BE AC5161B User manual

User Manual
AC5161B
AC5161BP
VERTICAL 60 GALLON
AIR COMPRESSOR

2 3
table of contents
Safety
6 Safety Rules
7 Safety Warnings
Overview
11 Basic Air Compressor Components
Assembly
13 Assembling the Compressor
Installation
15 Installation Chart
16 Typical Installation
Controls
17 Compressor Controls
Electrical Power Requirements
18 Electrical Wiring
18 Main Power Panel
18 Main Power Disconnect Switch
18 Low Voltage Problems
19 Grounding Instructions
Break-In of the Pump
20 Break-In of the Pump
table of contents
Operating
22 Daily Start-up
22 Cold Weather Starting
22 Shutdown
Maintenance
24 Draining the Tank
24 Checking the Oil
24 Changing the Oil
25 Belt Tension and Pulley Alignment
25 Adjusting Drive Belt Tension
26 Pulley Alignment
27 Cleaning the Air Filter
28 Checking the Relief Valve
27 Testing for Leaks
27 Storage
28 Service Interval
Troubleshooting
29 Troubleshooting Chart
Maintenance Notes
31 Maintenance Notes

4 5
Using the Operator’s manual
The operating manual is an important part of your Compressor. It should
be read thoroughly before initial use, and referred to often to make sure
adequate safety and service concerns are being addressed.
Reading the owner’s manual thoroughly will help avoid any personal injury
or damage to your pump. By knowing how best to operate this machine
you will be better positioned to show others who may also operate the
unit.
You can refer back to the manual at any time to help troubleshoot any
specific operating functions, so store it with the machine at all times.
Attention: Read through the complete
manual prior to the initial use of your
Compressor
introduction product identification
Record Identification Numbers
Compressor
If you need to contact an Authorized Dealer or Customer Service
(1-866-850-6662) for information on servicing, always provide the
product model and identification numbers.
You will need to locate the model and serial number for the pump and
record the information in the places provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
Product Identification Numbers
Model Number:
Serial Number:

6 7
safety
The safety alert symbol ( ) is used with a signal word (DANGER,
CAUTION, WARNING), a pictorial and/or a safety message to alert
you to hazards.
DANGER indicates a hazard which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazard which, if not avoided, could result in
death or serious injury.
CAUTION indicates a hazard which, if not avoided, might result in
minor or moderate injury.
NOTICE indicates a situation that could result in equipment damage.
Follow safety messages to avoid or reduce the risk of injury or
death.
Hazard Symbols and Meanings
Save these Instructions
SAFETY RULES
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.
explosion
read manual
fire
toxic fumes hot surface
flying objects
moving parts
hearing risk
electric
shock
safety
WARNING
Risk of Fire or Explosion.
Never spray flammable liquids in confined area. It is normal for the
motor and pressure switch to produce sparks while operating. If sparks
come into contact with vapors from gasoline or other solvents, they may
ignite, causing fire or explosion. Always operate the compressor in a
well-ventilated area. Do not smoke while spraying. Do not spray where
sparks or flame are present. Keep compressor as far from spray area as
possible.
WARNING
Risk of Bursting.
• Do not weld, drill or modify the air tank of this compressor. Welding
or modifications on the air compressor tank can severely impair tank
strength and cause an extremely hazardous condition. Welding or
modifying the tank in any manner will void the warranty.
• Check the manufacturer’s maximum pressure rating for air tools and
accessories. Compressor outlet pressure must be regulated so as
to never exceed the maximum pressure rating of the tool. Relieve all
pressure through the hose before attaching or removing accessories.
• Do not adjust the relief valve for any reason. Doing so voids all
warranties. The relief valve has been pre-set at the factory for the
maximum pressure of this unit. Personal injury and/or property
damage may result if the valve is tampered with.
• Do not use plastic or pvc pipe for compressed air. Use only
galvanized steel pipe and fittings for compressed air distribution lines.

8 9
safety
WARNING
Risk of Electrical Shock.
Never use an electric air compressor outdoors when it is raining or on a
wet surface, as it may cause an electric shock.
WARNING
Risk of Injury.
This unit starts automatically. ALWAYS shut off the main power
disconnect, 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. Stay alert and watch what you
are doing when operating the compressor. Do not use the compressor
while tired or under the influence of drugs or alcohol.
WARNING
Risk of Burns.
High temperatures are generated by the pump and manifold. To prevent
burns or other injuries, DO NOT touch the pump, manifold or transfer
tube while the pump is running. Allow them to cool before handling or
servicing. Keep children away from the compressor at all times.
WARNING
Risk of airbourne chemicals.
Be certain to read all labels when you are spraying paints or toxic ma-
terials, and follow the safety instructions. Use a respirator mask if there
is a chance of inhaling anything you are spraying. Read all instructions
and be sure that your respirator mask will protect you. Never directly in-
hale the compressed air produced by a compressor as it is not suitable
for breathing purposes.
safety
WARNING
Risk of Eye Injury.
Always wear ANSI Z87.1 approved safety goggles when using an air
compressor. Never point any nozzle or sprayer toward a person or
any part of the body. Equipment can cause serious injury if the spray
penetrates the skin.
WARNING
Risk of Hearing Loss.
Always wear hearing protection when using an air compressor. Failure
to do so may result in hearing loss.
WARNING
Wash hands after handling. The power cord on this
product contains lead, a chemical known to the State
of California to cause cancer, and birth defects or other
reproductive harm.
NOTICE
• ELECTRICAL WIRING. 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.
This product can expose you to chemicals
including lead, which is known to the State
of California to cause cancer and birth
defects or other reproductive harm. For more
information, go to www.P65Warnings.ca.gov.
Wash hands after handling.
!

10 11
safety
CAUTION
1. Drain the moisture from the tank on a daily basis. A clean, dry tank
will help prevent corrosion.
2. Pull the pressure relief valve ring daily to ensure that the valve
is functioning properly, and to clear the valve of any possible
obstructions.
3. To provide proper ventilation for cooling, the compressor must be
kept a minimum of 12 inches (31 cm) from the nearest wall, in a
well-ventilated area.
4. To prevent damage to tank and compressor on stationary models,
the tank must be shimmed to the pump base is level within 1/8” to
distribute oil properly. All feet must be supported, shimming where
necessary, prior to attaching to the floor. Fasten all feet to floor. We
also recommend the use of vibration pads (094-0137) under tank
feet.
5. Fasten the compressor down securely if transporting is necessary.
Pressure must be released from the tank before transporting.
6. Protect the air hose from damage and puncture. Inspect them
weekly for weak or worn spots, and replace if necessary.
7. To reduce the risk of electric shock, do not expose to rain. Store
indoors.
overview
The basic components of the air compressor are the electric motor,
Thermal Overload Protection System (TOPS), pump, and receiver (tank).
The tank may be vertical or horizontal, varying in size and capacity.
The electric motor (see A) powers the pump.
TOPS senses both temperature and current, providing more complete
motor overload protection than a magnetic starter, which senses only
current. If TOPS senses an overload condition, it will automatically
shutdown the compressor. Allow 10-15 minutes for the unit to cool
down, then press the reset button on the motor to restart the compressor.
The pump (see B) compresses the air and discharges it into the tank.
The tank (see C) stores the compressed air.
The pressure switch (see D) shuts down the motor and relieves air
pressure in the pump and transfer tube when the air pressure in the
tank reaches the kick–out pressure. As compressed air is used and the
pressure level in the tank drops to the kick–in pressure, the pressure
switch restarts the motor automatically, without warning and the pump
resumes compressing air.
Overview
BASIC AIR COMPRESSOR COMPONENTS

12 13
overview
BASIC AIR COMPRESSOR COMPONENTS
FIG 1
assembly
Assembly
ASSEMBLING THE COMPRESSOR
1. 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 as there are time limitations to damage
claims.
The carton should contain:
· air compressor
· operator and parts manuals
2. Check the compressor’s serial label to ensure that you have received
the model ordered, and that it has the required pressure rating for its
intended use.
3. Set up the compressor according to the following guidelines:
a. For optimum performance, locate the compressor close to the power
panel, as specified in ELECTRICAL POWER REQUIREMENTS,
and as close as possible to the place where the air will be used.
This ensures maximum power to the compressor and maximum air
pressure to the tool. If both of these conditions cannot be met, it is
better to locate the compressor close to the power panel, and use a
longer hose to reach the usage area.
b. The compressor must be at least 12 inches (31 cm) from any wall
or obstruction, in a clean, well-ventilated area, to ensure sufficient air
flow and cooling.
c. In cold climates, place the compressor in a heated building, to
reduce problems with lubrication, motor starting, and freezing of
water condensation.
d. Remove the compressor from the shipping pallet and place it on
the floor or a hard, level surface. The compressor must be level to
ensure proper lubrication of the pump and good drainage of the
moisture in the tank.
WARNING
Never place the compressor in an area where there are
fumes from flammable fluids such as paint, solvents, or
gasoline. It is normal for the motor and pressure switch
to produce sparks while operating. If sparks come into
contact with flammable fumes, they may ignite, causing
a fire or explosion. Always operate the compressor in a
well ventilated area.
C
A
B
D

14 15
CAUTION
• The shipping pallet is not designed as a base for an operating the
compressor. Operating the compressor while it is on the pallet will
void your warranty.
assembly
FIG 2
e. To prevent damage to tank and pump, the tank must be shimmed so
the pump is level within 1/8” per lineal foot maximum to distribute oil
properly. Fasten to floor and NEVER force tank feet to floor without
shims when tightening. We also recommend the use of vibration
pads (094-0137) under tank feet (see A).
5. Connect an air hose (not included) to the compressor.
installation
Installation
INSTALLATION CHART
WARNING
• Risk of bursting, resulting in injury. Never use Plastic pipe for
compressed air.
CAUTION
• Never use lubricator for paint spraying or similar applications.
FIG 4
A. Air flow
B. Feeder line
C. Drain leg
D. Moisture trap with drain
E. Non-lubricated supply line
F. 1/4 turn valve
G. Bypass
H. Air dryer or aftercooler
J. Line filter
K. Drip tee with drain
L. Air/water filter with petcock
M. Regulator
N. Lubricator
P. Quick coupler
R. Air hose to tool
T. Flexible air line

16 17
installation
TYPICAL INSTALLATION
Air dryers and after coolers
An air dryer or aftercooler is installed directly in the air line.
Moisture removal and air filtration
As the air cools, moisture will condense in the lines. This moisture
must be removed before it reaches the tool being used. To remove this
moisture, run the main air line downhill to a moisture trap and drain. Air/
water filters should also be installed in the positions shown.
Air pressure regulation
The air pressure gauge on the pressure switch measures air pressure
inside the tank, not pressure in the air line. Install an air regulator in the
drop line for each tool, to regulate air pressure to that tool. Never exceed
the maximum pressure rating of the tool.
Air lubrication
Install an air lubricator only for those tools requiring lubrication. Do not
use a lubricator for paint spraying or similar applications. The oil will
contaminate the paint and ruin the job.
Shut–off valves
Install shut–off valves in each drop line, to isolate the tool and its
accessories for servicing. You can also install a bypass line around an
accessory.
controls
Controls
COMPRESSOR CONTROLS
Motor Reset Switch
TOPS senses both temperature and current, providing more complete
motor overload protection than a magnetic starter, which senses only
current. If TOPS senses an overload condition, it will automatically shut
down the compressor. Allow 10-15 minutes for the unit to cool down,
than press the reset button on the motor to restart the compressor.
If the motor shuts down because of overload, wait 10–15 minutes so the
motor can cool down, then press (NEVER force) the reset switch on the
front of the motor to restart the motor.
Pressure Switch (see A)
This switch turns on the compressor. It is operated manually, but when
in the ON position, it allows the compressor to start up or shut down
automatically, without warning, upon air demand. ALWAYS set this switch
to OFF when the compressor is not being used, and before unplugging
the compressor.
The pressure switch also automatically bleeds pressure from the pump
head when the pump stops. This feature eliminates back pressure in the
pump, ensuring easier starting.
Pressure Relief Valve (see B)
If the pressure switch does not shut down the motor when pressure
reaches the preset level, this valve will pop open automatically to prevent
over pressurization. To operate manually, pull the ring on the valve to
relieve air pressure in the tank. Pull the ring daily to test.
Tank Pressure Gauge (see C)
This gauge measures the pressure level of the air stored in the tank. It is
not adjustable by the operator, and does not indicate line pressure.
WARNING
• For your safety, tank pressure is preset within the switch and must
never be tampered with.
Measures pressure in
tank, not line pressure.
FIG 5

18 19
electrical power requirements
Electrical Power Requirements
ELECTRICAL WIRING
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. Use electrical conduit to
protect the wiring.
MAIN POWER DISCONNECT SWITCH
LOW VOLTAGE PROBLEMS
MAIN POWER PANEL
Install a main power disconnect switch in the line from the panel to the
compressor. The main power disconnect switch must be located near the
compressor, for ease of use and safety. When turned OFF, the main power
disconnect switch shuts off all power to the compressor. When it is turned
ON, the compressor will start and stop automatically, controlled by the
pressure switch.
Low voltage will cause difficult starting or an overload. Low voltage can
be caused by a low supply voltage from the local power company, other
equipment running on the same line, or inadequate wiring. If any other
electrical devices are drawing from the compressor’s circuit, it may fail to
start.
Low voltage to the compressor can be caused by a supply wire of
insufficient gauge for the distance between the compressor and the
power source. The longer the distance, the larger the wire gauge (lower
the number) must be, to overcome the inherent voltage loss caused by the
wire resistance. Refer to the National Electrical Code to determine proper
wire size for your circuit.
If the wiring is not adequate, the input voltage will drop by 20 to 40 volts at
startup. Low voltage or an overloaded circuit can result in sluggish starting
that causes the circuit breaker to trip, especially in cold conditions.
For best performance and reliable starting, the air compressor must be
installed on a dedicated circuit, as close as possible to the electrical
power panel. Provide circuit breaker or fuse protection at your main power
panel. Use time delay fuses on the circuit, because the compressor will
momentarily draw several times its specified amperage when first started.
electrical power requirements
GROUNDING INSTRUCTIONS
This product must be connected to a grounded, metallic, permanent wiring
system, or an equipment - grounding terminal or lead on the product.