North Star 25653 User manual

1
M25653C.3
Owner’s Manual
Electric Portable Air Compressor
(115V/15A or 230V/7.5A, Single Phase/20 gallon, 2 HP)
(115V/15A or 230V/7.5A, Single Phase/11 gallon, 1 HP)
Instructions for Installation/Set-up, Operation, Maintenance, & Storage
NorthStar® Models 25653 and 25654 belt-driven compressors have a single stage 2-cylinder pump, made with
heavy-duty cast iron cylinders for long life, and a compact design rated for 135 maximum PSI. NorthStar® Model
48578 belt-driven compressor has a single stage 1-cylinder pump, made with heavy-duty cast iron for long life, and a
compact design rated for 135 maximum PSI. Their continuous-duty rating ensures long-lasting performance, and its
cast iron pump head ensures superior heat dissipation.
Read and understand this Owner’s Manual completely before using. Keep this manual for future review. Failure to
properly set up, operate and maintain the compressor in accordance with this manual could result in serious injury or
death to operator or bystanders.
WARNING: SPECIAL HAZARDS
Injection Injury: High-pressure air stream 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 air stream can cause flying debris and possible surface damage.
Not For Breathing Air: NorthStar compressors are NOT designed, intended, or approved for supplying breathing air. No
compressed air should be used for breathing unless air is treated in accordance with applicable standards.
Fire/Explosion: Sparks from air powered tool heads or attachments can ignite fuel or other flammable liquids or vapors in
the vicinity. Exceeding the maximum pressure for air tools or attachments could cause them to explode.
Burns: Compressor pump, motor and discharge tubing are hot surfaces that can cause burn injuries.
Electric Shock: Operating equipment in wet conditions or where not properly grounded can cause electric shock.
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 “Initial Set-Up”section for where
to report missing or damaged parts.
Add Pump Oil: Pump is NOT shipped with oil. Check the pump oil level before starting. See “Prepare for Operation”
section of this Owner’s Manual for capacity and viscosity.
Use Mechanical Lifting Equipment: Compressor may be too heavy to handle manually. Use proper lifting
equipment for unloading and moving to installation site.
Ensure Air Compressor is Electrically Connected Correctly: All wiring, grounding, and electrical connections
must be made by a competent electrician. Install according to local and national codes.
Run Pump Unloaded for Break-in Period: Before initial use, open drain valve and run compressor for 30 minutes
to break in pump parts.
Follow Maintenance Schedule: Pump, air filter, and tank require periodic inspection and servicing to provide
efficient function and long life. See “Maintenance & Repair”for frequency of servicing.
ITEM NUMBER: 25653, 25654, 48578
SERIAL NUMBER: _____________

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Table of Contents
Equipment Protection Quick Facts ........................................................................................................................................ 1
Table of Contents ........................................................................................................................................................2
About Your Air Compressor.......................................................................................................................................4
Specifications ..............................................................................................................................................................5
Component Identification ...........................................................................................................................................6
Safety Signal Words....................................................................................................................................................7
Hazard Signal Word Definitions ............................................................................................................................................ 7
Safety Labeling............................................................................................................................................................8
Safety Decal Locations ......................................................................................................................................................... 8
Safety Decals........................................................................................................................................................................ 9
Initial Set-Up ..............................................................................................................................................................10
Step 1. Inspect & Unpack...................................................................................................................................................... 10
Step 2. Assembly................................................................................................................................................................... 10
Step 3. Select Suitable Location........................................................................................................................................... 11
Operation ...................................................................................................................................................................12
Follow Operation Safety Rules............................................................................................................................................. 12
Prepare for Operation............................................................................................................................................................ 12
Check/Add Oil to the Pump................................................................................................................................................. 12
Proper Air Hose and Tool Use.............................................................................................................................................. 13
Pressure Control Related Devices ...................................................................................................................................... 13
Compressor - Tool Requirements ....................................................................................................................................... 13
Attaching/Disconnecting Air Hose and Tools ...................................................................................................................... 13
Using Compressor for Spraying........................................................................................................................................... 14
Flammable Materials........................................................................................................................................................... 14
Moisture in Compressed Air................................................................................................................................................ 14
Shutdown ............................................................................................................................................................................... 14
Procedure ........................................................................................................................................................................... 14
For Malfunction During Operation ....................................................................................................................................... 14
Maintenance & Repair...............................................................................................................................................15
Maintenance Schedule Summary.............................................................................................................................15
Detailed Instructions –Maintenance & Repair........................................................................................................15
Inspect Safety/Relief Valve ................................................................................................................................................. 15
Inspect Air Filter .................................................................................................................................................................. 15
Inspect Compressor for Air Leaks....................................................................................................................................... 15
Change Pump Oil................................................................................................................................................................ 16
Drain Receiver Tank and Inspect Tank............................................................................................................................... 16
Check Drive Belt for Tension and Alignment....................................................................................................................... 16
Keep Compressor Clean..................................................................................................................................................... 16
Cylinder Head Bolt Torque Specification............................................................................................................................. 17
Troubleshooting ........................................................................................................................................................18
Parts Explosions –Model 25653 Rev C.3................................................................................................................19
Parts List –Model 25653 Rev C.3.............................................................................................................................20
Parts Explosions –Model 25654 Rev C.3................................................................................................................21

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Parts List –Model 25654 Rev C.3.............................................................................................................................22
788876 Pump Explosion Rev C.3 .............................................................................................................................23
788876 Pump Parts List Rev C.3 ..............................................................................................................................24
788876 Pump Kits Rev C.3........................................................................................................................................24
Parts List –Model 48578 Rev C.3.............................................................................................................................25
Parts List –Model 48578 Rev C.3.............................................................................................................................26
792353 Pump Exploded View Rev C.3 .....................................................................................................................27
792353 Pump Parts List Rev C.3 ..............................................................................................................................28
Appendix A: Lubricants and Compatibility .............................................................................................................29
Alternate Lubricants. ........................................................................................................................................................... 29
Limited Warranty .......................................................................................................................................................30

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About Your Air Compressor
Thank you for purchasing a NorthStar air compressor!
It is designed for long life, dependability, and top
performance.
Intended Use. Provides compressed air used
primarily for operating air tools and pressurizing other
objects that require high air pressure, such as tires.
Do not use for low-pressure objects such as
balloons, air mattresses, and sport balls, which can
explode quickly and easily. Special precautions are
necessary when used for cleaning to prevent flying
debris hazards. It is not to be used to supply breathing
air.
Supplies Required. Normal operation will require you
to supply:
Compressor pump oil
Personal protection equipment
See “Specifications”section for more detail.
Site Location. Intended for indoor use.
Personal Protection. Wear safety apparel during
operation, including safety glasses with side and top
protection.
Adult Control Only. Only trained adults should set up
and operate the air compressor. Do not let children
operate.
Under The Influence. Never operate, or let anyone
else operate, the air compressor 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 air
compressor must have access to and read this
Owner’s Manual. Keep this manual with the air
compressor 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 air compressor and remain available
to answer any questions a renter/borrower might
have. Owner’s Manuals are available from NorthStar
at 1-800-270-0810.

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Specifications
MODEL
Model #
25653
25654
48578
FLOW OUTPUT
Max. Pressure
Rating
135 PSI
135 PSI
135 PSI
Volume Rating
4.8 CFM @100 PSI
5.0 CFM @ 90 PSI
6.0 CFM @ 40 PSI
4.8 CFM @100 PSI
5.0 CFM @ 90 PSI
6.0 CFM @ 40 PSI
3.1 CFM @ 90 PSI
3.8 CFM @ 40 PSI
Receiver Capacity
20 gal.
20 gal.
11 gal.
Power Requirements
Dedicated NEMA
Receptacles
5-15R
5-15R
5-15R
Volts
115V/230V
115V/230V
115V/230V
Amps
15A/7.5A
15A/7.5A
15A/7.5A
Motor
Horsepower
2 HP
2 HP
1 HP
DIMENSIONS / COMPONENTS
Length
22”
43”
18”
Width
23”
22”
16”
Height
43”
30”
36”
Weight
204 lbs.
207 lbs.
128 lbs.
SUPPLIES REQUIRED (not included)
Pump Oil
(not included)
SAE 30 non-detergent pump
oil (#4043)
SAE 30 non-detergent pump
oil (#4043)
SAE 30 non-detergent pump
oil (#4043)
Pump Oil Capacity
16.9 oz.
16.9 oz.
7.5 oz.

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Component Identification
1. Regulator: Controls outlet pressure.
2. Discharge Tube: Carries compressed air from pump to
safety/check valve, and then to the storage tank. It
becomes very hot during use and can cause severe
burns. Never touch.
3. Air Compressor Pump: Shipped with oil.
4. Compressor Air Filter: Keep clean and particle free.
See “Pump Explosion and Pump Parts List” for
replacement part number.
5. Belt Guard: Covers belt, engine pulley and flywheel.
NEVER operate compressor without belt guard in place.
6. Unloader: Vents discharge air to atmosphere in
start/stop operation.
7. Pressure Switch-Auto/Off switch: In AUTO
a. position, compressor shuts off automatically
when tank pressure reaches maximum
preset pressure. In OFF position,
compressor will not operate. Switch should
be in OFF position when connecting or
disconnecting power cord from electrical
outlet. NEVER attempt to adjust this
pressure switch.
8. Pressure Gauge: Air filled gauge. Shows pressure in
receiver tank.
9. Air Receiver / Storage Tank: 20 or 11 gallon ASME
certified tank.
10. Tank Drain Valve: Used to remove moisture from air
after compressor is shut off and air emptied from tank.
Drain moisture daily after each use.
11. ASME Safety/Check Valve: Automatically releases air if
tank exceeds preset pressure max. of 200 PSI. A check
valve is a pressure release port. Pull valve pin to relieve
pressure from receiver tank.
12. Magnetic Oil Drain Plug: Removal allows for drainage
of oil from pump. Attracts metal particles that could
damage pump.
8
10
9
6
7
2
1
11
12
3
5
4

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Safety Signal Words
Hazard Signal Word Definitions
DANGER
WARNING
CAUTION
CAUTION
NOTICE
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury
or death.
DANGER (red) indicates a hazardous situation, which if
not avoided, will result in death or serious injury.
WARNING (orange) indicates a hazardous situation,
which if not avoided, could result in death or serious
injury.
CAUTION (yellow), used with the safety alert symbol,
indicates a hazardous situation, which if not avoided,
could result in minor or moderate injury.
CAUTION (yellow), without the safety alert symbol, is
used to address practices not related to personal injury.
NOTICE is used to address practices not related to
personal injury.

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Safety Labeling
Safety Decal Locations
WARNING:
ALWAYS make sure safety labels are in place and in 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
792174
Breathing Hazard
2
792177
Corrosion Hazard
3
789060
Electrical Shock Hazard
4
792161
Air Compressor Instructions
5
792176
Burn Hazard
6
792175
Belt Hazard
4
1
5
3
2
6

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Safety Decals
To order replacement safety labels, call NorthStar Product Support
at 1-800-270-0810.
3
1
4
2
5
6

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Initial Set-Up
Step 1. Inspect & Unpack
Upon receipt, inspect air compressor for missing or
damaged parts. Verify that it is the compressor you
ordered.
See “Component Identification” section of this manual
for a diagram of the compressor and its components.
For missing components, contact Product
Support at 1-800-270-0810.
For damaged components, contact the freight
company that delivered the unit and file a claim.
If complete, fill out product serial number
information. See “Limited Warranty” section of
this manual.
Step 2. Assembly
1. Insert the handle from the grip set into the mounting
structure. Model 25653 - Secure handle by threading
bolts into holes in mounting structure. Model 25654 –
Secure handle by threading bolts with washers into
holes in mounting structure and holes in handle.
2. Attach the tank wheels to the tank frame using the
tank wheel bolts.
3. Install the rubber pad sets onto the tank feet in the
orientation shown.
Grip Set (Includes)
Handle –Qty 1
Bolt –Qty 2
Model 25653 & 48578
Grip Set (Includes)
Handle –Qty 1
Bolt –Qty 2
Washer –Qty 2
Model 25654 Only
Tank Wheel Bolt
Qty 2
Model 25653, 25654, 48578
Tank Wheel
Qty 2
Model 25653, 25654, 48578
Figure 1
Figure 2
Figure 3
Handle
Bolt
Tank
Wheel
Bolt
Wheel
Tank
Model 25653 & 48578
Model 25654