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M4592900A.4
ITEM NUMBER: 4592900, 4593000,
SERIAL NUMBER: _____________
Owner’s Manual
Belt-Driven Air Compressor Pumps
4593100
Instructions for Installation/Set-up, Operation, Maintenance, & Storage
This NorthStar® belt-driven compressor pump has either a single stage 2-cylinder pump (Model 4592900),
2-stage 3-cylinder pump (Model 4593000) or a 2-stage 2-cylinder pump (Model 4593100), made with heavy-duty cast
iron cylinders for long life, and a compact design rated for 130 maximum PSI (4592900) or 175 maximum PSI
(4593000 and 4593100). 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 pump 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 compressor pumps 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.
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.
Check Pump Oil: Pump is NOT shipped with oil. Check the pump oil level before starting. See “Preparing for
Operation” section of this Owner’s Manual for capacity and viscosity.
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 drain valves and run compressor pump 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.
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Table of Contents
Equipment Protection Quick Facts ........................................................................................................................................ 1
Table of Contents ........................................................................................................................................................ 2
About Your Air Compressor Pump ............................................................................................................................ 4
Specifications .............................................................................................................................................................. 5
Engine / Motor Pulley Sizing Calculations ............................................................................................................................. 5
Component Identification ........................................................................................................................................... 6
Mounting Dimensions ................................................................................................................................................. 7
Safety Signal Words .................................................................................................................................................... 8
Hazard Signal Word Definitions ............................................................................................................................................ 8
Initial Set-Up ................................................................................................................................................................ 9
Step 1. Inspect & Unpack ........................................................................................................................................................ 9
Step 2. Assembly ..................................................................................................................................................................... 9
Attach Regulator (Recommended) ........................................................................................................................................ 9
Step 3. Select Suitable Location ............................................................................................................................................. 9
Operation ................................................................................................................................................................... 10
Follow Operation Safety Rules ............................................................................................................................................. 10
Prepare for Operation ............................................................................................................................................................ 10
Check/Add Oil to the Pump ................................................................................................................................................. 10
Proper Air Hose and Tool Use .............................................................................................................................................. 11
Pressure Control Related Devices ...................................................................................................................................... 11
Compressor - Tool Requirements ....................................................................................................................................... 11
Using Compressor Pump for Spraying ................................................................................................................................ 11
Flammable Materials ........................................................................................................................................................... 11
Moisture in Compressed Air ................................................................................................................................................ 11
For Malfunction During Operation ....................................................................................................................................... 12
Maintenance & Repair ............................................................................................................................................... 13
Maintenance Schedule Summary ............................................................................................................................. 13
Detailed Instructions – Maintenance & Repair ........................................................................................................ 13
Inspect Safety/Relief Valve ................................................................................................................................................. 13
Inspect Air Filter .................................................................................................................................................................. 13
Keep Compressor Clean ..................................................................................................................................................... 13
Inspect Compressor for Air Leaks ....................................................................................................................................... 14
Change Pump Oil ................................................................................................................................................................ 14
Check Drive Belt for Tension and Alignment....................................................................................................................... 14
Keep Compressor Clean ..................................................................................................................................................... 14
Troubleshooting ........................................................................................................................................................ 15
4592900 Pump Explosion ......................................................................................................................................... 16
4592900 Pump Parts List .......................................................................................................................................... 17
4592900 Pump Kits .................................................................................................................................................... 17
4593000 Pump Explosion ......................................................................................................................................... 18
4593000 Pump Parts List .......................................................................................................................................... 19
4593000 Pump Kits .................................................................................................................................................... 20
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4593100 Pump Explosion ......................................................................................................................................... 21
4593100 Pump Parts List .......................................................................................................................................... 22
4593100 Pump Kits .................................................................................................................................................... 23
Appendix A: Lubricants and Compatibility ............................................................................................................. 24
Alternate Lubricants. ........................................................................................................................................................... 24
Limited Warranty ....................................................................................................................................................... 25
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About Your Air Compressor Pump
Thank you for purchasing a NorthStar air compressor
pump! 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:
Pressure regulator (recommended)
Pump oil
Personal protection equipment
See “Specifications” section for more detail.
Site Location. Intended for indoor/outdoor 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 pump. Do not let
children operate.
Under The Influence. Never operate, or let anyone else
operate, the air compressor pump 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
pump must have access to and read this Owner’s
Manual. Keep this manual with the air compressor pump
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 pump 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 #
4592900
4593000
4593100
Stages
1-stage
2-stage
2-stage
Cylinders
2-cylinder
3-cylinder
2-cylinder
Outlet Port Size
5/8”
1/2”
3/4”
FLOW OUTPUT
Max. Pressure Rating
130 PSI
175 PSI
175 PSI
Volume Rating @ 90PSI
13.7 CFM
14.9 CFM
17.4 CFM or 24.4 CFM
Pump Flywheel Diameter
10.5”
12.5”
16”
Maximum Pump RPM
1396 RPM
1242 RPM
809 RPM or 1132 RPM
MOTOR / ENGINE HORSEPOWER REQUIREMENT
Electric Motor
4 HP min.
5 HP min.
5 HP min. or 7.5 HP min.
Gasoline Engine
5.5 HP min.
9 HP min.
9 HP min. or 13 HP min.
DIMENSIONS / COMPONENTS
Length
14.9”
19.7”
22.8”
Width
12.6”
13.7”
13.8”
Height
12.6”
16.9”
20.5”
Weight
52 lbs.
73 lbs.
123 lbs.
Belt Style
A groove – Qty 1
A groove – Qty 1
A groove – Qty 2
SUPPLIES REQUIRED (not included)
Pump Oil
(shipped with oil, but
refills required)
SAE 30 non-detergent
pump oil (#4043)
SAE 30 non-detergent
pump oil (#4043)
SAE 30 non-detergent
pump oil (#4043)
Pump Oil Capacity
15.6 oz.
27 oz.
33.8 oz.
Engine / Motor Pulley Sizing Calculations
Engine/Motor Pulley Diameter = Pump RPM x Pump Flywheel Diameter
Engine/Motor RPM
Pump RPM = Engine/Motor Pulley Diameter x Engine/Motor RPM
Pump Flywheel Diameter
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1. Oil Cap: A cover for the hole where the oil is poured in.
2. Breather Cap: Allows air to enter/exit the crankcase.
3. Air Filter: Removes particles from the air before they
reach the pump. Keep clean and particle free. See
“Pump Explosion and Pump Parts List” for replacement
part number.
4. Sight Glass: A window through which the level of oil can
be checked visually.
5. Magnetic Oil Drain Plug: Removal allows for drainage
of oil from pump. Attracts metal particles that could
damage pump.
6. Intercooler: Cools the compressed air as it travels
between stages. The flywheel/fan creates an air flow that
rushes past and cools the intercooler.
7. Aftercooler: Cools the compressed air from the pump
before it enters the receiver tank. The heat from the
compressed air is transferred outward to the cast iron
fins of the Aftercooler, the flywheel/fan creates an air
flow that rushes past and cools the cast iron fins.
Oil Cap
Sight
Glass
Magnetic Drain
Plug
Breather Cap
Air Filter
Oil Cap
Sight
Glass
Magnetic Drain
Plug
Breather Cap
Air Filter
Oil Cap
Sight
Glass
Magnetic Drain
Plug
Breather
Cap
Air Filter
Intercooler
Intercooler
Aftercooler
Aftercooler
Intercooler
4592900
4593000
4593100
Component Identification
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4592900
4593000
4593100
Mounting Dimensions
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Safety Signal Words
DANGER
WARNING
CAUTION
CAUTION
NOTICE
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
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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