NorthStar 157495 Owner's Manual

Industrial

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Table Of Contents

Table of Contents

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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.

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

Owner's Manual

Industrial Water Heater

Equipment Protection Quick Facts

Call NorthStar Product Support 1-800-270-0810

ITEM NUMBER: 157495

SERIAL NUMBER: _____________

M157495U

Table of Contents

Summary of Contents for NorthStar 157495

Page 1: Equipment Protection Quick Facts
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.
Page 2: Table Of Contents
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.
Page 3 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...
Page 4: About Your Pressure Washer
About Your Pressure Washer Thank you for purchasing a NorthStar Industrial Water Site Selection. This unit is made for OUTDOOR USE Heater! It is designed for long life, dependability, and top ONLY unless specific exhausting guidelines are met. performance. Read additional details in the “Before Each Use” section of this manual.
Page 5: Specifications
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.
Page 6: Component Identification
Component Identification Water Outlet: Attach your high pressure hose. Fuel Filter: Filter in fuel line that removes water Control box: Box to house control switches. and screens out dirt and debris from fuel. Heat Switch: When turned to ON position water Exhaust Vent: Provides an exit for burner heater will begin heating with proper water flow.
Page 7: Special Equipment Safety Features
Special Equipment Safety Features 1. High Pressure Safety Device 2. Thermostat The high pressure safety device (rupture disc) is a backup The thermostat is another safety feature that keeps safety feature. If the system’s pressure exceeds its limits, the outlet water temperature below 250F. the rupture disc will open and relieve system pressure.
Page 8: Important Safety Information
Important Safety Information Read all the instructions before using the product. Make sure that your existing hose, gun, and all accessories are rated for high temperatures and the appropriate pressure. To reduce the risk of injury, close supervision is necessary when the product is used near children. Do not allow irresponsible use by children.
Page 9: Grounding Instructions
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.
Page 10: Safety
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 DANGER not avoided, will result in death or serious injury.
Page 11: Safety Decal Locations
Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.
Page 12: Un-Packing Instructions
Un-Packing Instructions Inspect water heater immediately after delivery for missing parts or damage. For missing or damaged components, contact Product  Support at 1-800-270-0810. Handle & Grip Qty-2 Wheel Qty-2 Hardware Bag Qty-1 Water Heater Qty-1 Remove 2 retaining blocks.
Page 13: Hardware Bag
Hardware Bag Owner’s Manual 4X - 5/16 X .75” Flange Bolt 4X - 5/16 Flange Nut 2X - 5/8 X 3.5” Hex Bolt 2X - 5/8 Hex Nut 2X - 5/8 Jam Nut...
Page 14: Assembly
Assembly To attach handles, use: 5/16 X .75” Flange Bolts (4x) 5/16 Flange Nuts (4x) To attach wheels: 1.) Slide 5/8 X 3.5” bolt through hub of wheel. 2.) Spin 5/8 Jam Nut onto bolt. Do not tighten against wheel. 3.) Slide bolt through hole in frame, secure with 5/8 Hex Nut.
Page 15: Before Each Use
Before Each Use After Machine Has Cooled: Step 1: Inspect Equipment 1. Remove burner fuel cap. Electrical 2. Add fuel through the fill opening. Do not overfill.  Inspect power cord before using. Do not use if cord Allow at least 1/2” of empty space below fill neck is damaged.
Page 16: For Indoor And Outdoor Uses
For Indoor and Outdoor Uses 1.) Turn the pump and heat switches on (Refer to Placement of the Machine: “Operation” for details). Have someone operate the Where it will NOT be exposed to rain, snow, or spray gun so the burner fires. ...
Page 17: Extension Cord And Usage
1. For a product rated at 125 volts or less, the GFCI is built into the power cord plug. This GFCI device provides additional protection  from the risk of electric shock. If replacement of the plug or cord is needed, use only identical replacement parts.
Page 18: Operation Instructions
 B.) Position the machine on a solid surface, with less water heater. Your NorthStar Water Heater is equip- than a three degree slope, and so it is protected ped with quick connect fittings, as are all NorthStar from external damage. pressure washers. Slide the collar back on the inlet ...
Page 19: To Start
Only use 5. Turn Your Pressure Washer ON NorthStar pressure washer chemicals or chemicals 1. Follow your pressure washer’s manual for its start-up specifically formulated for pressure washers, and procedure.
Page 20: Maintenance & Repair
All mechanical equipment, no matter how well designed, will need repairs. A NorthStar water heater is no exception. At times, a NorthStar water heater may be inoperable because repairs are required. NorthStar Customer Service will...
Page 21: Coil Descaling
7. Coil Descaling 8. Coil Desooting In hard water areas, scale build-up within the heating Poor grades of fuel oil or inadequate combustion air coil will occur. Scale deposits will decrease the water will cause heavy soot build-up on the outside surface temperature rise and may eventually clog the heating of the heating coil.
Page 22: Electrodes
9. Electrodes 4.Clean off carbon deposits that may have accumulated on the tips of the electrodes. On a yearly basis the electrodes should be inspected 5. Reset the spacing as shown below. and any necessary adjustments made. 1. Block up the front of the water heater 6 inches. 4 Nuts 2.
Page 23 5. Internal Sections 3) Slide out the “Shuttle Assembly”. If the magnet in the shuttle assembly is damaged or missing, replace the entire flow switch assembly. To order a replacement flow switch assembly, call Northstar Product Support at 1- 800-270-0810.
Page 24 To order a replacement flow switch The screws (QTY 5) in the “Enclosure” are assembly, call Northstar Product Support at 1- 800-270-0810. If the O-ring is not damaged, re- TORX T10. install the “Cap” onto the “Body”. Torque the cap to 100lb-in.
Page 25: Moving And Handling Instructions
Moving and Handling Instructions 1. Maneuvering Your Water Heater 2. Lifting Your Water Heater 1. Lift handles with both hands until the wheels come 1.To reduce risk of injury, it is recommended to use a in contact with the ground and the frame is lifted off hoist to lift this water heater.
Page 26: Troubleshooting Guide
Use less hose. Move machine closer to the work. Chemical strainer or injector clogged Clean the strainer and injector. Always start with a clean detergent container. Run clean water through the injector after each use. Any Questions, Comments, Problems or Parts Orders NorthStar Product Support 1-800-270-0810...
Page 27: Parts Explosion- 157495- Rev U
Parts Explosion- 157495- Rev U...
Page 28: Parts List-157495- Rev U
Parts List–157495- Rev U ITEM PART# DESCRIPTION 1/2” NPT Steel Street Elbow 5027 1/2” FPT Swivel x 3/8” MPT Straight 38379 797121 Flow Switch 1/2” Tee, FXFXM, Steel 787394 794626 Rupture Disc-8500, Kit High Pressure Inlet Hose, 3/8” X 5’...
Page 29: Wiring Diagrams
Wiring Diagrams...
Page 31: Limited Warranty
Any misuse, abuse, alteration or improper installation or operations will void warranty. Determining whether a part is to be replaced or repaired is the sole decision of NorthStar. NorthStar will not provide for replacement of complete products due to defective parts.
Page 32: California Proposition 65 Information
California Proposition 65 Information WARNING : This product can expose you to chemicals including gasoline engine exhaust, 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.