MA1578111N.

2
ITEM NUMBERS:
A1573701, A1573981, A1577541, A1578111, A1578171, A1578131, A1578181, A1578151, A1578201, A1578203, A1578173, A157711, A157712, A157594, A1577110, A15782030

Owners Manual
Pressure Washer Pump:
For high pressure cleaning machines.

WARNING
Read this manual.
Serious injury or death can result if safety instructions are not followed.

Pump is shipped with oil.

- Remove shipping plug and install vented fill cap. (Comet Pumps) - Remove shipping tape from pump oil fill cap. (Cat Pumps) - Remove shipping plug and install dipstick. (General Pumps) - Remove shipping plug and install dipstick. (NorthStar Pumps) - Remove shipping plug and install vented fill cap. (Powerhorse Pumps) - See pump oil cap section of this manual.

Closely inspect all components.

-If you have damaged components then: Contact the freight company that delivered the unit and file a claim. -If you have missing components then: Contact Customer Service at 1-800-270-0810.

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

Hazard Signal Word Definitions

Table of Contents Important Safety Rules ........................................4,5 Pump Oil Cap and Pump Component Identification 6 Operation Instructions .........................................7-9 Water Supply....7 Start-Up/Shut-Down Instructions8 Applying Chemicals.....9 Maintenance and Storage...................................10-12 Maintenance Mode and Maintenance Schedule10 Pump Oil Change....11 Long Term Storage.12 Winter Storage.12 Troubleshooting ..................................................13 Specifications ......................................................13 Parts Explosions ........................................................ 14 Pump Explosions ....................................................... 16

Important Safety Rules

WARNING
1.) Read owner's manual completely.
Serious injury or death can result if safety instructions are not followed. You must be 16 or older to operate this machine. Keep untrained people away.

2.) Skin puncture hazard.

High pressure fluid can inject under skin resulting in serious injury including amputation. Do not direct spray at people or animals. -If skin injection happens, seek IMMEDIATE surgical treatment. -Do not check for leaks with hand. Instead, use a piece of cardboard to check for leaks. -Do not use unit if exterior hose damage is evident. Make sure all fittings are tight before starting. Relieve system pressure before servicing. -Know how to stop engine and bleed pressures quickly. Be thoroughly familiar with the controls. -Make sure accessories meet the unit's temperature and pressure limits. -Stop engine, bleed pressure, and engage spray gun safety lock before leaving unit unattended.

3.) Risk of fire and explosion.

Hot exhaust fumes from engine can cause fire. Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. -Position muffler at least 7 feet from combustible objects. -Before adding fuel, stop the engine and keep heat, sparks, and flame away. Do not add fuel when engine is running or still hot. No smoking near engine. -Do not pump fuel directly into engine at gas station. Static charge can build and ignite fuel. Use a UL approved fuel container to transfer gas to the engine. Wipe up fuel spills immediately. -Only store and handle fuel outdoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. -Do not change or add to exhaust system. Fire can result. -Do not change or add fuel tanks or fuel lines. Fire can result. -Before each use, check fuel tank and fuel lines for leaks. Any fuel leak is a fire hazard. Fix any fuel leaks before starting engine. -During transportation take precautions to make sure pressure washer will not tip over and cause a fuel leak fire hazard.

4.) Poisonous gas.

This machine gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it. -ONLY run machine outdoors and away from air intakes. -NEVER run machine inside homes, garages, sheds, or other semi-enclosed spaces. These spaces can trap poisonous gases, EVEN IF you run a fan or open doors and windows. If you start to feel sick, dizzy, or weak while using this machine, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

Save These Instructions

4

Important Safety Rules

WARNING
5.) Risk of exposure to dangerous chemicals.
Serious injury or death can result if chemical manufacturer instructions are not followed. -Wear protective gloves when handling and cleaning with chemicals. -Understand all safety hazards and first aid for all chemicals being used. -When cleaning filters, check if chemicals have been used and take any precautions that are recommended by the chemical manufacturer. -Different chemicals may interact dangerously with each other, always follow chemical manufacturer directions before switching chemicals. -Calculate the correct amount of chemical to mix, dispose of excess chemical per the manufacturer instructions. -Never spray flammable liquids.

6.) Risk of electrocution.

Electricity can kill you. Keep water away from electrical outlets and electrical devices.

Save These Instructions

7.) Flying objects.

Small particles may fly out while spraying. Wear safety glasses. Serious eye injury can occur. Make sure nozzle is secure before squeezing trigger. If nozzle is not secure it will become a projectile.

8.) Fall hazard.

Pressure washer creates puddles and slippery surfaces. Keep good footing and balance. Serious injury can occur. -Wear footwear cabable of maintaining a good grip on wet surfaces. -Gun kicks back. Hold with both hands. -Do not overreach or stand on unstable supports. -Do not stand on ladders or scaffolding. -Do not place pressure washer on soft or unstable ground.

CAUTION
1.) Hot muffler.
You can be burned by muffler. Do not touch.

Pump Oil Cap and Pump Component Identification

Operation Instructions
Water Supply 1.) Make sure the water supply is clean. Debris can cause excess pump wear and reduce performance. 2.) An insufficient water supply will damage your pump. Make sure the water supply is steady and is 20% over the rated flow of your pump. Use a stopwatch to time how long it takes to fill a 5 gallon bucket with your garden hose. The bucket must fill faster than the times listed in the table below. Model A157711 A1577541 A1578111 A1578171 A1578173 A1573701 A1578131 A1578181 A1573981 A157712 A1578151 A1578203 A1578201 A157594 A1577110 A15782030 Time to fill 5 gallon bucket 100 seconds 100 seconds 100 seconds 100 seconds 100 seconds 84 seconds 84 seconds 84 seconds 63 seconds 63 seconds 72 seconds 72 seconds 72 seconds 63 seconds 100 seconds 50 seconds

3.) The water supply garden hose must have an inside diameter of at least 5/8. If the hose is more than 100 ft. long, the diameter must be at least 3/4. 4.) Never use a reservoir tank as a water source. Drawing water out of a tank may cause pump cavitation and damage to your pump. This pressure washer is designed for a pressurized water source such as a city water faucet. However, the water source pressure must not exceed 115 psi (8 bar). 5.) Always use a flexible rubber hose for your water supply. Do not use rigid piping.

Operation Instructions

Start-Up Instructions 1. Attach garden hose to water inlet. 2. Attach pressure hose to water outlet and gun. 3. Attach spray gun to lance. 4. Turn water supply ON. 5. Squeeze trigger to purge air from pump. 6. Insert nozzle. 7. Start engine. Shut-Down Instructions 1. Turn engine OFF. 2. Turn water supply OFF. 3. Squeeze trigger to relieve system pressure. 4. Remove garden hose. 5. Remove pressure hose. 6. Turn fuel valve OFF (if equipped).

WARNING
Skin puncture hazard.
High pressure fluid can inject under skin resulting in serious injury including amputation. Do not direct spray at people or animals. -If skin injection happens, seek IMMEDIATE surgical treatment. -Do not check for leaks with hand. Instead, use a piece of cardboard to check for leaks. -Do not use unit if exterior hose damage is evident. Make sure all fittings are tight before starting. Relieve system pressure before servicing. -Know how to stop engine and bleed pressures quickly. Be thoroughly familiar with the controls. -Make sure accessories meet the unit's temperature and pressure limits. -Stop engine and bleed pressures before leaving unit unattended.

Operation Instructions
Applying Chemicals 1.) 2.) 3.) 4.) 5.) Install the black nozzle to spray chemicals onto the cleaning surface. Start the pressure washer according to the start-up instructions. Submerge the chemical hose in cleaning solution. Squeeze the spray gun trigger. The chemical injector will draw the chemical into the water stream. Apply chemicals evenly onto the cleaning surface. Allow the chemicals to react with the dirt, then clean at high pressure with green nozzle. 6.) Never use more chemical than is necessary to clean the surface. 7.) To clean the chemical injector, draw water through the strainer until all the chemical is purged from the system.
pump

pump outlet

pump inlet

diluted chemical strainer

WARNING
Risk of exposure to dangerous chemicals.
Serious injury or death can result if chemical manufacturer instructions are not followed. -Wear protective gloves when handling and cleaning with chemicals. -Understand all safety hazards and first aid for all chemicals being used. -When cleaning filters, check if chemicals have been used and take any precautions that are recommended by the chemical manufacturer. -Different chemicals may interact dangerously with each other, always follow chemical manufacturer directions before switching chemicals. -Calculate the correct amount of chemical to mix, dispose of excess chemical per the manufacturer instructions. -Never spray flammable liquids.

Maintenance and Storage

Maintenance Mode Before performing any maintenance on the pressure washer, it must be placed in maintenance mode. 1.) Turn off engine. 2.) Turn off water supply. 3.) Squeeze trigger to relieve system pressure. 4.) Shut off fuel valve. 5.) Unplug spark plug wire from spark plug, (see engine owners manual). Maintenance Schedule What to Check Inlet Filter Pressure Hose When To Check Each Use Each Use What to Do Visually inspect and clean inlet filter with clear water. Visually inspect pressure hose and hose couplings. Replace hose if any of the following is evident: hose coupling is damaged, wire mesh is exposed or damaged, hose is permanently kinked or flattened, outer hose cover is blistered or loose. Tighten any loose bolts. See engine manual for oil change instructions Change pump oil. See pump oil change instructions on next page.

Bolts Engine Oil Pump Oil

Each Use See engine manual After 1st 50hrs, then 3mo/500hr

10

Maintenance and Storage

Pump Oil Change
1.) Place a suitable container below the pump to catch used oil, then remove the oil fill cap and oil drain plug. 2.) Allow the used oil to drain completely, then reinstall the drain plug and tighten securely. 3.) Please dispose of used oil in a manner that is compatible with the environment. We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash, pour it on the ground or down the drain. 4.) With the pump in a level position, fill to the half way point on the oil sight glass (see pump oil capacities below). For Comet or NorthStar pumps use Universal Tractor Transmission Oil or Mobil1 synthetic oil (15W50). For Cat pumps use SAE30 non-detergent oil or Cat Pump Oil Item# 22158. For General Pumps use SAE30 non-detergent oil. For Powerhorse pumps, use SAE30 non-detergent.
A1577541 fill cap A1573701 fill cap A1573981 fill cap

drain plug Oil capacity: 3.4 oz. (.10 L) A1578111 fill cap

drain plug

sight glass

Oil capacity: 11 oz. (.33 L) A1578131 fill cap

sight glass drain plug Oil capacity: 14 oz. (.41 L) A1578151 fill cap

drain plug

sight glass

drain plug

sight glass

Oil capacity: 4.3 oz. (.13L) A1578171 fill cap

Oil capacity: 5.7 oz. (.17L) A1578181 fill cap

sight glass drain plug Oil capacity: 10.3 oz. (.30L) A1578201 fill cap

sight glass drain plug Oil capacity: 8.5 oz. (.25L) A157594 fill cap

sight glass drain plug Oil capacity: 10.2 oz. (.30L) A1578173 fill cap drain plug sight glass

Oil capacity: 22.6 oz. (.62L) A1578203 fill cap

sight glass drain plug Oil capacity: 22.6 oz. (.62L) A15782030 fill cap

sight glass

drain plug Oil capacity: 11 oz. (.32L) A157711 & A1577110 dipstick breather plug

drain plug Oil capacity: 10.3 oz. (.30L) A157712 fill cap

sight glass

sight glass

drain plug Oil capacity: 19 oz. (.56L)

drain plug Oil capacity: 5 oz. (.15L)

sight glass drain plug Oil capacity: 20.3 oz. (.60L)

FIG04752

11

Maintenance and Storage

Checking Oil Level for A157711 & A1577110 1.) Turn off engine, allow it to cool and disconnect the spark plug wire. 2.) Twist the dipstick cap until the arrow on the cap lines up with the arrow on the breather plug. Remove the dipstick from the breather plug. Then remove the breather plug from the pump. 3.) Wipe the dipstick off with a clean dry cloth. Insert the dipstick into the pump housing and remove it. The oil level should be at least to the lower L notch on the dipstick, but not above the upper H notch. Add above recommended oil as needed. 4.) Thread the pump breather plug tube back into the pump housing. 5.) Align the arrow on the dipstick cap with the arrow on the breather plug tube, insert it, and twist it to secure. Reconnect the spark plug.
Dipstick Cap

Shipping Plug

Pump Breather Plug Tube

Pump Housing

Long Term Storage Follow the engine owners manual for storing the engine. Winter Storage Protect your pump, hose, and gun from freezing. Items needed: 12 piece of garden hose or equivalent, funnel and RV antifreeze (approximately 6 oz.) 1.) Follow the storage instructions listed above. 2.) Disconnect spark plug cable. Make sure the engine start switch is OFF, and the fuel valve is OFF. 3.) Attach the garden hose with funnel to the pump inlet (see illustration). 4.) Pour RV antifreeze into the funnel, pull the engine recoil until antifreeze comes out the pump outlet. 5.) Drain all water from the high pressure hose. Depress trigger on gun and drain all water out of gun/lance.

RV Antifreeze

Funnel

Hose Water Inlet 12

Troubleshooting

Problem
Engine will not start Low/Surging pressure or no water flow No chemical injection SOLUTION: A,B SOLUTION: C,D,E,F,G,H SOLUTION: I,J,K,L

Cause
A- Low oil shutdown B- Engine starting instructions not followed C- Insufficient water supply D- Plugged pump inlet filter E- Wrong nozzle F- Plugged nozzle G- Worn nozzle H- Leak in pressure hose I- Wrong nozzle J- Back pressure from extra long discharge hose K- Leak in chemical siphon hose L- Chemical strainer not submerged

Solution
See engine manual for oil requirements See engine manual for starting instructions See water supply section of this manual See maintenance section of this manual Make sure high pressure nozzle is being used Remove nozzle, check for blockage Replace nozzle Replace pressure hose Make sure chemical nozzle is being used Try shorter hose Replace hose use hose clamps if necessary Make sure strainer is completely submerged

Specifications
Item # A1573701 A1577541 A1578111 A1578171 A1573981 A157711 A1578173 A1578131 A1578181 A157712 A1578151 A1578201 A1578203 A157594 A1577110 A15782030 PSI 2500 2700 2700 2750 3000 3000 3000 3000 3200 3500 4000 4000 4000 4000 3000 3000 GPM 3.0 2.5 2.5 2.5 4.0 2.5 2.5 3.0 3.0 4.0 3.5 3.5 3.5 4.0 2.5 5.0 Max Water Temp Power 5-6.5hp Gas engine 5-6.5hp Gas engine 5-6.5hp Gas engine 5-6.5hp Gas engine 11-13hp Gas engine 5-6.5hp Gas engine 5-6.5hp Gas engine 8-9hp Gas engine 8-9hp Gas engine 11-13hp Gas engine 11-13hp Gas engine 11-13hp Gas engine 11-13hp Gas engine 15hp Gas engine 5-6.5hp Gas engine 11-13hp Gas engine Shaft Size 3/4 keyed 3/4 keyed 3/4 keyed 3/4 keyed 1 keyed 3/4 keyed 3/4 keyed 1 keyed 1 keyed 1 keyed 1 keyed 1 keyed 1 keyed 1 keyed 3/4 keyed 1 keyed Nozzle Size #3.5 #3.0 #3.0 #3.0 #4.5 #3.0 #3.0 #3.5 #3.5 #4.0 #3.5 #3.5 #3.5 #4.0 #3.0 #5.5

140F

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.

13

Parts Explosions Rev N.2

A1577541 A1578203 A1573701 A1573981

A1578111

A1578131

A1578151

A1578201

A157712

A157594

A1578173

A157711 & A1577110

A15782030

A1578181

A1578171

14

Parts Explosions Rev N.2 (contd)

Item Part# A1577541 A1573701 A1573981 A1578111 A1578171 A1578131 A1578181 A1578151 A1578201 A1578173 A1578203 A157711 A157712 A157594 A1577110 A15782030 777915 2 221009 4027 3 38596 35169 777340 777834 777165 38584 777347 35918 777836 22393 35814 782121 35813 82141 82142 82143 777165 221222 777837 2296 788419 777839 777840 777119 2264 777410 Inlet Filter 1/4 x 1/4 Hose Barb Fitting 1/4 Hose Clamp 1/4 Braided Chem. Hose (Sold by foot) Easy Start Valve 3/8 Street Tee Thermal Valve Pop Off Valve Manifold Inlet 3/16 x 1.5 Shaft Key 3/16 x 2 Shaft Key 1/4 x 1-3/4 Shaft key 1/4 Braided Chem. Hose (Sold by foot) Chemical Strainer 3/8 plug 3/8 hex nipple Unloader Valve 1/2Nipple x 3/8 MPT 1/2 Barb x 1/4 MPT 1/2 Hose Clamp 1/2 PVC Hose 3/8 Street Elbow 1 Quick Connect Outlet Plug 1 Description Comet VRX Pump General TP 2530 General EZ3040 Comet BXD Pump Cat 4DNX Pump Comet AXD Pump Cat 3SPX Pump Comet ZWD Pump Cat 66DX Pump NorthStar NSLW Pump NorthStar NSZW Pump 3025A Pump 1807A Pump Cat 66DX Pump 3025A Easy Start Pump NorthStar NSSHFD Pump Qty Model A1577541 A1573701 A1573981 A1578111 A1578171 A1578131 A1578181 A1578151 A1578201 A1578173 A1578203 A157711 A157712 A157594 A1577110 A15782030 1573701, 3981, 8111, 8171, 8131, 8181, 8151, 8201, 8173, 8203, 712, 594, 7710, 82030 A1577541 A1577541, 3701, 3981,8111,8131, 8151,8173,8203,711,712, 7710 A1578171, 8181 A1578201, 594, 82030 A1578171, 181, 8201, 82030 A1578171, 8181, 8201, 82030 A1578171, 8181, 8201, 82030 A1578171, 8181, 8201, 82030 A1578171, 8181 8201, 82030 A1578171, 8181 A1578201, 3701, 3981, 82030 A1578181, 8201, 82030 A1573701 A1573981 A1573701, 3981 A1578171, 8173 A1573701 A1578181, 8131, 3981, 8151, 8201, 82030 All All A1578181 A157594 A157594 A157594 A157594 A157594 A157594 A15782030

4 5 6 7 8 9 10 18 19 20 21 22 23 24 25 26 27 28 29

1 2 1.2ft 1 1 1 1 1 1 3ft 1 1 1 1 1 1 2 1 ft 1

15

Comet VRX Pump Exploded View

Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13

Code 2801 0079 1210 0218 0424 0402 1210 0475 3230 0031 1802 0217 1002 0116 2803 0395 1223 0093 2800 0096 3218 0351 3609 0195 3202 0276

Description Thermo Valve Cover O-Ring Thermal Valve Body O-Ring Sensor Spring Suction Filter Quick Coupler Wing Nut Straight Hose Tail Kit Pump Manifold Screw Plug

Qty 1 1 1 1 1 1 1 1 1 3 1 3 1

Ref # 39 40 41 42 43 44 45 46 47 48 49 50 51

Code 2432 0018 1802 0213 2409 0099 0009 0267 5026 0260 1210 0391 1210 0463 2409 0102 1802 0218 5026 0262 1210 0465 0801 0066 1210 0170

Description Pump Crankcase Piston Spring Piston Ring Piston Kit O-Ring O-Ring Check Valve Spring Check Valve Kit O-Ring Detergent Injector O-Ring

Qty 1 3 3 3 3 1 1 1 1 1 1 1 1

16

Comet VRX Pump Exploded View

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1802 0219 2811 0117 3605 0104 1210 0392 1210 0470 0009 0272 Regulation Valve Spring Washer Special Screw O-Ring O-Ring Ring 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 3 3 3 3 3 3 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 72 73 74 100 103 104 105 1410 0322 0204 0051 1802 0216 3003 0033 1210 0466 1210 0465 2800 0104 5026 0261 0436 0020 0001 0460 1210 0394 0438 0081 0031 0012 0019 0112 0403 0156 Detergent Injector Kit Bushing Spring Ball O-Ring O-Ring Detergent Straight Hose Tail Complete Detergent Kit Axial Ball Bearing Throu-Eccentric Shaft O-Ring Ball Bearing Pump Crankshaft Oil Seal Pump Crankcase 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 4 1 3 1 1

1210 0055 O-Ring 3021 0034 0015 0187 1210 0465 0009 0112 1215 0334 3009 0136 1210 0170 3003 0032 5026 0269 1220 0061 1220 0062 3302 0279 1241 0068 0009 0274 2811 0004 0009 0270 0019 0111 1220 0061 Elastic Pin Valve Rod O-Ring Backup Ring Regulation Valve Kit Regulation Valve Seal O-Ring Ball Regulation Valve Seat Kit Delivery Valve Delivery Valve Plug Packing Anti-Extr. Ring Washer Packing Retainer Oil Seal Suction Valve

3200 0071 Plug 2417 0064 1210 0492 0604 0015 3016 0042 3625 0062 0009 0225 3000 0781 5026 0276 3200 0093 Extension O-Ring Nut Support Screw Anti-Extr. Ring Oil Seal Spacer Thermo Valve Kit Oil Tap Kit

Complete Valve Kit

(50260270) Part # 30 31 38 Code 1220 0061 1220 0062 1220 0061 Qty 2 1 3

Piston Seal Kit

(502602556)

Part # Code Qty 33 1241 0068 3 34 0009 0274 3

17

General Pump Triplex 2530 Exploded View

*Unloader not shown

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PART # 51.0106.22 98.2100.00 90.3833.00 51.2091.02 90.1565.00 98.2041.00 51.1200.41 96.6938.00 99.1943.00 90.3841.00 36.2003.66 36.2001.76 94.7376.00 36.2025.51 90.3847.00 98.2216.00 36.7115.01 51.1000.51 90.2620.00 51.0800.70 90.3604.00 90.3835.00 97.5968.00 20.2128.35 98.2103.00 92.2216.00 96.7008.00 51.0400.09 90.3572.00 90.5022.00 96.0707.00 97.0310.00 51.1600.22 99.1867.00 DESCRIPTION CRANKCASE PLUG, 3/8 O-RING PROTECTOR OIL SEAL PLUG, 1/4 MANIFOLD WASHER SCREW O-RING VALVE SEAT VALVE PLATE SPRING VALVE CAGE O-RING VALVE CAP VALVE ASSEMBLY HEAD RING PACKING PACKING RETAINER O-RING O-RING SIGHT GLASS NEEDLE BEARING OIL DIP STICK NUT WASHER PLUNGER, 15mm O-RING BACK UP RING FLINGER WASHER CONNECTING ROD PIN CRANKCASE COVER SCREW QTY 1 1 1 1 3 1 1 8 8 6 6 6 6 6 6 6 6 3 3 3 3 3 1 1 1 3 3 3 3 3 3 3 1 4 ITEM 35 36 37 49 50 51 52 53 54 55 56 57 58 59 PART # 90.3917.00 51.0301.22 51.0500.56 99.2730.00 96.7014.00 10.0346.22 99.1867.00 96.6938.00 50.2115.51 90.4097.00 90.1644.00 90.0667.00 20.2835.21 51.0221.65 DESCRIPTION COVER O-RING CONNECTING ROD PLUNGER ROD SCREW, J34 OPTION WASHER, J34 OPTION FLANGE, J34 OPTION SCREW WASHER SPACER O-RING OIL SEAL SNAP RING BEARING CRANKSHAFT QTY 1 3 3 4 4 1 4 4 1 1 1 1 1 1

VALVE KIT
ITEM 10 11 12 13 14 123 PART # 90.3841.00 36.2003.66 36.2001.76 94.7376.00 36.2025.51 QTY 6 6 6 6 6

SEAL KIT
ITEM 18 19 21 22 97 PART # 51.1000.51 90.2620.00 90.3604.00 90.3835.00 QTY 3 3 3 3

18

General Pump Triplex EZ3040 Exploded View

*Unloader not shown

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22 23 24 25 26 27 28 29 30 31 32 33 34 PART # 44.1200.41 99.3175.00 96.7014.00 90.3841.00 36.2003.66 36.2001.76 94.7376.00 36.2025.51 90.3847.00 98.2226.00 36.7115.01 99.1807.00 50.1500.74 44.2118.01 90.4097.00 91.8328.00 90.1614.00 44.0100.22 98.2103.00 44.0500.66 44.0300.22 90.3920.00 44.1600.22 99.1837.00 90.3585.00 98.2041.00 97.7340.00 96.7350.00 90.5022.00 90.3572.00 52.0400.09 96.7008.00 DESCRIPTION MANIFOLD SCREW WASHER O-RING VALVE SEAT VALVE SPRING VALVE CAGE O-RING CAP SCREW VALVE ASSEMBLY SCREW BEARING COVER SPACER O-RING BALL BEARING OIL SEAL CRANKCASE OIL DIPSTICK PISTON GUIDE CONNECTING ROD O-RING REAR COVER SCREW O-RING CAP SCREW PIN WASHER ANTI-EXT. RING O-RING PISTON WASHER QTY 1 8 8 6 6 6 6 6 6 6 6 4 1 1 1 1 3 1 1 3 3 1 1 5 1 1 3 3 3 3 3 3 ITEM 35 40 41 42 43 44 45 46 47 48 49 50 51 75 76 77 78 81 82 83 84 PART # 92.2216.00 90.3612.00 44.0800.70 52.2166.70 90.2622.00 90.2620.00 51.1000.51 98.2100.00 98.2176.00 96.7380.00 96.7514.00 98.1966.00 90.2617.00 90.0635.00 44.0209.65 91.8568.00 90.4097.00 10.0518.22 90.1690.00 96.6938.00 99.1912.00 DESCRIPTION NUT O-RING PACKING RETAINER INTERMEDIATE RING PACKING PACKING HEAD RING CAP SCREW CAP SCREW WASHER WASHER CAP SCREW SEAL, LOW PRESSURE RETAINING RING CRANKSHAFT ROLLER BEARING O-RING FLANGE FOR GAS ENGINES OIL SEAL WASHER SCREW QTY 3 3 3 3 3 3 3 1 1 1 1 1 3 1 1 1 1 1 1 4 4

VALVE KIT
ITEM 4 5 6 7 8 123 PART # 90.3841.00 36.2003.66 36.2001.76 94.7376.00 36.2025.51 QTY 6 6 6 6 6

SEAL KIT
ITEM 40 41 42 43 44 45 51 130 PART # QTY 90.3612.00 1 44.0800.70 1 52.2166.70 1 90.2622.00 1 90.2620.00 1 51.1000.51 1 90.2617.00 1

19

Comet BXD 2530G Pump Exploded View

20

Comet BXD 2530G Pump Exploded View

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Part # CO3202001800 CO1215035400 CO1802021700 CO3230003100 Not Available Not Available Not Available CO3202001800 CO1802022700 CO1210046300 CO3003003300 CO1210046300 CO3202031900 CO1215058600 CO1817006400 CO1220005800 CO1210041500 Not Available CO3604002800 Not Available Not Available CO1210015100 CO3202023600 CO2816008800 CO0436001700 CO0001052800 Not Available CO0438010300 Not Available CO0019003400 CO1210056100 CO3201002700 CO1210004800 CO3200013800 Not Available CO2811000400 CO3607011900 Not Available Description Plug, 1/8 Thermal Valve, 3/8 Spring Thermal Feeler O-Ring Thermal Valve Body Thermal Valve Cap Plug, 1/8 Easy-Start Spring O-Ring Ball O-Ring Easy-Start Plug Unloader Unloader Knob Suct/Del Valve Assy Kit O-Ring Valve Seat Suct/Del Valve Suct/Del Valve Spring Suct/Del Valve Cage O-Ring Plug Piston Washer Ball Bearing Eccentric Shaft O-Ring Ball Bearing Hallow Shaft Oil Seal O-Ring Oil Sight Glass O-Ring Oil Cap Support Washer Hex Screw Gasket Disk Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 6 6 6 6 6 3 3 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 Ref # 39 40 41 42 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 100 101 Part # CO0009026700 CO1802027600 CO2409014100 CO0403017900 CO3609000500 CO1241005700 CO0009030900 CO1210007100 Not Available CO1241005900 CO1210014600 CO1209011700 CO3200010200 Not Available CO0009022400 CO1210009300 CO3202029400 CO3410031800 Not Available CO1210004000 CO1210004900 CO2409009100 CO1802019700 CO2409008600 CO1210046000 CO8102045000 CO1223010900 CO2800051100 Not Available Not Available CO1802018000 CO3003002600 Not Available CO2803043500 CO2803338000 CO5109066700 CO5025002700 Description Ring Spring Piston Pump Crankcase Screw Low Pressure Packing Packing Retainer O-Ring Anti-Extrusion Ring Packing + Ring O-Ring Gasket Oil Discharge Cap Suction Valve Plug Ring O-Ring Suction Valve Plug Kit Injector Body Kit Injector Body O-Ring O-Ring Check Valve Kit Check Valve Spring Check Valve O-Ring Water Filter Wing Nut Special Coupling Pump Manifold Screw Spring Ball Chemical Coupling Chemical Coupling Kit Outlet Coupling Piston Seal Kit Complete Valve Kit Qty 3 3 3 1 4 3 3 3 3 3 2 1 1 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1

21

Cat 4DNX Pump Exploded View

Ref# 5 8 10 11 15 20 24 25 27 32 33 37 38 48 49 53 64 65 70 90 98 99 100

P/N Not Available CA547153 CA14041 CA55337 CA14488 CA547048 Not Available CA549446 CA56084 CA547961 CA14179 CA92241 CA44428 CA44842 CA14179 Not Available CA46229 CA542402 CA47215 CA547091 CA46730 CA542405 CA46233

DESCRIPTION Screw Bearing Cover O-Ring, Bearing Cover Oil Seal Inner Ball Bearing Connecting Rod Oil Plug Cap Crankshaft Ball Bearing Cap O-ring for Oil Filter Cap Gauge, Bubble Oil w/Gasket Gasket, Flat Flex Oil Gauge Drain Plug O-Ring for Drain Plug Crankcase Crosshead Pin Plunger Rod Oil Seal Plunger Washer Retainer, Plunger Retainer, Seal

QTY 3 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3

Ref# 106 120 121 125 160 161 162 163 164 166 167 168 169 172 174 185 188 197 249 255 469 Kit#1 Kit#2

P/N Kit #1 Not Available CA13976 Kit #1 CA17428 CA547077 CA48361 CA43358 CA547076 CA547098 CA46865 CA543988 Kit #2 CA142807 CA547104 Not Available Not Available CA941516 CA30520 CA30516 CA7332 CA76975 CA76976

DESCRIPTION Seal Seal Case O-Ring for Seal Case Seal O-Ring, Inlet Seat, Inlet Back-up Ring O-Ring Seat, Discharge Valve Spring Retainer, Spring, Inlet Retainer, Spring, Discharge O-Ring for Plug Plug, Valve w/o-ring Head, Manifold w/Unloader Body Screw Inlet Fitting Assembly Adapter Mount Assembly Bolt Mount Assembly Chemical Fixed Injector KITS Seal Kit: Inclds: 98, 106, 121, 125 Valve Kit: Inclds: 160, 161, 162, 163, 164, 166, 167, 168, 169, 172

QTY 3 3 3 3 3 3 3 3 3 6 6 3 3 3 3 1 6 1 1 1 1 1 1

*One Kit will Complete One Pump*

22

Comet AXD Pump Exploded View

Part # 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Code 3218 0413 3609 0099 1210 0415 3009 0170 3604 0028 1802 0227 1205 0033 1210 0151 3202 0311 3609 0088 1004 0012 0402 0360 0402 0329 1210 0386 3019 0011 0009 0275 0438 0069 3200 0051

Description Brass Manifold Screw O-Ring Suct. /Del. Valve Seat Suct. /Del. Valve Spring Suct. /Del. Valve Cage O-Ring Cap + O-Ring Screw Crankcase Flange Transparent Cover Aluminum Cover O-Ring Outer Seeger Spacer Ball Bearing Oil Dipstick

Qty 1 8 6 6 6 6 6 6 6 3 1 1 1 1 1 1 1 1

Part # 63 64 65 66 67 68 69 70 71 73 74 75 76 77 78 79 80 81 23

Code 1210 0040 1210 0049 1802 0197 2409 0086 1210 0446 3410 0318 2409 0154 1210 0403 3009 0122 3002 0526 0009 0233 0009 0205 1210 0405 1210 0404 1210 0407 0204 0044 2409 0088 1210 0430

Description O-Ring O-Ring Spring Check Valve O-Ring Injector Body Kit Check Valve Kit Viton O-Ring Valve Seat Unloader Ball Ring Ring O-Ring O-Ring O-Ring Bushing Piston Rod O-Ring

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Comet AXD Pump Exploded View

19 20 23 24 25 26 28 32 33 34 36 37 38 39 40 41 44 45 47 49 50 61 62 0403 0195 1241 0105 1241 0057 0009 0374 1210 0333 0019 0103 2811 0084 2409 0151 3011 0014 0205 0050 1210 0441 3200 0007 1210 0561 0402 0357 3609 0032 3609 0032 3607 0119 3016 0023 0019 0102 0437 0045 0001 0645 1220 0167 3410 0316 Pump Crankcase Packing + Ring Packing Packing Retainer O-Ring Oil Seal Washer Piston Gudgeon Pin Con. Rod Assembly O-Ring Cap O-Ring Crankcase Cover Screw Screw Hexagonal Screw Flange Oil Seal Roller Bearing Eccentric Shaft Suct. /Del. Valve Assy kit Injector Body 1 3 3 3 3 3 1 3 3 3 1 1 1 1 4 4 4 1 1 1 1 6 1 82 83 84 85 86 87 88 89 90 91 92 93 102 103 104 105 106 107 108 150 151 153 0009 0205 0009 0207 1802 0182 3622 0030 1227 0022 0204 0046 1215 0403 1817 0064 1802 0180 3003 0026 2803 0424 2803 0435 2803 3380 1002 0158 1223 0108 2803 0395 1215 0328 1215 0443 0608 0032 5025 0030 5019 0686 5019 0687 Ring Spring Spacer Spring (Wire 3, 25) Stop Adjustable Nut Ring Nut Bushing Reg. Valve Kit + Seat Pressure knob Detergent Spring Detergent Ball Detergent Coupling Detergent Coupling Kit Outlet Quick Coupler Water Filter Wing Nut Special Coupling Thermal Valve Safety Valve External Easy Start Device Valve Kit Water Seal Kit Oil Seal Kit 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

24

Cat 3SPX Pump Exploded View

25

Comet ZWD Pump Exploded View

26

Comet ZWD Pump Exploded View

27

Cat 66DX Pump Exploded View

28

NorthStar NSLW Pump Exploded View

Part # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Code 3218 0424 3202 0018 3609 0014 1210 0046 3009 0087 3604 0017 1802 0177 1205 0025 1210 0048 3202 0315 3609 0088 1004 0012 0402 0329 1210 0386 3019 0011 0009 0275 0438 0069 3200 0051 0403 0199

Description Qty Brass Pump Manifold Kit 1 Plug 1 Screw 8 O-Ring 6 Suct. /Del. Valve Seat 6 Suct. /Del. Valve 6 Spring 6 Suct./Del. Valve Cage 6 O-Ring 6 Plug + O-Ring 6 Screw 3 Crankcase Flange 1 Aluminum Cover 1 O-Ring 1 Outer Seeger 1 Spacer 1 Ball Bearing 1 Oil Dipstick 1 Pump Crankcase 1 29

Part # 54 55 56 72 73 74 75 76 77 78 79 80 81 82 83 84 85 87 88

Code 2811 0084 3200 0007 2811 0086 0204 0072 1802 0279 1227 0051 3622 0049 0009 0367 2409 0148 0009 0365 1210 0613 1210 0614 0009 0366 0204 0071 1210 0615 1210 0616 3002 0673 3009 0164 1210 0603

Description Washer Cap Washer Bushing Spring Ring Nut Stop Adjustable Nut Spring Spacer Rod Ring O-Ring O-Ring Ring Bushing O-Ring O-Ring Support/Ball Valve Seat O-Ring

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

NorthStar NSLW Pump Exploded View

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 44 45 46 47 48 49 50 51 52 0009 0196 1241 0065 0009 0223 1241 0030 0009 0222 1210 0223 0019 0095 0600 0048 2811 0080 0202 0020 2812 0038 1210 0055 2409 0044 3011 0014 0205 0050 3019 0033 3201 0026 1210 0333 1210 0621 0402 0392 3609 0180 3609 0032 3607 0199 3016 0012 0019 0102 3020 0012 0204 0038 0437 0045 0001 0399 1210 0441 3200 0007 Packing Head Ring Packing Back Ring Packing Packing Retainer O-Ring Oil Seal Special Bolt Washer Ceramic Bushing Washer O-Ring Piston Guides Gudgeon Pin Con. Rod Assembly Outer Seeger Oil Indicator O-Ring O-Ring Cover Screw Screw Hexagonal Screw Flange Oil Seal Inner Seeger Bushing Bearing Eccentric Shaft O-Ring Cap 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 4 4 4 1 1 1 1 1 1 1 1 90 91 92 93 94 95 96 97 98 99 101 103 104 105 107 108 109 110 111 112 113 114 115 116 117 118 120 121 122 123 1215 0403 1817 0064 3410 0288 1210 0398 1210 0402 1802 0197 2409 0122 1210 0460 3410 0287 2409 0123 1220 0030 1802 0180 3003 0026 2803 0552 2803 0395 1223 0108 1002 0158 1215 0381 1215 0329 2803 3380 3202 0319 1210 0463 3003 0033 1210 0463 1802 0277 5033 0010 5025 0011 5019 0064 2409 0071 5019 0065 Reg. Valve Kit + Seat Pressure Knob Injector Body O-Ring O-Ring Spring Check Valve O-Ring Injector Body Kit Check Valve Kit Suct. /Del. Valve Assy kit Detergent Spring Detergent Ball Detergent Coupling Special Coupling Wing Nut Water Filter Safety Valve Thermal Valve Quick Outlet Coupler Easy Start Cap O-Ring Easy Start Ball O-Ring Easy Start Spring Easy Start Kit Valve Kit Water Seal Kit Piston Kit Oil Seal Kit 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

30

NorthStar NSZW Pump Exploded View

Part # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Code 3218 0424 3202 0018 3609 0014 1210 0046 3009 0087 3604 0017 1802 0177 1205 0025 1210 0048 3202 0315 3609 0088 1004 0012 0402 0329 1210 0386 3019 0011 0009 0275 0438 0069 3200 0051 0403 0199 0009 0196 1241 0065

Description Brass Pump Manifold Kit Plug Screw O-Ring Suct. /Del. Valve Seat Suct. /Del. Valve Spring Suct. /Del. Valve Cage O-Ring Plug + O-Ring Screw Crankcase Flange Aluminum Cover O-Ring Outer Seeger Spacer Ball Bearing Oil Dipstick Pump Crankcase Packing Head Ring Packing

Qty 1 1 8 6 6 6 6 6 6 6 3 1 1 1 1 1 1 1 1 3 3 31

Part # 52 54 56 72 73 74 75 76 77 78 79 80 81 82 83 84 85 87 88 90 91

Code 3200 0007 2811 0084 2811 0086 0204 0072 1802 0279 1227 0051 3622 0049 0009 0367 2409 0148 0009 0365 1210 0613 1210 0614 0009 0366 0204 0071 1210 0615 1210 0616 3002 0673 3009 0164 1210 0603 1215 0404 1817 0053

Description Cap Washer Washer Bushing Spring Ring Nut Stop Adjustable Nut Spring Spacer Rod Ring O-Ring O-Ring Ring Bushing O-Ring O-Ring Support/Ball Valve Seat O-Ring Reg. Valve Kit + Seat Pressure knob

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

NorthStar NSZW Pump Exploded View

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47 48 49 50 51 0009 0223 1241 0030 0009 0222 1210 0223 0019 0095 0600 0048 2811 0080 0202 0020 Back Ring Packing Packing Retainer O-Ring Oil Seal Special Bolt Washer Ceramic Bushing 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 4 4 4 4 1 1 1 1 1 1 1 92 93 94 95 96 97 98 99 101 103 104 105 107 108 109 110 111 112 113 114 115 116 117 118 120 121 122 123 3410 0297 1210 0398 1210 0402 1802 0197 2409 0122 1210 0460 3410 0296 2409 0123 1220 0030 1802 0180 3003 0026 2803 0552 2803 0395 1223 0108 1002 0158 1215 0381 1215 0329 2803 3380 3202 0319 1210 0463 3003 0033 1210 0463 1802 0277 5033 0010 5025 0011 5019 0064 2409 0071 5019 0065 Injector Body O-Ring O-Ring Spring Check Valve O-Ring Injector Body Kit Check Valve Kit Suct. /Del. Valve Assy kit Detergent Spring Detergent Ball Detergent Coupling Special Coupling Wing Nut Water Filter Safety Valve Thermal Valve Quick Outlet Coupler Easy Start Cap O-Ring Easy Start Ball O-Ring Easy Start Spring Easy Start Kit Valve Kit Water Seal Kit Piston Kit Oil Seal Kit 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2812 0038 Washer 1210 0055 2409 0044 3011 0014 0205 0050 3019 0033 3201 0026 1210 0333 1210 0621 0402 0391 3609 0180 3609 0032 2811 0098 3607 0168 3016 0023 0019 0102 3020 0012 0204 0038 0437 0045 0001 0415 1210 0441 O-Ring Piston Guides Gudgeon Pin Con. Rod Assembly Outer Seeger Oil Indicator O-Ring O-Ring Cover Screw Screw Washer Hexagonal Screw Flange Oil Seal Inner Seeger Bushing Bearing Eccentric Shaft O-Ring

32

3025A Pump Exploded View

33

3025A Pump Exploded View

Item Description 1 Socket head screw 2 Pump basal flange 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 O-ring 80X2.4 Radial shaft seal FB36-50-7 Angular contact bearing Wearable sheath Wobble plate Front bearing (51307B) Spring disk Plunger Plunger spring Crankcase O-ring 14.2X1.9 Outlet plug Oil seal O-ring 15X2.2 Spacer O-ring 21.8X1.9 Water seal Compaction washer Inlet plug Washer O-ring 9.8X1.9 Valve Hose barb O-ring 3.68X1.78 Steel ball Small cone spring O-ring 5.3X2.65 Outlet cone valve Part # 781361 Kit #1 Kit #1 Kit #1 N/A N/A N/A N/A N/A N/A N/A N/A 781373 Kit #5 Kit #2 Kit #2 Kit #2 Kit #2 Kit #2 Kit #2 N/A N/A 781383 or Kit #3 781384 or Kit #3 Kit #4 Kit #4 Kit #4 Kit #4 Kit #4 Kit #4 Qty 1 1 1 1 1 1 1 1 1 1 1 1 2 5 3 3 3 3 3 3 3 3 9 6 1 1 1 1 1 1 Item Description 31 Cone valve spring 32 O-ring 14.2X1.9 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Hose barb seat Outlet nut M221.5-14 Back up ring 9X6.2X1.2 O-ring 6X1.78 Back water valve core Pump head Inlet water seal Inlet water body Thermal relief valve Inlet swivel nut Clip ring Water filter Socket head screw M8X50 Adjusting screw Adjusting screw plug O-ring 15X2.5 Back up ring 8.4X5.3X1.2 O-ring 5.2X1.9 Spring holder Big pressure spring Part # Kit #4 Kit #4 Or Kit #5 Kit #4 Kit #4 Kit #5 Kit #5 Kit #5 N/A Kit #6 Kit #6 781401 Kit #7 Kit #7 Kit #7 N/A Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #9 Qty 1 7 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1

53 Small pressure spring 54 Ball holder 55 56 57 58 59 Steel ball 8.7 Back water valve port O-ring 9.25X1.78 Breather Plug Dipstick

N/A part not available to order

34

3025A Pump Exploded View

Kit # 1 Description Flange w/ Seal Kit Item # 2 3 4 15 16 17 18 19 20 23 24 25 26 27 28 29 30 31 32 33 34 14 32 35 36 37 39 40 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Items Included Pump basal flange O-ring 80X2.4 Radial shaft seal FB36-50-7 Oil seal O-ring 15X2.2 Spacer O-ring 21.8X1.9 Water seal Compaction washer O-ring 9.8X1.9 Valve Hose barb O-ring 3.68X1.78 Steel ball Small cone spring O-ring 5.3X2.65 Outlet cone valve Cone valve spring O-ring 14.2X1.9 Hose barb seat Outlet nut M221.5-14 Outlet plug O-ring 14.2X1.9 Back up ring 9X6.2X1.2 O-ring 6X1.78 Back water valve core Inlet water seal Inlet water body Inlet swivel nut Clip ring Water filter Adjusting screw Adjusting screw plug O-ring 15X2.5 Back up ring 8.4X5.3X1.2 O-ring 5.2X1.9 Spring holder Big pressure spring Small pressure spring Ball holder Steel ball 8.7 Back water valve port O-ring 9.25X1.78 Breather Plug Dipstick Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Kit Part # 782837 Kit Qty Needed 1

Seal Kit

782843

Valve Kit

781122

Outlet Kit w/ Injector

782838

5 Valve Cap Kit

782839

6 7

Inlet Flange Kit

782840 782841

1 1

Inlet Kit

Unloader Kit

1 1 1 1 1 1 1 1 1 1 1
1 1

782842

Breather Plug with Dipstick Kit

785819

35

1807A Pump Exploded View

36

1807A Pump Exploded View

Item 1 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Description Screw M6*16 Drain plug Gasket, drain plug O-ring 110*3 Cover, oil plug, Black Oil plug O-ring 12.6*1.8 Crankcase Screw M8*20 Oil seal, crankshaft 40*52*7 Flange O-ring 51.8*2.2 Needle roller bearing NK42/20 Crankshaft Ball bearing 6304 Clip 20 O-ring 51.8*2.2 Cover, crankshaft Screw M8*16 Oil seal, plunger Locating ring O-ring 26.7*1.78 Low pressure seal Compaction ring Compaction flake High pressure seal Supporting ring Plunger rod Checking ring Backup ring O-ring Ceramic pipe Plain washer Fix nut M8 Connecting rod Fix pin 9*23 Fix screw M6*5 Plastic cap, knob Knob Spring Spring seat Jam nut Fix screw M4*4 Valve rod Backup ring 8.2*11*1.2 O-ring 7.65*1.78 Part # N/A Kit #1 Kit #1 Kit #2 Kit #3 Kit #3 Kit #3 N/A N/A
Kit #4 Kit #4 Kit #4

N/A N/A N/A N/A Kit #5 Kit #5 N/A Kit #6 Kit #6 Kit #6 Kit #6 Kit #6 Kit #6 Kit #6 Kit #6 N/A Kit #7 Kit #7 Kit #7 Kit #7 Kit #7 Kit #7 N/A N/A Kit #11 Kit #11 Kit #11 Kit #11 Kit #11 Kit #11 Kit #11 Kit #11 Kit #11 Kit #11

Qty 6 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 4 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1

Item 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95

Description Valve body O-ring 17.17*1.78 O-ring 6.08*1.78 Backup ring 6.2*9*1.2 O-ring 12.42*1.78 Seat, valve body Bullet O-ring 9.25*1.78 Seat O-ring 18.2*2.4 Outlet Tee connector O-ring 11.6*2.4 O-ring 4.2*2.4 Checking valve Spring O-ring 15*2.5 Outlet connector O-ring 12.2*2.4 Outlet banjo bolt O-ring 23.4*2.4 Inlet Tee connector Inlet connector Swivel nut Water filter O-ring 16.2*2.4 Inlet banjo bolt Water injection tube Soap injector 3/8 quick connect plug Soap suction nozzle O-ring 3.68*1.78 Ball Spring Manifold head O-ring 15.54*2.62 Valve O-ring 18*2.65 Valve plug Pop off valve Thermal relief valve Bolt M8*65 Siphon filter Crankcase Cover O-ring Oil Gauge Spring Disk

Part # Qty Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 or Kit #8 1 Kit #11 or Kit #8 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 1 Kit #11 or Kit #8 1 Kit #11 or Kit #8 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 Kit #11 or Kit #9 1 N/A 1 Kit #10 6 Kit #10 6 Kit #10 6 N/A 6 782191 1 782192 1 N/A 8 782194 1 Kit #2 1 Kit #1 1 Kit #1 1 Kit #1 1

N/A part not available to order 37

1807A Pump Exploded View

Kit # Description 4 5 93 94 95 7 92 8 9 10 13 14 15 20 21 23 24 25 26 27 28 29 30 32 33 34 35 36 37 67 68 74 75 76 77 78 79 80 81 82 84 85 86 Items Included Drain plug Gasket, drain plug O-ring Oil Gauge Spring Disk O-ring 110*3 Crankcase Cover Cover, oil plug, Black Oil plug O-ring 12.6*1.8 Oil seal, crankshaft 40*52*7 Flange O-ring 51.8*2.2 O-ring 51.8*2.2 Cover, crankshaft Oil seal, plunger Locating ring O-ring 26.7*1.78 Low pressure seal Compaction ring Compaction flake High pressure seal Supporting ring Checking ring Backup ring O-ring Ceramic pipe Plain washer Fix nut M8 O-ring 12.2*2.4 Outlet banjo bolt O-ring 16.2*2.4 Inlet banjo bolt Water injection tube Soap injector 3/8 quick connect plug Soap suction nozzle O-ring 3.68*1.78 Ball Spring O-ring 15.54*2.62 Valve O-ring 18*2.65 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 6 6 Part # Kits Qty Needed

Oil Drain Plug & Sight Glass Kit Crankcase Cover Kit Breather Cap w/dipstick Kit Flange w/Seal Kit Crankshaft Cover Kit

784969

2 3

784968 782846

1 1

4 5

782847 782848

1 1

Seal Kit

782849

Plunger Kit

782878

Banjo Bolt Kit

782852

Chemical Injector Kit

782853

10

Valve Kit

782850

38

3025A W/Easy Start Pump Exploded View

39

3025A W/Easy Start Pump Exploded View

Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Socket head screw Pump basal flange O-ring 80X2.4 Radial shaft seal FB36-50-7 Angular contact bearing Wearable sheath Wobble plate Front bearing (51307B) Spring disk Plunger Plunger spring Crankcase O-ring 14.2X1.9 Outlet plug Oil seal O-ring 15X2.2 Spacer O-ring 21.8X1.9 Water seal Compaction washer Inlet plug Washer O-ring 9.8X1.9 Valve Hose barb O-ring 3.68X1.78 Steel ball Small cone spring O-ring 5.3X2.65 Outlet cone valve Cone valve spring Part # 781361 Kit #1 Kit #1 Kit #1 N/A N/A N/A N/A N/A N/A N/A N/A 781373 Kit #5 Kit #2 Kit #2 Kit #2 Kit #2 Kit #2 Kit #2 N/A N/A 781383 or Kit #3 781384 or Kit #3 Kit #4 Kit #4 Kit #4 or Kit #10 Kit #4 Kit #4 Kit #4 Kit #4 Qty 1 1 1 1 1 1 1 1 1 1 1 1 2 4 3 3 3 3 3 3 3 3 9 6 1 1 2 1 1 1 1 Item Description 32 O-ring 14.2X1.9 33 Hose barb seat 34 Outlet nut M221.5-14 35 Back up ring 9X6.2X1.2 36 O-ring 6 X1.78 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Back water valve core Pump head Inlet water seal Inlet water body Thermal relief valve Inlet swivel nut Clip ring Water filter Socket head screw M8X50 Adjusting screw Adjusting screw plug O-ring 15X2.5 Back up ring 8.4X5.3X1.2 O-ring 5.2X1.9 Spring holder Big pressure spring Small pressure spring Part # Kit #4 or Kit #5 Kit #4 Kit #4 Kit #5 Kit #5 or Kit #10 Kit #5 N/A Kit #6 Kit #6 781401 Kit #7 Kit #7 Kit #7 N/A Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #8 Kit #9 789237 Kit # 10 789480 Qty 7 1 1 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

54 Ball holder 55 Steel ball 8.7 56 57 58 59 60 61 62 63 Back water valve port O-ring 9.25X1.78 Breather Plug Tube Dipstick Siphon hose with filter Easy start Spring Drain plug

40

3025A W/Easy Start Pump Exploded View

Kit # 1 Description Flange w/ Seal Kit Item # 2 3 4 15 16 17 18 19 20 23 24 25 26 27 28 29 30 31 32 33 34 14 32 35 36 37 39 40 42 43 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 27 36 61 62 Items Included Pump basal flange O-ring 80X2.4 Radial shaft seal FB36-50-7 Oil seal O-ring 15X2.2 Spacer O-ring 21.8X1.9 Water seal Compaction washer O-ring 9.8X1.9 Valve Hose barb O-ring 3.68X1.78 Steel ball Small cone spring O-ring 5.3X2.65 Outlet cone valve Cone valve spring O-ring 14.2X1.9 Hose barb seat Outlet nut M221.5-14 Outlet plug O-ring 14.2X1.9 Back up ring 9X6.2X1.2 O-ring 6X1.78 Back water valve core Inlet water seal Inlet water body Inlet swivel nut Clip ring Water filter Adjusting screw Adjusting screw plug O-ring 15X2.5 Back up ring 8.4X5.3X1.2 O-ring 5.2X1.9 Spring holder Big pressure spring Small pressure spring Ball holder Steel ball 8.7 Back water valve port O-ring 9.25X1.78 Breather Plug Tube Dipstick Steel ball O-ring 6X1.78 Easy start Spring
41

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Kit Part # 782837

Kit Qty Needed 1

Seal Kit

782843

Valve Kit

781122

Outlet Kit w/ Injector

782838

5 Valve Cap Kit

782839

6 7

Inlet Flange Kit

782840 782841

1 1

Inlet Kit

Unloader Kit

782842

Breather Plug with Dipstick Kit Easy Start Kit

785819

10

789479

NSSHFD5030 Pump Exploded View

42

NSSHFD5030 Pump Exploded View

Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 36 Part # Not Available Not Available CO3202011200 CO1210004600 CO3009008700 Not Available CO1802017700 Not Available CO1210004800 CO3202031200 Not Available Not Available Not Available Not Available Not Available CO1241002200 CO0009021700 CO1210015600 CO0019006600 CO0600005400 CO2811008200 CO0202002200 CO2812009400 CO1210003900 CO0009017000 Not Available Not Available Not Available Not Available CO3200005100 CO3019003300 CO3201002600 Not Available Not Available Not Available Description Manifold Screw Cap O-Ring Suct./Del. Valve Seat Suct./Del. Valve Suct. Del. Valve Spring Suct./Del. Valve Cage O-Ring Cap + O-ring Packing Head Ring Packing Back Ring Packing Retainer Packing Head Ring Packing Packing Retainer O-Ring Oil Seal Special Bolt Washer Ceramic Bushing Washer O-Ring Anti-Extr. Ring Piston Guides Gudgeon Pin Con. Rod Assembly Pump Crankcase Oil Dipstick Snap Ring Oil Indicator O-Ring O-Ring Crankcase Cover Qty 1 8 1 6 6 6 6 6 6 6 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 Ref # 37 38 39 40 41 42 43 53 54 55 56 65 66 67 68 69 70 70 70 70 71 72 73 74 75 76 77 78 79 80 150 151 152 153 Part # CO3609003000 CO3200000700 CO1210044100 CO3200000700 CO2811008400 CO3202001500 CO2811008600 CO3609003200 Not Available CO1210038800 Not Available CO1220007200 Not Available Not Available CO1210010900 CO0019005200 Not Available Not Available Not Available Not Available Not Available Not Available Not Available CO3607011900 Not Available Not Available CO3201002600 CO3019003300 CO1817009700 CO1215054800 CO5025002500 CO5019021800 CO2409007300 CO5019004500 Description Screw Cap O-Ring Cap Washer Cap Washer Screw Flange O-Ring Roller Bearing Suct./Del. Valve Assy. Kit Hollow Shaft Roller Bearing O-Ring Oil Seal Shim 0.05mm Shim 0.10mm Shim 0.19mm Shim 0.25mm Flange Washer Screw Hexagonal Screw Hexagonal Screw O-Ring Oil Indicator Snap Ring Knob Unloader Valve Valve Kit Water Seal Kit Piston Kit Oil Seal Kit Qty 6 1 1 1 1 1 1 4 1 1 1 6 1 1 1 1 1 1 1 1 1 4 4 4 4 1 1 1 1 1 1 1 1 1

43

NSSHFD5030 Pump Exploded View

Ref # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part # Not Available CO3622003000 CO1227002200 Not Available CO0009020700 CO2409008800 Not Available Not Available Not Available CO1210061500 Not Available Not Available Not Available Not Available CO3002065400 CO3009001300 Not Available Not Available CO1210057000 Not Available Not Available

Description Bushing Stop Adjustable Nut Ring Nut Spring Spring Spacer Piston Rod Anti-Extr. Ring O-Ring Bushing O-Ring O-Ring Anti-Extr. Ring O-Ring Gasket Unloader Ball Seat Gasket Upper Body O-Ring Check Valve Spring

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
44

Ref # 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 50

Part # CO3410036600 Not Available Not Available CO1802018000 CO3003002600 CO2812006700 CO2803064600 CO1802034400 CO1210056400 CO2803064500 CO1817009500 Not Available Not Available CO1210041000 CO1210041000 CO2803063400 Not Available CO2803063500 CO1210041100 CO1210041100 CO5015004900

Description Injector Body 2.3 O-Ring Coupling Spring Ball Washer Coupling Spring O-Ring Detergent Coupling Knob Gasket Lower Body O-Ring O-Ring Coupling O-Ring Coupling O-Ring O-Ring Valve Repair Kit

Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Limited Warranty
Dear Valued Customer: The Northstar or Powerhorse Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a Northstar or Powerhorse 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 or Powerhorse Product Support at 1-866-443-2576 prior to having any service or warranty work performed, as some services performed by parties other than Northstar or Powerhorse approved service centers may void this warranty. This warranty is in lieu of any other warranty expressed or implied and Northstar or Powerhorse assumes no other responsibility or liability outside that expressed within this warranty.

Limited Warranty
Northstar or Powerhorse 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:
Powerhorse Warranty Item # A157711 A157712 A1577110 Northstar Warranty Item # A1573701, A1573981 A1577541, A1578111 A1578171, A1578131 A1578181, A1578151 A1578201, A157594 A1578203 A1578173 A15782030 Consumer Warranty Period 12 months from date of purchase by user Commercial Warranty Period 12 months from date of purchase by user

Consumer Warranty Period 12 months from date of purchase by user

Commercial Warranty Period 12 months from date of purchase by user

4 years from date of purchase by user

3 years from date of purchase by user

Consumer use means personal residential household use by a consumer. Commercial use means all other uses, including use f or 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 nontransferable, 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 warranty. Determining whether a part is to be replaced or repaired is the sole decision of Northstar or Powerhorse. Northstar or Powerhorse will not provide for replacement of complete products due to defective parts. Any costs incurred due to replacement or repair of items outside of a Northstar or Powerhorse approved facility is the responsibility of the buyer and not covered under warranty. Transportation costs to and from service center is the responsibility of the customer. In addition to the normal warranty, Northstar or Powerhorse shall warrant any normal wear item from defects in material or workmanship for a period of 90 days from the date of purchase by user. Normal wear items include, but are not limited to, nozzles, quick connect fittings, valves, seals, hoses, springs, Orings, 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 or Powerhorse in writing, corrosion caused by chemicals, use of replacement parts which do not conform to manufacturers 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 merchantability of 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. 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 or Powerhorse Date Code: ________________________________________________ Item Number: __________________________________________________________________

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

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