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(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.
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.
Owner's Manual
Electric Portable Air Compressor

Equipment Protection Quick Facts

M25653C.3
ITEM NUMBER: 25653, 25654, 48578
SERIAL NUMBER: _____________
1

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Summary of Contents for North Star 25653

  • Page 1: Equipment Protection Quick Facts

    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.
  • Page 2: Table Of Contents

    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...
  • Page 3 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 –...
  • Page 4: About Your Air Compressor

    About Your Air Compressor Thank you for purchasing a NorthStar air compressor! Adult Control Only. Only trained adults should set up It is designed for long life, dependability, and top and operate the air compressor. Do not let children performance. operate.
  • Page 5: Specifications

    Specifications MODEL Model # 25653 25654 48578 FLOW OUTPUT Max. Pressure 135 PSI 135 PSI 135 PSI Rating 4.8 CFM @100 PSI 4.8 CFM @100 PSI 3.1 CFM @ 90 PSI 5.0 CFM @ 90 PSI Volume Rating 5.0 CFM @ 90 PSI 3.8 CFM @ 40 PSI...
  • Page 6: Component Identification

    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.
  • Page 7: 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 8: 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 Breathing Hazard...
  • Page 9: Safety Decals

    Safety Decals To order replacement safety labels, call NorthStar Product Support at 1-800-270-0810.
  • Page 10: Initial Set-Up

    Figure 1 Figure 3 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.
  • Page 11: Step 3. Select Suitable Location

    Step 3. Select Suitable Location Electrical: MUST be connected to a 115V/230 Volt, single-  WARNING: Lifting hazard phase outlet having operating capacity of 15 The compressor is heavy. Ensure that proper lifting amps on 115V or 7.5 amps on 230V. equipment is available to unload and move compressor Wiring: to installation site.
  • Page 12: Operation

    Moving Parts. Keep hands, feet, hair and apparel away engine and pump. from moving parts. Never remove any guards while the unit is operating. Do not reach into an air vent or Models 25653 and 25654 cavity, as they may cover dangerous moving parts. Breather Cap Oil Cap Ear Protection.
  • Page 13: Proper Air Hose And Tool Use

    Model 48578 WARNING: Overheating This compressor is equipped with “auto shut off”. However, failure to allow adequate cooling ventilation or Breather Cap Oil Cap a restriction in the intake airflow may cause the machine to overheat. WARNING: Inflatables/Low PSI tire Never use compressor to inflate small low-pressure objects, i.e., balloons/inflatables, small or low volume PSI tires.
  • Page 14: Using Compressor For Spraying

    Shutdown CAUTION: Air tools hazard Do not attach air tools to open end of the hose until Procedure start-up is completed and the unit checks out OK. When you are finished using the compressor: Quick Connect Procedure: 1. Move the pressure switch to the OFF position. Keep finger off tool or activation switch until ready ...
  • Page 15: 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 16: Change Pump Oil

    Change Pump Oil Belts will stretch from normal use. When properly adjusted, a 5 lb. force applied to the belt between the WARNING: Burn hazard motor pulley and the pump will deflect the belt about ½”. Never open oil fill port while compressor is running. Hot oil can spray over face and body.
  • Page 17: Cylinder Head Bolt Torque Specification

    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.
  • Page 18: 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 19: Parts Explosions - Model 25653 Rev C.3

    Parts Explosions – Model 25653 Rev C.3 Pump not shown on this parts explosion Note: NorthStar tank decal part # 792438 (no shown)
  • Page 20: Parts List - Model 25653 Rev C.3

    Parts List – Model 25653 Rev C.3 Ref# Part# Description Ref# Part# Description Air Tank 791566 Motor 788886 Drain Valve 788895 Motor Feet Set Bolt (4 pcs) Tank Wheel Bolt Motor Pulley Kit # 1 Kit # 6 Tank Wheel...
  • Page 21: Parts Explosions - Model 25654 Rev C.3

    Parts Explosions – Model 25654 Rev C.3 Pump not shown on this parts explosion Note: NorthStar tank decal part # 792438 (no shown)
  • Page 22: Parts List - Model 25654 Rev C.3

    Parts List – Model 25654 Rev C.3 Ref# Part# Description Ref# Part# Description Air Tank 791566 Motor 788886 Drain Valve 788895 Motor Feet Set Bolt (4 pcs) Tank Wheel Bolt Motor Pulley Kit # 1 Kit # 2 Tank Wheel Bolt Kit # 4 Rubber Pad Set...
  • Page 23: 788876 Pump Explosion Rev C.3

    788876 Pump Explosion Rev C.3 Wing nut for # 28 not shown...
  • Page 24: 788876 Pump Parts List Rev C.3

    788876 Pump Parts List Rev C.3 Ref# Part# Description Kit # 788877 Cylinder head Allen bolt set In.& Ex. valve assembly Double head screw set Cylinder Cylinder gasket Kit # 1 & Kit # 2 Piston ring set Kit # 1 Piston set Rod set Crankcase...
  • Page 25: Parts List - Model 48578 Rev C.3

    Parts List – Model 48578 Rev C.3...
  • Page 26: Parts List - Model 48578 Rev C.3

    Parts List – Model 48578 Rev C.3 Ref# Part# Description Ref# Part# Description Air Tank Cable Kit # 8 788886 Drain Valve Power Cable Tank Wheel Bolt Pressure Switch Kit # 1 Kit # 4 Tank Wheel Pressure Relief Valve Kit # 2 Rubber Pad Set 792362...
  • Page 27: 792353 Pump Exploded View Rev C.3

    792353 Pump Exploded View Rev C.3...
  • Page 28: 792353 Pump Parts List Rev C.3

    792353 Pump Parts List Rev C.3 Ref# Part# Description Cylinder head Kit # 1 Allen bolt set (M6x40) Exhaust elbow 789354 Air filter set 789355 Filter element 792324 Kit # 3 In. & Ex. Valve assembly Double head screw Kit # 2 Cylinder Kit # 2 Kit # 3...
  • Page 29: 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 30: Limited Warranty

    NorthStar Warranty Item # Consumer Warranty Period Commercial Warranty Period 25653 25654 4 years from date of purchase by user 2 years from date of purchase by user 48578 “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 32 Assembled by Northern Tool & Equipment Company, Inc. Burnsville, MN 55306 NorthernTool.com...

This manual is also suitable for:

25654

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