352| SPRING RETAINER| 1| 444| CA45924| SPRING| 1
412| CA45694| PISTON STEM| 1| 446| CA26133| O-RING, BODY| 1
414| CA20184| BACK UP RING| 1| 468| CA31767| O-RING KIT INCLUDES 414, 415, 424,

429, 431, 437, 439, 446

| 1
415| CA14190| O-RING, PISTON STEM| 1| 469| CA7332| CHEMICAL FIXED INJECTOR| 1
423| CA46249| RETAINER VALVE| 1|

470

|

CA76179

| UNLOADER REPAIR KIT INCLUDES: 412, 414, 415, 423, 424, 425, 426, 429, 431, 435,

436, 437

|

1

424| CA13966| O-RING, VALVE RETAINER (OUTER)| 1| 471| CA76146| CHECK VALVE KIT INCLUDES: 438, 439,

443, 444, 446

| 1
425| CA547799| PISTON RETAINER| 1| 472| Not Available| BARB| 1
426| CA46250| WASHER| 1| 476| Not Available| O-RING, BARB -70D| 1
428| CA26133| O-RING, VALVE RETAINER| 1| 477| Not Available| BALL| 1
429| CA17399| O-RING, PISTON RETAINER (INNER)| 1| 478| Not Available| SPRING| 1
435| CA547800| VALVE| 1| 479| Not Available| ORIFICE| 1
436| CA49664| SEAT| 1| 480| Not Available| BODY| 1
437| CA13963| O-RING, SEAT| 1| 483| CA76176| KIT, REPAIR (INCLUDES: 476, 477, 478)| 1

Pump Exploded View – Cat 67DX

Ref#| P/N| DESCRIPTION| QTY| | Ref#| P/N| DESCRIPTION| QTY
---|---|---|---|---|---|---|---|---
5| Not Available| SCREW| 4| 128| CA49605| MALE ADAPTER| 3
8| Not Available| BEARING COVER| 1| 160| CA26129| O-RING, INLET VALVE SEAT| 3
10| CA14023| O-RING, BEARING COVER| 1| 161| CA49378| SEAT, INLET| 3
11| CA125351| OIL SEAL| 1| 162| CA48361| BACK-UP RING, DISCHARGE SEAT| 3
15| CA146421| INNER BALL BEARING| 1| 163| CA43358| O-RING| 3
20| CA49364| CONNECTING ROD| 3| 164| CA49376| SEAT, DISCHARGE| 3
24| CA549608| PLUG, OIL CAP| 1| 166| CA547098| VALVE| 6
25| CA49391| CRANKSHAFT| 1| 167| CA49354| SPRING| 6
27| CA49363| BALL BEARING| 1| 168| CA49377| RETAINER, SPRING, INLET| 3
31| CA549726| CAP, VENTED W/ O-RING| 1| 169| CA547441| RETAINER, SPRING| 3
32| CA547961| CAP| 1| 172| CA49382| O-RING FOR PLUG| 3
33| CA14179| O-RING FOR OIL FILTER CAP| 1| 174| CA49380| PLUG, VALVE W/O-RING| 3
37| CA92241| GAUGE, BUBBLE OIL W/GASKET| 1| 185| CA49372| HEAD, MANIFOLD W/UNLOADER BODY| 1
38| CA44428| GASKET, FLAT OIL GAUGE| 1| 188| CA126512| SCREW| 8
48| CA44842| DRAIN PLUG| 1| 255| CA31445| BOLT MOUNT ASSY.| 1
49| CA14179| O-RING FOR DRAIN PLUG| 1| 300| CA76362| SEAL KIT (INCLUDES: 98, 106, 121, 127, 128)| 1
53| CA49352| CRANKCASE| 1| 310| CA76260| VALVE KIT (INCLUDES: 160- 164,166,167,168,169, 172)| 1
64| CA49366| CROSSHEAD PIN| 3| 469| CA7367| INJECTOR, CHEMICAL FIXED| 1
106| CA45188| SEAL| 3| | | |
120| CA49374| SEAL CASE| 3| | | |
121| CA13977| O-RING FOR SEAL CASE| 3| | | |
127| CA49606| V-PAVKING| 3| | | |
98| CA46730| WASHER, SEAL-90D| 3| | | |
99| CA49369| RETAINER, PLUNGER| 3| | | |

Pump Unloader Exploded View – Cat 67DX

Ref#| P/N| DESCRIPTION| QTY| | Ref#| P/N| DESCRIPTION| QTY
---|---|---|---|---|---|---|---|---
401| CA49100| HANDLE, ADJUSTING (BLACK)| 1| | 460| CA126974| FITTING, DISCHARGE, 3/8”| 1
402| Not Available| CAP, ADJUSTING| 1| | 468| CA31708| KIT, O-RING (INCLUDES: 414, 415, 424,

428-430, 437, 446, 454

| 1
403| CA125521| NUT, LOCKING (M25X1)| 1| | 469| CA7367| INJECTOR, CHEMICAL FIXED| 1
404| CA88953| SCREW, SET (M4X4)| 1| | 470| CA31556| KIT, REPAIR (INCLUDES: 418,425,428,436,437)| 1
408| CA45198| SPRING, PRESSURE| 1| | 471| CA76185| KIT, CHECK VALVE (INCLUDES: 443, 444,

| 1
410| CA49101| RETAINER. SPRING| 1| | 472| Not Available| BARB| 1
412| CA49103| STEM, PISTON| 1| | 476| Not Available| O-RING, BARB – 70D| 1
414| CA129638| BACK-UP-RING, PISTON STEM| 1| | 477| Not Available| BALL| 1
415| CA49104| O-RING, PISTON STEM –

90D

| 1| | 478| Not Available| SPRING| 1
423| CA49105| RETAINER, VALVE| 1| | 479| Not Available| ORIFICE| 1
424| CA49106| O-RING, VALVE RETAINER –

70D

| 1| | 480| Not Available| BODY| 1
425| CA49102| RETAINER, PISTON| 1| | 468| CA31708| KIT, O-RING (INCLUDES: 414, 415, 424,

428-430, 437, 446, 454

| 1
426| CA49107| WASHER| 1| | 469| CA7367| INJECTOR, CHEMICAL FIXED| 1
428| CA26133| O-RING, PISTON RETAINER

– 80D

| 1| | 480| Not Available| BODY| 1
429| CA22056| O-RING, VALVE RETAINER –

70D

| 1| | 483| CA76176| KIT, INJECTOR REPAIR (INCLUDES: 476, 477, 478)| 1
430| CA49123| BACK-UP-RING, VALVE RETAINER| 1| | | | |
435| CA49383| VALVE/BALL ASSEMBLY| 1| | | | |
436| CA49384| SEAT| 1| | | | |
437| CA13965| O-RING, SEAT – 70D| 1| | | | |
438| CA49386| SEAT, CHECK VALVE| 1| | | | |

Limited Warranty

Dear Valued Customer: The NorthStar Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits of its high performance. By purchasing a NorthStar product, you show a desire for quality and durability. Like all mechanical equipment, this unit requires a due amount of care. Treat this unit like the high-quality piece of machinery it is. Neglect and improper handling may impair its performance. Please thoroughly read the instructions and understand the operation before using your product. Always contact NorthStar Product Support at 1-800-270-0810 before having any service or warranty work performed, as some services performed by parties other than NorthStar-approved service centers may void this warranty. This warranty is instead of any other warranty expressed or implied and NorthStar assumes no other responsibility or liability outside that expressed within this warranty.

Limited Warranty
NorthStar shall warranty any piece of equipment manufactured, or parts of equipment manufactured, to be free from defects in material or workmanship for a period of:

NorthStar Warranty

Item #| Consumer Warranty Period| Commercial Warranty Period
157119

157120

| 4 years from the date of purchase by the years| ears from the date of purchase by the user
Engine Warranty
Item #| Consumer Warranty Period| Commercial Warranty Period
157119

157120

| 3 years from the date of purchase by the user| 3 years from the date of purchase by the user

“Consumer use” means personal residential household use by a consumer. “Commercial use” means all other uses, including use for commercial, income- producing, or rental purposes or when purchased by a business. This warranty applies to the original purchaser of the equipment (verification of purchase, in the form of a receipt, is the responsibility of the buyer), is non- transferable, and covers parts and labor. Parts will be replaced or repaired at no charge, except when the equipment has failed due to lack of proper maintenance. If a part is no longer available, the part may be replaced with a similar part of equal function. Any misuse, abuse, alteration, or improper installation or operations will void the warranty. Determining whether a part is to be replaced or repaired is the sole decision of NorthStar. NorthStar will not provide for the replacement of complete products due to defective parts. Any costs incurred due to the replacement or repair of items outside of a NorthStar-approved facility are the responsibility of the buyer and are not covered under warranty. Transportation costs to and from the service center are the responsibility of the customer. In addition to the normal warranty, NorthStar shall warrant any normal wear item from defects in material or workmanship for 90 days from the date of purchase by the user. Normal wear items include but are not limited to, nozzles, quick-connect fittings, valves, seals, hoses, springs, O-rings, unloader valves, and filter elements.

This warranty specifically excludes the following; failure of parts due to damage caused by accident, fire, flood, windstorm, acts of God, applications not approved by NorthStar in writing, corrosion caused by chemicals, use of replacement parts that do not conform to manufacturer’s specifications, damage related to rodent and/or insect infestation and damage caused by vandalism. Additional exclusions: loss of running time, inconvenience, loss of income, or loss of use, including any implied warranty of merchantabilityorf fitness for a specific use. Also, Outdoor Power Equipment needs periodic parts and service to perform well, and this warranty does not cover instances when normal use has exhausted the life of a component or the engine. This warranty does not cover any personal injury or damage to surrounding property caused by failure of any part. Repair or replacement of parts does not extend the warranty period. The engine warranty is covered under the terms and conditions as outlined by the engine manufactures warranty contained herein and is the sole responsibility of the engine manufacture. Normal engine maintenance such as spark plugs, air filters, adjustments, fuel system cleaning and obstruction due to build is not covered by this NorthStar warranty. Please fill in the following information and have it on hand when you call in on a warranty claim.

• Customer Number: __
• Date of Purchase: ___
• NorthStar Serial Number: _____
• Item Number: __

WARNING: This product can expose you to chemicals including gasoline, which is known to the State of California to cause cancer, and carbon monoxide, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Assembled by
Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com

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