NorthStar 459232 Owner's Manual

Electric stationary air compressor (230v, single phase/80 gallon, 5 hp and 7.5 hp)

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Instructions for Installation/Set-up, Operation, Maintenance, & Storage
This NorthStar® belt-driven compressor has a 2-stage 3-cylinder pump (Model 459232) or a 2-stage 2-cylinder pump
(Model 459242), made with a heavy-duty cast iron cylinders for long life, and a compact design rated for 175
maximum PSI. Its 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.
Inspect Upon Delivery: FIRST! Inspect for missing or damaged components. See "Initial Set-Up" section for where
to report missing or damaged parts.
Check Pump Oil: Pump is shipped with oil. Check the pump oil level before starting. See "Preparing for Operation"
section of this Owner's Manual for capacity and viscosity.
Use Mechanical Lifting Equipment: Compressor is shipped on a pallet and is too heavy to handle manually. Use
proper lifting equipment for unloading and moving to installation site.
Install Using a Qualified Electrician: All wiring, grounding, and electrical connections must be made by a qualified
electrician. Install according to local and national codes.
Install a Regulator: We recommend installing a regulator on the compressor at each distribution point to maintain
constant pressure in the outlet hose line and provide reduced pressure appropriate for air tool being used.
Run Pump Unloaded for Break-in Period: Before initial use, open ball 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 Schedule" for frequency of servicing.
Owner's Manual
Electric Stationary Air Compressor
(230V, single phase/80 gallon, 5 HP and 7.5 HP)

Equipment Protection Quick Facts

M459232C.3
ITEM NUMBER: 459232 & 459242
SERIAL NUMBER: _____________
1

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Summary of Contents for NorthStar 459232

  • Page 1: Equipment Protection Quick Facts

    Instructions for Installation/Set-up, Operation, Maintenance, & Storage This NorthStar® belt-driven compressor has a 2-stage 3-cylinder pump (Model 459232) or a 2-stage 2-cylinder pump (Model 459242), made with a heavy-duty cast iron cylinders for long life, and a compact design rated for 175 maximum PSI.
  • Page 2: Table Of Contents

    Maintenance Schedule Summary ..........................17 Detailed Instructions – Maintenance & Repair ......................17 Troubleshooting ................................ 20 Parts Explosions – Model 459232 & 459242 Rev C.3 ....................21 Parts List – Model 459232 & 459242 Rev C.3 ......................22 459232 Pump Explosion ............................23 459232 Pump Parts List ............................
  • Page 3: About Your Air Compressor

    About Your Air Compressor Thank you for purchasing a NorthStar air compressor! It Adult Control Only. Only trained adults should set up is designed for long life, dependability, and top and operate the air compressor. Do not let children performance. operate.
  • Page 4: Specifications

    Specifications MODEL Model # 459232 459242 FLOW OUTPUT Max. Pressure Rating 175 PSI 175 PSI Volume Rating @ 90PSI 14.9 CFM 24.4 CFM Receiver Capacity 80 gal. 80 gal. Power Requirements Dedicated NEMA 6-30R 6-50R Receptacles Volts 230V 230V Amps...
  • Page 5: Component Identification

    Component Identification Lifting Eyes: May also be used as tie down locations. Ball Valve: On/Off control for pressurized air supply from receiver tank (not the output pressure). A regulator and/or quick connect fittings can attach to its ½” NPT outlet. A regulator should be installed for pressure regulation purposes.
  • Page 6: Safety Signal Words

    Safety Signal Words 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 7: Safety Labeling

    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 Air Compressor Instructions...
  • Page 8: Safety Decals

    Safety Decals File Name: 788998.ai Decal Part Numbe r: 788998 Decal Desc ription: AC Instruction Label, 80 Gal Material: KB14 Drawn By: Betsy Dramdahl Date D rawn: 10/04/2012 To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.
  • Page 9: Initial Set-Up

    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 ...
  • Page 10: Step 3. Select Suitable Location

    Step 3. Select Suitable Location If temperatures consistently drop below 32 F (0C), install within a heated building. If this is not possible, WARNING: Lifting hazard protect the safety/relief and drain valves from freezing. The compressor is heavy. Ensure that proper lifting equipment is available to unload and move compressor Note: Excessive moisture is likely to occur if unit is to installation site.
  • Page 11: Step 5. Installing Distribution Piping

    vibrating excessively. Use metal shims under regulating the distribution line pressure at the the “short” feet if necessary. compressor outlet to under 150 PSI (usually in the 90- 5. A rubber isolation mat or pads may be used 120 PSI range) is mandatory for many compressed air under each mounting foot to reduce vibration.
  • Page 12 Grounding CAUTION: Inadequate wiring hazard This product and its associated conduit and junction box Overheating, short-circuiting and fire damage will result must be grounded. Do not ground to a gas supply line. from inadequate wire sizing. WARNING: Electrical shock hazard Circuit Breaker Improperly grounded motors are shock hazards.
  • Page 13 Model #459232 (230 Volt; 5 HP) Model #459242 (230 Volt; 7.5 HP) You will recognize this unit since it has a motor reset This unit has a motor starter. Connect power lines to the button. The power lines can be connected directly to the starter (Figure 11).
  • Page 14: Operation

    Figure 13 Make sure that any regular maintenance has been performed as prescribed in “Maintenance & Repair” 459232 Model Pump: The compressor pump capacity is section. 27 oz. Use SAE 30 non-detergent pump oil (part Refer to the engine Owner’s Manual for engine ...
  • Page 15: Proper Air Hose And Tool Use

    pressure in the tank drops to a preset low level, the Breather pressure switch automatically turns the motor back on. WARNING: Overheating This compressor is equipped with “auto shut off”. However, failure to allow adequate cooling ventilation or a restriction in the intake airflow may cause the machine to overheat.
  • Page 16: Using Compressor For Spraying

    connect fitting on the main compressor outlet or after the the tank. Part of the moisture will be discharged in the user installed regulator. outlet air. When using a paint spray or sandblast gun, this water CAUTION: Air tools hazard will be carried from the tank through the hose, and out of Do not attach air tools to open end of the hose until start-up is completed and the unit checks out OK.
  • Page 17: Maintenance & Repair

    Maintenance & Repair WARNING: Maintenance hazards ALWAYS disconnect, lock out and tag the main power supply and then release air pressure from the receiver tank before cleaning, adjusting, or servicing the compressor. Make sure all guards and shields are replaced before re-starting. Maintenance Schedule Summary Item Frequency...
  • Page 18: Inspect Compressor For Air Leaks

    Inspect Compressor for Air Leaks Check Drive Belt for Tension and Alignment Inspect system for air leaks on a monthly basis. To test: Squirt soapy water around joints during  CAUTION: Pulley/sheave hazard compressor operation and watch for bubbles. Improper pulley/sheave alignment and belt tension can Developing bubbles indicate a leak is present.
  • Page 19: Keep Compressor Clean

    IMPORTANT Keep Compressor Clean If a part needs replacement, only use parts that meet Do not allow air intakes to become blocked. If dust or the manufacturer’s part number specifications. Replacement parts that do not meet specifications may debris accumulates in the compressor, clean the result in a safety hazard or poor operation of the compressor with a damp cloth or soft bristle brush.
  • Page 20: Troubleshooting

    Troubleshooting This section provides a list of the more frequently encountered compressor malfunctions, their causes and corrective actions. Some corrective actions can be performed by the operator or maintenance personnel, but others may require assistance of a qualified electrician or Service Center. PROBLEM POSSIBLE CAUSE Motor does not turn.
  • Page 21: Parts Explosions - Model 459232 & 459242 Rev C.3

    Parts Explosions – Model 459232 & 459242 Rev C.3...
  • Page 22: Parts List - Model 459232 & 459242 Rev C.3

    Parts List – Model 459232 & 459242 Rev C.3 Ref# Part# Description Model Ref# Part# Description Model ¼” NPT Bulkhead 788040 Manual Tube 34744 Fitting 788398 459232 Drain Plug, ¼” NPT Unloader Tube 35413 788399 459242 ¼” NPT, ¼” Plastic ½”...
  • Page 23: 459232 Pump Explosion

    459232 Pump Explosion...
  • Page 24: 459232 Pump Parts List

    459232 Pump Parts List Ref# Part# Description Kit # Cylinder head Kit # 1 Allen bolt set 789354 Air filter * 789355 Filter element Cylinder head gasket Kit # 2 In.& ex. valve assembly Kit # 3 Valve seat gasket...
  • Page 25: 459232 Pump Kits

    459232 Pump Kits Kit # 6 – Piston Ring Kit– Part # 789360 Kit # 1 - Cylinder Head Kit– Part # 789336 Ref# Description Kit Qty Ref# Description Kit Qty Cylinder head Cylinder gasket Allen bolt set Piston ring Piston ring Kit # 2 –...
  • Page 26: 459232 Pneumatic Schematic

    459232 Pneumatic Schematic Safety Relief Valve 4593000 Pump Unloader Pressure Switch Safety Relief Valve 80-Gallon Tank...
  • Page 27: 459242 Pump Explosion

    459242 Pump Explosion...
  • Page 28: 459242 Pump Parts List

    459242 Pump Parts List Ref# Part# Description Kit # Cylinder head Allen bolt set Kit # 1 Allen bolt set 789375 Air filter * 789376 Filter element Cylinder head gasket Kit # 2 In.& ex. valve assembly Kit # 3 Valve seat gasket Kit # 2 Double head screw set...
  • Page 29: 459242 Pump Kits

    459242 Pump Kits Kit # 1 - Cylinder and Bolt Kit – Part # 789374 Kit # 6 – Rod Kit– Part # 789382 Ref# Description Kit Qty Ref# Description Kit Qty Cylinder head Allen bolt set Allen bolt set Kit # 7 –...
  • Page 30: 459242 Pneumatic Schematic

    459242 Pneumatic Schematic Safety Relief Valve 4593100 Pump Unloader Pressure Switch Safety Relief Valve 80-Gallon Tank...
  • Page 31: Appendix A: Lubricants And Compatibility

    Appendix A: Lubricants and Compatibility Alternate Lubricants The following table lists materials that are suitable or not You may use a petroleum-based lubricant that is recommended for use with synthetic oil. As some oil premium quality, does not contain detergents, contains escapes into the compressed air, all components that only anti-rust, anti-oxidation, and anti-foam agents as come into contact with the air (i.e., piping, filters, hoses,...
  • Page 32: Limited Warranty

    NorthStar Warranty Item # Consumer Warranty Period Commercial Warranty Period 459232 4 years from date of purchase by user 2 years from date of purchase by user 459242 “Consumer use” means personal residential household use by a consumer. “Commercial use” means all other uses, including use for commercial, income producing or rental purposes or when purchased by a business.
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  • Page 34 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com...

This manual is also suitable for:

459242

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