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NorthStar 459232, Owner'S Manual

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NorthStar 459232 Owner'S Manual Download Page 2

 

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Table of Contents 

Equipment Protection Quick Facts ........................................................................................................................................ 1

 

Table of Contents ........................................................................................................................................................ 2

 

About Your Air Compressor ....................................................................................................................................... 3

 

Specifications .............................................................................................................................................................. 4

 

Component Identification ........................................................................................................................................... 5

 

Safety Signal Words .................................................................................................................................................... 6

 

Safety Labeling ............................................................................................................................................................ 7

 

Initial Set-Up ................................................................................................................................................................ 9

 

Step 1. Inspect & Unpack ........................................................................................................................................................ 9

 

Step 2. Assembly ..................................................................................................................................................................... 9

 

Step 3. Select Suitable Location ........................................................................................................................................... 10

 

Step 4. Permanent Mounting ................................................................................................................................................ 10

 

Step 5. Installing Distribution Piping ................................................................................................................................... 11

 

Step 6. Wiring Installation ..................................................................................................................................................... 11

 

Operation ................................................................................................................................................................... 14

 

Follow Operation Safety Rules ............................................................................................................................................. 14

 

Prepare for Operation ............................................................................................................................................................ 14

 

Proper Air Hose and Tool Use .............................................................................................................................................. 15

 

Using Compressor for Spraying ........................................................................................................................................... 16

 

Shutdown ............................................................................................................................................................................... 16

 

Maintenance & Repair ............................................................................................................................................... 17

 

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 ............................................................................................................................................ 24

 

459232 Pump Kits ...................................................................................................................................................... 25

 

459232 Pneumatic Schematic................................................................................................................................... 26

 

459242 Pump Explosion ........................................................................................................................................... 27

 

459242 Pump Parts List ............................................................................................................................................ 28

 

459242 Pump Kits ...................................................................................................................................................... 29

 

459242 Pneumatic Schematic................................................................................................................................... 30

 

Appendix A: Lubricants and Compatibility ............................................................................................................. 31

 

Alternate Lubricants ............................................................................................................................................................ 31

 

Limited Warranty ....................................................................................................................................................... 32

 

Summary of Contents for 459232

Page 1: ...ity 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 Quic...

Page 2: ...Safety Rules 14 Prepare for Operation 14 Proper Air Hose and Tool Use 15 Using Compressor for Spraying 16 Shutdown 16 Maintenance Repair 17 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 24 459232 Pump Kits 25 4592...

Page 3: ...arel 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 Comp...

Page 4: ...30A 40A Motor Horsepower 5 HP 7 5 HP DIMENSIONS COMPONENTS Length 25 25 Width 33 33 Height 68 69 Weight 409 lbs 537 lbs Mounting Hole Diameter 56 56 Suggested Mount Bolt Diameter 7 16 7 16 SUPPLIES REQUIRED not included Engine Oil Refer to engine owner s manual Refer to engine owner s manual Pump Oil shipped with oil but refills required SAE 30 non detergent pump oil 4043 SAE 30 non detergent pump...

Page 5: ... 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 7 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 8 ASME Safety Check Valve Automatically releases air if tank exceeds preset pressure max of 20...

Page 6: ...ous 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...

Page 7: ... 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 788998 Air Compressor Instructions 2 788924 Air Compressor Safety 3 789060 Electrical Shock Hazard ...

Page 8: ...acement safety labels call NorthStar Product Support at 1 800 270 0810 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 1 2 3 ...

Page 9: ...propriate tool on specified location Figure 3 Figure 4 Figure 3 Figure 4 5 Replace air filter housing and washer Secure with wing nut hand tighten only Figure 5 Figure 5 Attach Regulator Recommended We recommend using a regulator with this compressor since the pre set tank pressure ranges between 145 and 175 PSI and is usually greater than what is needed by tools Without the addition of a regulato...

Page 10: ...rating capacity of 30 amp Model 459231 5 H P or 40 amp Model 459241 7 5 H P Wiring Proper wire size should take into consideration length from distribution panel See Step 6 Wiring Installation for more information Ideal operating temperatures 40 and 100 F 4 and 37 C Operating Limitations 15 F 9 C or above 125 F 52 C If temperatures consistently drop below 32 F 0 C install within a heated building ...

Page 11: ...l contractors with expertise in compressed air systems to plan and or install your distribution system WARNING Bursting hazard This unit can produce pressures in excess of 150 PSI which is beyond the capabilities of many piping types and pipe fittings Failure of undersized and or inadequate distribution components can lead to serious injury WARNING Restriction hazard If an aftercooler check valve ...

Page 12: ...member the momentary starting current of an electric motor is greater than its full load current Time delay or slow blow circuit breakers are recommended Grounding This product and its associated conduit and junction box must be grounded Do not ground to a gas supply line WARNING Electrical shock hazard Improperly grounded motors are shock hazards Make sure all equipment is properly grounded Check...

Page 13: ... switch Figure 9 Model 459231 Top View Pressure Switch Figure 9 Figure 10 Model 459242 230 Volt 7 5 HP This unit has a motor starter Connect power lines to the starter Figure 11 Note For this model do NOT connect the power line to the pressure switch The motor will not start and will be damaged Model 459241 Side View Motor Starter Figure 11 Figure 12 ...

Page 14: ... to prevent health and fire hazards Prepare for Operation Make sure that any regular maintenance has been performed as prescribed in Maintenance Repair section Refer to the engine Owner s Manual for engine maintenance instructions Drain receiver tank of any moisture Inspect for oil leaks Check for any unusual noise vibration Ensure the area around compressor is free from rags tools debris and flam...

Page 15: ...lume PSI tires It is easy to over pressurize them causing them to rupture Identify the inflation capacity of an object prior to filling it with air Use a gauge to check the pressure regularly when inflating anything Proper Air Hose and Tool Use Pressure Control Related Devices Never remove adjust bypass change modify or make substitutions for safety relief valves pressure switches or other pressur...

Page 16: ...t acceptable for your application an external air dryer must be added to the system Shutdown Procedure When you are finished using the compressor 1 Move the pressure switch to the OFF position 2 Close the ball valve to stop airflow 3 Unplug the power cord 4 Operate tools briefly to release live pressure 5 Disconnect all tools 6 Drain air receiver tank by pulling safety relief valve 7 After all sto...

Page 17: ...fety hazards and will void the warranty Inspect Safety Relief Valve This valve should be inspected and tested on a weekly basis The safety valve automatically releases air if the tank pressure exceeds the preset maximum Check the safety relief valve by pulling the rings It is spring loaded and should not be stuck but come out about and then snap back into position when released Replace safety reli...

Page 18: ...sted air receiver tank will eventually result in tank rupture or explosion which could cause substantial property damage severe personal injury or death Never modify or repair a tank Obtain replacement from service center Check Drive Belt for Tension and Alignment CAUTION Pulley sheave hazard Improper pulley sheave alignment and belt tension can result in motor overload excessive vibration and pre...

Page 19: ...d cause damage to the engine and pump IMPORTANT If a part needs replacement only use parts that meet the manufacturer s part number specifications Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the compressor Major service including installation or replacement of parts should be made by a qualified electrical service technician Contact NorthSta...

Page 20: ...e good contact on motor terminals or starter connections F Compressor viscosity too high for ambient temperature Drain existing lubricant and refill with proper lubricant G Poor ground Check all ground connections H Belt tension too tight or sheaves not aligned Check tension alignment i Air leaks in discharge piping Check tubing connections Tighten joints or replace as required J Poor power regula...

Page 21: ...21 Parts Explosions Model 459232 459242 Rev C 3 ...

Page 22: ...lief All 1 38 34758 Strain Relief Right Angle 459242 1 11 35388 12 3 SOOW Cord Assembly 459232 1 39 789463 Overload Relay 459242 1 35385 8 3 SOOW Cord Assembly 459242 1 40 36047 Wire Assembly R3 459242 1 12 777255 NPT x 5 8 Compression Elbow 459232 1 42 35387 Fuse Holder 459242 1 459242 2 43 35386 Fuse 459242 2 13 36107 Long Brass Adapter All 1 45 35383 Wire Assembly B3 459242 1 14 35645 Round Tub...

Page 23: ...23 459232 Pump Explosion ...

Page 24: ... 1 N A 20 789386 Oil filling plug 1 N A 21 N A Bearing 1 N A 22 N A Crankshaft and balancer 1 N A 23 N A Pulley Key 1 N A 24 N A Bearing 1 N A 25 N A Rear bearing seat gasket 1 Kit 2 26 N A Rear bearing seat 1 N A 27 N A Oil seal 1 Kit 2 28 788882 Breathing cover 1 N A 29 789366 Balanced pulley 1 N A 30 N A Plate washer 1 Kit 7 31 N A Hexagon bolt 1 32 N A Rod 1 N A 33 N A Exhaust elbow 1 Kit 8 34...

Page 25: ...t 4 2 Kit 5 Cylinder and Piston Kit Part 789342 Ref Description Qty Kit Qty 9 Cylinder 1 2 10 Cylinder gasket 1 11 Piston ring 1 12 Piston 1 Kit 6 Piston Ring Kit Part 789360 Ref Description Qty Kit Qty 10 Cylinder gasket 2 1 11 Piston ring 2 40 Piston ring 1 Kit 7 Plate and Bolt Kit Part 789367 Ref Description Qty Kit Qty 30 Plate washer 1 1 31 Hexagon bolt 1 Kit 8 Elbow and Pipe Kit Part 789368 ...

Page 26: ...26 459232 Pneumatic Schematic Safety Relief Valve 4593000 Pump Pressure Switch Safety Relief Valve 80 Gallon Tank Unloader ...

Page 27: ...27 459242 Pump Explosion ...

Page 28: ... A 21 N A Bolt M8 x 25 10 N A 22 788880 Oil sight gauge 1 N A 23 789386 Oil filling plug 1 N A 24 789387 Bearing 2 N A 25 N A Crankshaft and balancer 1 N A 26 789388 Pulley key 1 N A 27 N A Rear bearing seat gasket 1 Kit 2 28 N A Rear bearing seat 1 N A 29 788882 Breathing cover 1 N A 30 N A Oil seal 1 Kit 2 31 789391 Balanced pulley 1 N A 32 N A Plate washer 1 Kit 8 33 N A Bolt M12 x 50 1 34 N A ...

Page 29: ...789395 Ref Description Qty Kit Qty 43 Exhaust elbow 1 1 44 Aftercooler 1 46 Exhaust elbow 1 Kit 1 Cylinder and Bolt Kit Part 789374 Ref Description Qty Kit Qty 1 Cylinder head 1 1 2 Allen bolt set 4 3 Allen bolt set 1 Kit 2 Gasket Kit Part 789377 Ref Description Qty Kit Qty 6 Cylinder head gasket 1 1 36 Cylinder head gasket 1 8 valve seat gasket 1 38 valve seat gasket 1 11 cylinder gasket 2 18 fro...

Page 30: ...30 459242 Pneumatic Schematic Safety Relief Valve 4593100 Pump 80 Gallon Tank Unloader Pressure Switch Safety Relief Valve ...

Page 31: ... Modified Alkyds indicates trademark of DuPont Corporation Neoprene Natural Rubber SBR Rubber Acrylic Paint Lacquer Varnish Polystyrene PVC ABS Polycarbonite Cellulose Acetate Latex EPR Acrylics Phenoxy Polysulfones Styrene Acrylonitile San Butyl Alternate Lubricants You may use a petroleum based lubricant that is premium quality does not contain detergents contains only anti rust anti oxidation a...

Page 32: ...t 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 NorthStar 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 approved facility is the responsibil...

Page 33: ...33 This page has been left intentionally blank ...

Page 34: ...34 Assembled by Northern Tool Equipment Company Inc Burnsville MN 55306 NorthernTool com ...

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