60 Gal. Hi-Flow Electric Air Compressor ELECTRICCOMPRESSOR Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
Thank you very much for choosing a NorthStar® product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This air compressor is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 5 Packaging Contents .............................................................................................................................. 5 Technical Specifications ...................................................................................................................... 5 Safety Signal Words ..........................
Checking Air Filter .......................................................................................................................... 21 Draining Air Tank ............................................................................................................................ 21 Pump Oil...............................................................................................................................................22 Compressor Pump Oil ..............................................
Intended Use The NorthStar 60 Gallon Hi-Flow Electric Air Compressor provides compressed air for air tools and pressurized objects that require high air pressure. • Maximum Efficiency: Heavy-duty 230V induction motor for maximum performance and efficiency. • Long Lasting Operation: One-piece cast iron oil-lubricated pump for long service life. • Efficient Operation: Three-cylinder design provides consistent cooling for long pump life.
Important Safety Information ⚠WARNING • Read and understand all instructions. Failure to follow all instructions may result in serious injury or property damage. • The warnings, cautions, and instructions in this manual cannot cover all possible conditions or situations that could occur. Exercise common sense and caution when using this tool. Always be aware of the environment and ensure that the tool is used in a safe and responsible manner.
• Keep your work area clean and well lit. Ensure floors are not slippery from wax or dust. • The compressed air directly from your compressor is not safe for breathing. The air stream may contain carbon monoxide, toxic vapors, or solid particles from the air tank. Breathing these contaminants can cause serious injury or death. Never use air obtained directly from the compressor to supply air for human consumption.
• The compressed air stream can cause soft tissue damage to exposed skin and can propel dirt, chips, loose particles and small objects at high speed, resulting in property damage or personal injury. Never point any nozzle or sprayer toward any part of the body or at other people or animals. ⚠CAUTION AIR COMPRESSOR USE AND CARE • Do not force the air compressor. Products are safer and do a better job when used in the manner for which they are designed.
Specific Operation Warnings ⚠WARNING • Repairs attempted by unqualified personnel can result in serious injury or death by electrocution. Any electrical wiring or repairs required on this product should be performed by authorized service center personnel in accordance with national and local electrical codes. • Failure to provide adequate grounding to this product could result in serious injury or death from electrocution. Refer to the grounding instructions paragraph in the Installation section.
Components 1. Safety Valve: This valve is designed to prevent system failures by relieving pressure from the system when the compressed air reaches a predetermined level. The valve is preset by the manufacturer and must not be removed or modified in any way. 2. Tank Pressure Gauge: The tank pressure gauge indicates the reserve air pressure in the tank. 3. Pressure Switch: The pressure switch automatically starts the motor when the air tank pressure drops below the factory set cut-in pressure.
Figure B Assembly ⚠WARNING • This compressor was shipped with oil in the pump crankcase. Check oil before operating the air compressor, see Check Oil under Maintenance. Unpack the air compressor. Inspect the unit for damage. If the unit has been damaged in transit, contact the carrier and complete a damage claim. Do this immediately because there are time limitations to damage claims.
Disconnecting Hoses 1. Ensure regulated pressure gauge reads 0 PSI. 2. Remove hose from air outlet. Installation Lubrication and Oil The air compressor pump was filled with oil at the manufacturer. Check the air compressor pump oil level before operating unit. See Compressor Pump Oil under Pump Oil. Compatibility Air tools and accessories that are run off the compressor must be compatible with petroleum-based products.
The air compressor MUST be bolted to a level, solid concrete surface. Use 3/8” lag screws, vibration pads, and concrete anchors. If help is needed anchoring the air compressor, consult a licensed contractor. 1. Place the air compressor on a level, solid concrete surface. Make sure the concrete is in good condition without cracks or damage. 2. Mark the surface using the holes in the air compressor feet as a template. 3. Drill holes in the surface for the concrete anchors. Install concrete anchors. 4.
Wiring Instructions A qualified electrician needs to know the following before wiring: 1. The amperage rating of the electrical box should be adequate. Refer to the air compressor’s serial label for the unit’s voltage and amperage requirements. Ensure that all wiring is done by a licensed electrician, in accordance with the National Electrical Code. 2. The supply line should have the same electrical characteristics (voltage, cycle, and phase) as the motor.
Motor Reset ⚠WARNING • Make sure that all guards and shrouds are in place before pressing the reset switch to restart the motor. Motor Reset Switch If the motor shuts down because of an overload, wait 10–15 minutes so the motor can cool down, then press (NEVER force) the reset switch (see Figure D) to restart the motor. Figure D Air Distribution System ⚠WARNING • Risk of bursting. Plastic or PVC piping is not designed for use with compressed air.
Figure E How to Use Your Unit ⚠WARNING • Do not operate this unit until you read this instruction manual for safety, operation, and maintenance instructions.
Figure F How to Stop Set the Auto/Off switch to OFF. Break-In Procedure ⚠WARNING • Risk of property damage. Serious damage may result if the following break-in instructions are not closely followed. This procedure is required before the air compressor is put into service and when the check valve or a complete compressor pump has been replaced. 1. Make sure the Auto/Off switch is in the OFF position. 2. Check oil level in pump. See the Pump Oil section for instruction. 3. Recheck all wiring.
NOTE: After about 30 minutes, if the unit does not operate properly, SHUT DOWN IMMEDIATELY, and contact the customer service department. 7. Check all air line fittings and connections/piping for air leaks by applying a soap solution. Correct if necessary. NOTE: Minor leaks can cause the air compressor to overwork, resulting in premature breakdown or inadequate performance. 8. Check for excessive vibration. Readjust or shim air compressor feet, if necessary. 9.
Operating Instructions ⚠WARNING • Risk of bursting. If any unusual noise or vibration is noticed, stop the compressor immediately and have it checked by a trained service technician. How to Start 1. Turn the Auto/Off switch to AUTO and allow tank pressure to build. Motor will stop when tank pressure reaches “cut-out” pressure. 2. When the tank pressure reaches “cut-out” pressure, open the globe valve/air discharge valve.
rupture or an explosion. • Risk of burn. Tubes, pump head, and surrounding parts are very hot; do not touch these. See the Hot Surfaces section with areas identified in Figure B. Allow compressor to cool prior to servicing. • Risk from flying objects. Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA Z94.3 with side shields). • Risk from noise. Use ear protection ANSI S12.6 (S3.19) as air flow noise is loud when draining. • Risk of bursting.
Checking Safety Valve Before starting the compressor, pull the ring on the safety valve to make sure that the safety valve operates freely. If the valve is stuck or does not operate smoothly, it must be replaced with the same type of valve. Checking Air Filter A dirty air filter will not allow the compressor to operate at full capacity. Keep the air filters clean at all times. Figure G 1. Ensure Auto/Off switch is in the OFF position. 2. Allow unit to cool. 3. Remove the 3 nuts (A). 4.
Pump Oil Compressor Pump Oil ⚠WARNING • Risk of property damage. Use air compressor oil only. Multi-weight automotive engine oils like 10W30 should not be used in air compressors. They leave carbon deposits on critical components, thus reducing performance and compressor life. • Use synthetic blend, non-detergent air compressor oil. • Crankcase oil capacity is approximately 33 fluid ounces (976 ml). Checking Oil 1. The oil level should be to the middle of the sight glass (G). 2.
Belt Replacement / Belt Tension / Motor Pulley & Flywheel Adjustment ⚠WARNING • This unit starts automatically. ALWAYS shut off and disconnect the compressor and bleed all pressure from the system before servicing the compressor, and when the compressor is not in use. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts. • Hot surfaces. Risk of burn. Pump head and surrounding parts are very hot; do not touch.
1. Set the Auto/Off lever to OFF, unplug the unit, and relieve all air pressure from the air tank. 2. Remove the belt guard. 3. Place a straight edge against the outside of the flywheel and the motor drive pulley. 4. Measure the distance between the edge of the belt and the straightedge (points A1 and A2 in figure L). The difference between measurements should be no more than 1/16” (1.6 mm). Figure L 5. If the difference is greater than 1/16” (1.
⚠WARNING • Risk of unsafe operation. Unit cycles automatically when power is on. When performing maintenance, you may be exposed to voltage sources, compressed air, or moving parts. Personal injuries can occur. Before performing any maintenance or repair, disconnect power source from the compressor and bleed off all air pressure. Replace or Clean Check Valve 1. Release all air pressure from the air tank. See Draining Air Tank in the Maintenance section. 2.
Troubleshooting Failure Possible Cause Corrective Action Fittings are not tight Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. DO NOT OVERTIGHTEN. Air leaks in air tank or at air tank welds Defective air tank Air tank must be replaced. Do not repair the leak. Warning: Risk of bursting. Do not drill into, weld, or otherwise modify air tank or it will weaken. The air tank can rupture or explode.
Failure Possible Cause Loose pulley Loose flywheel Carbon build-up in pump Belt too tight Pump oil is low Loose belt Loose pulley Excessive belt wear Belt to tight Pulley misalignment Squealing sound Loose belt Fittings are not tight Leaking seals Unit operating in damp or humid conditions Corrective Action Tighten pulley set screw, torque to 15-20 ft.-lb. (20.3-27.1 Nm). Tighten flywheel screw, torque to 14–18 ft.-lb. (20.0–24.4 Nm). Contact an authorized service center.
Failure Possible Cause Corrective Action circuit. If using extension cord, try using without. If compressor is connected to a circuit protected by a fuse, use dual element time delay fuses (Buss Fuse Tron type “T” only). Restricted air passages Compressor won’t start in cold temperatures Compressor stalls Overheating Inspect and replace transfer tubes or check valve, as required.
Air Compressor Parts Diagram Air Compressor Parts Diagram Reference 1 2 3 4 5 6 7 8 9 10 11 13 15 Part Number 145-0439 058-0016 031-0060 064-0003 145-0698 059-0012 114-0825 059-0010 058-0149 065-0005 See page 33 021-0251 Part Description Transfer tube Compression nut Check valve Elbow Bleeder tube Pump assembly Bolt, 5/16 x 1/2” Bracket Bolt, 5/16 x 1.25” Nut, 5/16” Nipple, 1/4” NPT x 2.
Reference 15a 15b 15c 15d 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 Part Number 512-0041 072-0019 512-0043 513-0001 098-3870 098-2856 058-0125 098-3031 059-0362 026-0735 160-0370 125-0232 060-0146 061-0113 007-0069 061-0238 146-0016 006-0159 061-0134 060-0144 125-0233 103-0205 071-0003 061-0255 060-0156 Part Description Bushing, 2” NPT x 1/4” NPT Petcock Bushing, 2” NPT x 3/4” NPT O-ring 2” Warning label Warning label Nut, 5/16-18 Warning label Bolt, 5/16 x .
Pump Parts Diagram Pump Parts List Reference 1 2 3 4 4A 7 8 9 10 11 12 13 Part Number 059-0412 060-0219 042-0117 019-0222 019-0221 058-0016 069-0025 145-0447 N/A 069-0024 064-0077 046-0286 Part Description Screw, M8 x 65 Washer, M8 Head Filter canister assembly (includes item 4A) Element, filter replacement Compression nut Tee fitting Finned tube (includes item 10) Airflow nut (included on item 9) Tee fitting Elbow Gasket, head to valve plate Page 31 of 36 Quantity 12 12 3 3 3 1 1 2 4 1 1 3
Reference 14 15 16 17 18 19 20 21 22 23 23A 24 24A 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 ** 43 ** 44 ** Part Number 043-0194 046-0287 058-0188 059-0413 060-0222 050-0062 046-0288 054-0241 048-0117 047-0094 056-0068 047-0095 056-0069 056-0070 059-0414 060-0220 077-0180 046-0289 032-0125 062-0075 049-0051 051-0100 053-0105 146-0026 046-0290 046-0291 077-0181 056-0096 060-0221 059-0415 044-0063 060-0183 059-0416 45 046-0292 46 165-0265 040-0348 ** Must be purchased separately Part Descrip
Switch Assembly Parts Diagram Switch Assembly Parts List Reference 1 2 3 4 5 6 7 Part Number 032-0025 034-0184 071-0033 061-0216 136-0077 062-0035 136-0090 Part Description Gauge, 300# 1/4” bottom connect Switch, pressure 155 PSI (includes items 3-4 and 6-7) Strain relief Screw Valve, ASME Plug, 1/4” Valve, bleeder Quantity 1 1 1 1 1 1 1 Replacement Parts • For replacement parts and technical questions, please call Customer Service at 1-888-895-4549.
Limited Warranty Dear Valued Customer: The NorthStar® 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® 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.
chemicals, use of replacement parts which do not conform to manufacturer’s specifications, and damage related to rodent and/or insect infestation and damage caused by vandalism. EXCEPT AS PROVIDED HEREIN, NORTHSTAR® BY AND THROUGH ITS OWNER NORTHERN TOOL & EQUIPMENT COMPANY, INC. (“NTE”) HEREBY DISCLAIMS ALL WARRANTIES (WHETHER EXPESS, STATUTORY, OR IMPLIED) INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT.
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