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M157494H
ITEM NUMBER: 157494
SERIAL NUMBER:
Volts:______ Amp:______ Ph:_____
PSI:________ GPM:______
Max. Discharge Temperature:_____________
Proven Performance
K-BAR Industries, Faribault, MN, 55021
Installation, Operation, and Maintenance Manual
INDUSTRIAL WATER HEATER: Upgrades cold water pressure
washers into hot water/steam
cleaners.
To the Owner:
Thank you for purchasing a NorthStar water heater. Your machine is de
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Table of Contents Important Safety Instructions 2 Safety Features 12 Grounding Instructions 3 Maintenance Instructions 13-15 Extension Cords 3 Moving and Handling Instructions 16 Specifications 4 Long Term Storage 16 Machine Component Identification 5 Troubleshooting Guide 17 Installation Instructions 6-9 Parts Breakdowns 18-19 Operation Instructions 10-11 Wiring Diagrams 20-21 Important Safety Instructions WARNING -Risk of Injection or Injury to Persons - Do not direct discharge stream at perso
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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 c
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Specifications Item Number 157494 Max. Pressure Rating 3000 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. 4
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Machine Component Identification 157494 Description Ref # Description Ref # Description 1 Water Outlet 6 Fuel Tank 11 Safety Relief Valve 2 Control Box 7 Burner 12 Heating Coil 3 Heat Switch 8 Fuel Filter 13 Water Inlet (pressure washer) 4 Thermostat 9 Exhaust Vent 14 Power Cord (w/ GFCI) 5 Fuel Fill Cap 10 Flow Switch 5
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Installation Instructions I.) Unpack Separate and identify all components. Use the assembly instructions in this manual for assembly. Handle & Grip Qty-2 Wheel Qty-2 Hardware Bag Qty-1 Water Heater Qty-1 Remove 2 retaining blocks. 6
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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 7
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II.) Assembly Instructions 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. 5/8 Hex Nut 5/8 Jam Nut 5/8 X 3.5” Hex Bolt 1. Attach handles, see above. 2. Attach wheels, see above. 3. Remove water heater from the pallet. It is recommended that a hoist is used, or that two people lift
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III.) Getting Started V.) Oil Burner IMPORTANT: Proper initial installation of equipment Burner Air Adjustment: The oil burner is preset and performance tested at the factory (elevation 1100 feet). will assure more satisfactory performance, longer service life, and lower maintenance cost. A one-time initial correction of the burner for your location will pay off in economy, performance, and Make sure the water heater is on a level surface and in a extended service life. protected area where it i
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Operating Instructions Follow these instructions every time you use the water heater. I.) Pre-Operation 1. Connect electrical cord to NEMA receptacle, 5-15R. A.) Position the machine for easy access to all 2. Connect outlet of your pressure washer to inlet of the controls. water heater. Your NorthStar Water Heater is equip- B.) Position the machine on a solid surface, with ped with quick connect fittings, as are all NorthStar less than a three degree slope, and so it is pressure washers. Slid
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IV.) To Start DANGER: Do not point the spray wand at yourself or Adjustment Knob High Pressure Hose at any person. Bodily injury may result from hot Water Outlet water or water under high pressure. WARNING: Wear eye, ear, hand, foot, and skin Diluted protection at all times while operating this water Chemical heater. 1. Turn water supply ON. Chemical Injector 2. Squeeze the trigger to allow air to purge from the Strainer 00322 system. This step goes faster with the pressure nozzle removed. 2.
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Safety Features I.) Safety Relief II.) High Temperature Limit The safety relief valve is a backup safety feature. If the The high temperature limit, or thermostat, keeps the system’s pressure exceeds its limits, the safety relief outlet water temperature below 250 °F. valve will open and relieve system pressure. High Temp. Limit Safety Relief WARNING: If the safety relief valve ever discharges water, turn the unit off and do not use the machine. See a dealer or call Customer Service at 1-800-2
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Maintenance Instructions WARNING: Unauthorized machine modification or use of non-approved replacement parts may cause personal injury and/or property damage and will void the manufacturer warranty. 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 assist in these repairs as needed, but if an inoperable water heate
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VII.) Coil Descaling VIII.) Coil Desooting In hard water areas, scale build-up within the Poor grades of fuel oil or inadequate combustion heating coil will occur. Scale deposits will decrease air will cause heavy soot build-up on the outside the water temperature rise and may eventually clog surface of the heating coil. These deposits will the heating coil. insulate the coil. This will restrict the air flow 1. Mix scale remover in a 5 gallon bucket and through the coil, further aggravating t
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IX.) Electrodes 4.Clean off carbon deposits that may have On a yearly basis the electrodes should be accumulated on the tips of the electrodes. inspected and any necessary adjustments made. 5. Reset the spacing as shown below. 1. Block up the front of the water heater 6 inches. Electrodes 4 Nuts 1/8” 1/16” 7/16” 2. Remove the 4 nuts that attach the burner to the heating chamber. You do not have to disconnect the fuel lines or the electric cords, but be careful not to subject them to excessive st
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Moving and Handling Instructions I.) Maneuvering Your Water Heater II.) Lifting Your Water Heater 1. Lift handles with both hands until the wheels come in 1. To reduce risk of injury, it is recommended to use a contact with the ground and the frame is lifted off of hoist to lift this water heater. the ground. 2. Lift from four lifting points. 2. Push the water heater forward if it is being moved on 3. If the water heater is to be moved a short distance, the solid, smooth ground. (concrete, hard-
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Troubleshooting Guide Water Heater Will Not Run - No Power Causes Solutions Machine not plugged in Plug machine in. GFCI tripped Make sure machine is dry. Press RESET on the GFCI. Machine turned OFF Turn heat switch ON. Line circuit breaker tripped Check for tripped circuit breaker in building. GFCI Trips During Operation Causes Solutions Voltage too low Check the voltage. Extension Cord Make sure connections are dry and off of the ground. Check extension cord section on page 3 for more guide
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157494H 157494 Parts Breakdown 18
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157494H ITEM PART# DESCRIPTION QTY 1 5027 1/2” NPT Steel Street Elbow 1 2 38379 1/2” FPT Swivel x 3/8” MPT Straight 1 3 37537 Flow Switch 1 4 777347 3/8” NPT Street Tee 1 5 22392 Safety Relief Valve 1 6 37538 High Pressure Inlet Hose, 3/8” X 5’ 1 7 30822 Power Cord w/ GFCI, 15A, 115V 1 8 313108 3/8” Quick Coupler, Female 1 9 22502 Strain Relief, 1/2” NPT 4 10 305267 Nut, 1/2” NPT for Strain Relief 4 11 777312 Control Box 1 12 35198 Small Grommet 1 13 30501 1/4” Split Loom 44” 14 38126 Decal Shee
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