Compresor 750h

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®SULLAIR®

PORTABLE AIR COMPRESSOR600H, 600HH, 750, 750H

750HH, 825, 900, 900H, 1050Caterpillar

PART NUMBER:02250167-521

KEEP FORFUTUREREFERENCE

©SULLAIR CORPORATIONThe information in this document iscorrect at the time of printing for utilitycompressor serial number000–00000and all subsequent serial numbers.

OPER

ATOR

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®SULLAIR®

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenanceand service of Sullair equipment. Individual seminars on Portable compressors and compressor electricalsystems are presented at regular intervals throughout the year at a dedicated training facility at Sullair's corporateheadquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of themost common problems, and actual equipment operation. The seminars are recommended for Maintenanceand Contractor Maintenance and Service Personnel.

For detailed course outlines, schedule and cost information contact:

Sullair Customer Care Training Department : 1-888-SULLAIR or

219-879-5451 (ext. 5623)www.sullair.com

- Or Write -Sullair Corporation3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department

http://www.sullair.com

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1 - SAFETY...................................................................................................1General...................................................................................................1Towing ...................................................................................................1

Preparing To Tow...............................................................................1Towing..............................................................................................3Parking Or Locating Compressor .........................................................3

Pressure Release.....................................................................................4Fire And Explosion...................................................................................5Moving Parts............................................................................................6Hot Surfaces, Sharp Edges And Sharp Corners...........................................6Toxic And Irritating Substances..................................................................6Electrical Shock.......................................................................................7Lifting......................................................................................................7Entrapment..............................................................................................8Jump Starting...........................................................................................8California Proposition 65...........................................................................9

2 - DESCRIPTION.......................................................................................11Introduction............................................................................................11Description of Components.....................................................................11Sullair Compressor Unit, Functional Description.........................................14Compressor Cooling and Lubrication System, FunctionalDescription............................................................................................15Control System, Functional Description.....................................................18

Start - 0 to 65 psig (0 to 4.5 bar)..........................................................18Normal Operation - 80 to 100 psig (5.5 to 6.9 bar) .................................18Modulation - 100 to 115 psig (6.9 to 7.9 bar) .........................................18Dual Pressure – 150 psig (10.3 bar) models and 175 psig (12.1 bar) "HH"models............................................................................................18Manifold Valve – Control System........................................................19Control System.................................................................................20

Compressor Discharge System, Functional Description..............................21Air Inlet System, Functional Description....................................................22Instrument Panel Group, Functional Description.........................................23Engine Control Module, Functional Description..........................................23Electrical System, Functional Description..................................................25Electrical System....................................................................................26Aftercooler Air System, Functional Description...........................................28

3 - SPECIFICATIONS..................................................................................29Table of Specifications – 600H, 600HH, 750, 750H, 750HH.........................29Table of Specifications – 825, 900, 900H, 1050..........................................31

®SULLAIR®

TABLE OF CONTENTS

®SULLAIR®600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List iii

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Lubrication Guide – Compressor..............................................................33Application Guide...................................................................................33Lubrication Guide, Engine.......................................................................33

4 - OPERATION...........................................................................................35General.................................................................................................35Purpose of Controls................................................................................35Compressor Start-up Procedure...............................................................37Shutdown Procedure..............................................................................38

5 - MAINTENANCE......................................................................................39General.................................................................................................39Daily Operation......................................................................................39Maintenance After Initial 50 Hours of Operation..........................................39Maintenance Every 100 Hours.................................................................40Maintenance Every 250 Hours.................................................................40Maintenance Every 300 Hours.................................................................40Maintenance Every 600 Hours.................................................................40Maintenance Every 1000 Hours...............................................................40Maintenance Every 1200 Hours...............................................................40Parts Replacement and Adjustment Procedures........................................40

Compressor Fluid Change Procedure.................................................40Running Gear Lubrication..................................................................40Wheel Bearing Lubrication.................................................................42Main Fluid Filter Servicing..................................................................42Air Filter Maintenance.......................................................................43Element Removal.............................................................................44Element Inspection...........................................................................44Primary Element Replacement...........................................................44Control System Adjustment...............................................................45Separator Element Replacement........................................................47

Troubleshooting Guide............................................................................486 - NOISE CONTROL...................................................................................51

Noise Emissions Warranty.......................................................................51Tampering with the Noise Control System is Prohibited...............................51Noise Emissions Maintenance and Maintenance Record Log......................52

Noise Emission Maintenance and Maintenance RecordLog..................................................................................................52

7 - PARTS LISTS.........................................................................................55Serial Number Plate Location...................................................................55Recommended Spare Parts List...............................................................58Engine and Compressor Assembly...........................................................60Engine Assembly and Mounting...............................................................62Air Inlet System......................................................................................64Exhaust System.....................................................................................66Engine Cooling System, Standard............................................................68Engine Cooling System, Aftercooled.........................................................70Radiator and Fluid Cooling System, Non-Aftercooled.................................72Radiator and Fluid Cooling System, Aftercooled.........................................76Control System Manifold.........................................................................80Control System Components and Parts.....................................................82Discharge System, Non-Aftercooled.........................................................84Discharge System, Aftercooled................................................................88Discharge System, Aftercooled and Filtered..............................................92Receiver Sub-Assembly..........................................................................96Fuel System...........................................................................................98Moisture Trap Assembly, Aftercooled.....................................................102Drain Line Routing................................................................................104

TABLE OF CONTENTS

iv 600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List®SULLAIR®

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Shutters, Cold Weather.........................................................................106Downstream Filters...............................................................................108Control Lines........................................................................................110Frame, Running Gears and Parts, Tandem Axle, Electric BrakesStandard..............................................................................................112Frame, Running Gears and Parts, Tandem Axle, HydraulicBrakes.................................................................................................114Frame, Running Gears and Parts, 4-Wheel..............................................118Frame and Parts, Less Running Gear......................................................120Canopy and Parts.................................................................................122Canopy Panel Assembly, Front Panels....................................................130Canopy Panel Assembly, Curbside.........................................................132Canopy Panel Assembly, Street Side......................................................134Canopy Panel Assembly, Back...............................................................136Acoustic Insulation and Parts.................................................................138Electrical Parts.....................................................................................146Instrument Panels and Parts..................................................................148Controller and Pneumatic Assembly.......................................................150Decal Group.........................................................................................152Decal Locations, Tandem......................................................................154Decal Locations, 4-Wheel......................................................................156Decal Locations, Less Running Gear......................................................158Wiring Diagram.....................................................................................160

TABLE OF CONTENTS

®SULLAIR®600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List v

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vi 600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List®SULLAIR®

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NOTE

OPERATOR IS REQUIRED TO READENTIRE INSTRUCTION MANUAL.

1.1 GENERALSullair Corporation designs and manufactures all of itsproducts so they can be operated safely. However, theresponsibility for safe operation rests with those who useand maintain these products. The following safetyprecautions are offered as a guide which, ifconscientiously followed, will minimize the possibility ofaccidents throughout the useful life of this equipment.Read the CIMA Safety Manual prior to compressoroperation and towing, if applicable in your area.The air compressor should be operated only by those whohave been trained and delegated to do so, and who haveread and understood this Operator's Manual. Failure tofollow the instructions, procedures and safety precautionsin this manual can result in accidents and injuries.NEVER start the air compressor unless it is safe to do so.DO NOT attempt to operate the air compressor with aknown unsafe condition. Tag the air compressor andrender it inoperative by disconnecting the battery so otherswho may not know of the unsafe condition will not attemptto operate it until the condition is corrected.Use and operate the air compressor only in full compliancewith all pertinent OSHA requirements and/or all pertinentFederal, State and Local codes or requirements.

DO NOT modify the compressor except with writtenfactory approval.Each day, walk around the air compressor and inspect forleaks, loose or missing parts, damaged parts or parts outof adjustment. Perform all recommended dailymaintenance.Inspect for torn, frayed, blistered or otherwise deterioratedand degraded hoses. Replace as required.

CAUTIONEstimated hose life based on a 5-day8-hour work week is 3 years. Theseconditions exist on an 8-hour shiftonly. Any other operation of theequipment other than 8-hour shiftswould shorten the hose life based onhours of operation.

1.2 TOWING (I)Preparing To Tow

WARNINGDO NOT tow the compressor shouldits weight exceed the rated limit of thetow vehicle, as the vehicle may notbrake safely with excess weight. Seerated limit in tow vehicle Operator'sManual, and review its instructionsand other requirements for safetowing.

(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED PORTABLE AIR COMPRESSORS AS WELL.

®SULLAIR®

Section 1SAFETY

®SULLAIR®600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List 1

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A. Prior to hitching the air compressor to the tow vehicle,inspect all attachment parts and equipment, checkingfor (i) signs of excessive wear or corrosion, (ii) partsthat are cracked, bent, dented or otherwise deformedor degraded, and (iii) loose nuts, bolts or otherfasteners. Should any such condition be present, DONOT TOW until the problem is corrected.

B. Back the tow vehicle to the compressor and positionit in preparation for coupling the compressor.

C. If the compressor is provided with a drawbar latchedin the vertical upright position, carefully unlatchdrawbar and lower it to engage the coupling device. Ifnot, raise drawbar to engage coupling device orotherwise couple the compressor to the towingvehicle.

WARNINGThis equipment may be tongue heavy.DO NOT attempt to raise or lower thedrawbar by hand if the weight is morethan you can safely handle.Use the screw jack provided or a chainfall if you cannot lift or lower it withoutavoiding injury to yourself or others.Keep hands and fingers clear of thecoupling device and all other pinchpoints. Keep feet clear of drawbar toavoid injury in case it should slip fromyour hands.

D. Make sure the coupling device is fully engaged,closed and locked.

E. If chains are provided, pass each chain through itspoint of attachment on the towing vehicle; then hookeach chain to itself by passing the grab hookover (not through) a link. Cross chains under front ofdrawbar before passing them through points ofattachment on towing vehicle to support front ofdrawbar in case it should accidentally becomeuncoupled.

F. Make sure that the coupling device and adjacentstructures on the towing vehicle (and also, if utilized,chain adjustment, brake and/or electricalinterconnections) DO NOT interfere with or restrictmotion of any part of the compressor, including itscoupling device, with respect to the towing vehiclewhen maneuvering over any anticipated terrain.

G. If provided, make sure chain length, brake andelectrical interconnections provide sufficient slack toprevent strain when cornering and maneuvering, yetare supported so they cannot drag or rub on road,terrain or towing vehicle surfaces which might causewear that could render them inoperative.

WARNINGThis equipment may be tongue heavy.DO NOT attempt to raise or lower thedrawbar by hand if the weight is morethan you can safely handle.

CAUTIONRetract the front screw jack only afterattaching the compressor to the towvehicle. Raise the screw jack to its fullup position and pull the pinconnecting the jack to the drawbar.Rotate the screw jack to its stowedposition, parallel to the drawbar, andreinsert the pin. Make sure the jack issecured in place prior to towing.If a caster wheel is provided on thescrew jack it is part of the screw jackand can not be removed. Follow thesame procedure for stowing away thewheeled jack as you would for thestandard screw jack. Pull the pinconnecting the jack to the drawbarand raise the screw jack to its full upposition. Rotate the screw jack to itsstowed position, parallel to thedrawbar, and reinsert the pin. Makesure the jack is secured in place priorto towing.

H. On two-wheeled models, fully retract front screw jackand any rear stabilizer legs. If a caster wheel isprovided on the screw jack it is part of the screw jack,and can not be removed. Follow the same procedurefor stowing away the wheeled jack as you would forthe standard screw jack. Pull the pin connecting thejack to the drawbar and raise the screw jack to its fullupright position. Rotate the screw jack to its stowedposition, parallel to the drawbar, and reinsert the pin.Make sure the jack is secured in place prior to towing.

I. Make sure tires are in good condition and are the size(load range) specified and are inflated to the specifiedpressures. DO NOT change the tire size or type. Also,make sure wheel bolts, lugs or nuts are tightened tothe specified torques.

SECTION 1

2 600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator's Manual and Parts List®SULLAIR®

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J. If provided, make sure all dual stop, tail directional andclearance lights are operating properly and that theirlenses are clean and functional. Also, make sure allreflectors and reflecting surfaces, including the slowmoving vehicle emblem on compressors providedwith same, are clean and functional.

K. Make sure all service air hoses (not air brake hoses)are disconnected or are fully stowed and secured onhose reels, if provided.

L. Make sure all access doors and tool box covers areclosed and latched. If the compressor is large enoughto hold a man, make sure all personnel are out beforeclosing and latching access doors.

M. Make sure parking brakes in towing vehicle are set, orthat its wheels are chocked or blocked, or that it isotherwise restrained from moving. Then, release thecompressor parking brakes, if provided.

N. Make sure the compressor wheels are not chocked orblocked, and that all tie-downs, if any, are free.

O. Test running brake operation, including breakawayswitch operation if provided, before attempting to towthe compressor at its rated speed or less whenconditions prevail.

P. DO NOT carry loose or inappropriate tools, equipmentor supplies on or in the compressor.

Q. DO NOT load this equipment with accessories or toolssuch that it is unbalanced from side to side or front toback. Such unbalance will reduce the towability of thisequipment and may increase the possibility of tipping,rolling over, jackknifing, etc. Loss of control of thetowing vehicle may result.

TowingA. Observe all Federal, State, and Local laws while

towing this equipment (including those specifyingminimum speed).

B. DO NOT exceed the towing speeds listed below underideal conditions. Reduce your speed according toposted speed limits, weather, traffic, road or terrainconditions.1. Two axle four-wheel or three axle six-wheel

steerable models: 15 MPH (24 km/h).2. All other models: 55 MPH (88 km/h).

C. Remember that the portable air compressor mayapproach or exceed the weight of the towing vehicle.Maintain increased stopping distancesaccordingly. DO NOT make sudden lane changes, U-turns or other maneuvers. Such maneuvers can causethe compressor to tip, roll over, jackknife or slide andcause loss of control of the towing vehicle. Tipping,rolling over, etc. can occur suddenly without warning.U-turns especially should be made slowly andcarefully.

D. Avoid grades in excess of 15˚ (27%).E. Avoid potholes, rocks and other obstructions, and soft

shoulders or unstable terrain.

F. Maneuver in a manner that will not exceed thefreedom of motion of the compressor's drawbar and/or coupling device, in or on the towing vehicle'scoupling device and/or adjacent structure whethertowing forward or backing up, regardless of the terrainbeing traversed.

G. DO NOT permit personnel to ride in or on thecompressor.

H. Make sure the area behind, in front of, and under thecompressor is clear of all personnel and obstructionsprior to towing in any direction.

I. DO NOT permit personnel to stand or ride on thedrawbar, or to stand or walk between the compressorand the towing vehicle.

Parking Or Locating CompressorA. Park or locate compressor on a level surface, if

possible. If not, park or locate compressor acrossgrade so the compressor does not tend to roll downhill.DO NOT park or locate compressor on gradesexceeding 15˚ (27%).

B. Make sure compressor is parked or located on a firmsurface that can support its weight.

C. Park or locate compressor so the wind, if any, tendsto carry the exhaust fumes and radiator heat awayfrom the compressor air inlet openings, and alsowhere the compressor will not be exposed toexcessive dust from the work site.

D. On steerable models, park compressor with frontwheels in straight-ahead position.

E. Set parking brakes and disconnect breakaway switchcable and all other interconnecting electrical and/orbrake connections, if provided.

F. Block or chock both sides of all wheels.G. If provided, unhook chains and remove them from the

points of chain attachment on the towing vehicle, thenhook chains to bail on drawbar or wrap chains aroundthe drawbar and hook them to themselves to keepchains off the ground which might accelerate rusting.

SAFETY


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H. Lower front screw jack and/or any front and rearstabilizer legs. Make sure the surface they contact hassufficient load bearing capability to support the weightof the compressor.

WARNINGThis equipment may be tongue heavy.DO NOT attempt to raise or lower thedrawbar by hand if the weight is morethan you can safely handle.

CAUTIONRetract the front screw jack only afterattaching the compressor to the towvehicle. Raise the screw jack to its fullup position and pull the pinconnecting the jack to the drawbar.Rotate the screw jack to its stowedposition, parallel to the drawbar, andreinsert the pin. Make sure the jack issecured in place prior to towing.On two-wheeled models, fully retractfront screw jack and any rearstabilizer legs. If a caster wheel isprovided on the screw jack it is part ofthe screw jack and can not beremoved. Follow the same procedurefor stowing away the wheeled jack asyou would for the standard screwjack. Pull the pin connecting the jackto the drawbar and raise the screwjack to its full up position. Rotate thescrew jack to its stowed position,parallel to the drawbar, and reinsertthe pin. Make sure the jack is securedin place prior to towing.

I. If a caster wheel is provided on the screw jack, it is partof the screw jack and cannot be removed. Follow thesame procedure for stowing away the wheeled jack asyou would for the standard screw jack. Raise thescrew jack to its full upright position and pull the pinconnecting the jack to the drawbar. Rotate the screwjack to its stowed position, parallel to the drawbar andreinsert the pin. Make sure the jack is secured in placeprior to towing.

J. Disconnect coupling device, keeping hands andfingers clear of all pinch points. If the compressor isprovided with a drawbar, DO NOT attempt to lift thedrawbar or if hinged, to raise it to the upright positionby hand, if the weight is more than you can safelyhandle. Use a screwjack or chain fall if you cannot liftor raise the drawbar without avoiding injury to yourselfor others.

K. When possible, stow hinged drawbar in the verticalupright position. Make certain it is securely latched inthe vertical upright position. Keep feet clear of drawbarat all times to avoid crushing accidents in case itshould slip from your hands or otherwise fall to theground.

L. Move the towing vehicle well clear of the parkedcompressor and erect hazard indicators, barricadesand/or flares (if at night) if compressor is parked on oradjacent to public roads. Park so as not to interferewith traffic.

NOTEWhile not towed in the usual sense ofthe word, many of these instructionsare directly applicable to skid-mounted portable air compressors aswell.

1.3 PRESSURE RELEASEA. Open the pressure relief valve at least weekly to make

sure it is not blocked, closed, obstructed or otherwisedisabled.

B. Install an appropriate flow-limiting valve between thecompressor service air outlet and theshutoff (throttle) valve, when an air hose exceeding1/2" (13mm) inside diameter is to be connected to theshutoff (throttle) valve, to reduce pressure in case ofhose failure, per OSHA Standard 29 CFR 1926.302(b) (7) or any applicable Federal, State and Localcodes, standards and regulations.

C. When the hose is to be used to supply a manifold,install an additional appropriate flow-limiting valvebetween the manifold and each air hose exceeding1/2" (13mm) inside diameter that is to be connectedto the manifold to reduce pressure in case of hosefailure.

D. Provide an appropriate flow-limiting valve for eachadditional 75 feet (23 m) of hose in runs of air hoseexceeding 1/2" (13 mm) inside diameter to reducepressure in case of hose failure.

E. Flow-limiting valves are listed by pipe size and ratedCFM. Select appropriate valve accordingly.

F. DO NOT use tools that are rated below the maximumrating of this compressor. Select tools, air hoses,pipes, valves, filters and other fittings accordingly. DONOT exceed manufacturer's rated safe operatingpressures for these items.

G. Secure all hose connections by wire, chain or othersuitable retaining device to prevent tools or hose endsfrom being accidentally disconnected and expelled.

H. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) to zerointernal pressure before removing the cap.

SECTION 1


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I. Vent all internal pressure prior to opening any line,fitting, hose, valve, drain plug, connection or othercomponent, such as filters and line oilers, and beforeattempting to refill optional air line anti-icer systemswith antifreeze compound.

J. Keep personnel out of line with and away from thedischarge opening of hoses, tools or other points ofcompressed air discharge.

K. DO NOT use air at pressures higher than 30psig (2.1 bar) for cleaning purposes, and then onlywith effective chip guarding and personal protectiveequipment per OSHA Standard 29 CFR 1910.242 (b)or any applicable Federal, State and Local codes,standards and regulations.

L. DO NOT engage in horseplay with air hoses as deathor serious injury may result.

M. This equipment is supplied with an ASME designedpressure vessel protected by an ASME rated reliefvalve. Lift the handle once a week to make sure thevalve is functional. DO NOT lift the handle whilemachine is under pressure.

N. If the machine is installed in an enclosed area it isnecessary to vent the relief valve to the outside of thestructure or to an area of non-exposure.

O. DO NOT remove radiator filler cap until the coolanttemperature is below its boiling point. Then loosen capslowly to its stop to relieve any excess pressure andmake sure coolant is not boiling before removing capcompletely. Remove radiator filler cap only when coolenough to touch with a bare hand.

P. The ethyl ether in the replaceable cylinders used indiesel ether starting aid systems (optional) is underpressure. DO NOT puncture or incinerate thosecylinders. DO NOT attempt to remove the center valvecore or side pressure relief valve from these cylindersregardless of whether they are full or empty.

Q. If a manual blowdown valve is provided on thereceiver, open the valve to ensure all internal pressurehas been vented prior to servicing any pressurizedcomponent of the compressor air/fluid system.

1.4 FIRE AND EXPLOSIONA. Refuel at a service station or from a fuel tank designed

for its intended purpose. If this is not possible, groundthe compressor to the dispenser prior to refueling.

B. Clean up spills of fuel, fluid, battery electrolyte orcoolant immediately if such spills occur.

C. Shut off air compressor and allow it to cool. Then keepsparks, flames and other sources of ignition away andDO NOT permit smoking in the vicinity when addingfuel, or when checking or adding electrolyte tobatteries, or when checking or adding fluid, or whenchecking diesel engine ether starting aid systems orreplacing cylinders, or when refilling air line anti-icersystems antifreeze compound.

D. DO NOT permit liquids, including air line anti-icersystem antifreeze compound or fluid film, toaccumulate on bottom covers or on, under or aroundacoustical material, or on any external or internalsurfaces of the air compressor. Wipe down using anaqueous industrial cleaner or steam clean as required.If necessary, remove acoustical material, clean allsurfaces and then replace acoustical material. Anyacoustical material with a protective covering that hasbeen torn or punctured should be replacedimmediately to prevent accumulation of liquids or fluidfilm within the material. DO NOT use flammablesolvents for cleaning purposes.

E. Disconnect the grounded (negative) batteryconnection prior to attempting any repairs or cleaninginside the enclosure. Tag the battery connections soothers will not unexpectedly reconnect it.

F. Keep electrical wiring, including the battery terminalsand other terminals, in good condition. Replace anywiring that has cracked, cut abraded or otherwisedegraded insulation or terminals that are worn,discolored or corroded. Keep all terminals clean andtight.

G. Turn off battery charger before making or breakingconnections to the battery.

H. Keep grounded conductive objects such as toolsaway from exposed live electrical parts such asterminals to avoid arcing which might serve as asource of ignition.

I. Replace damaged fuel tanks or lines immediatelyrather than attempt to weld or otherwise repairthem. DO NOT store or attempt to operate thecompressor with any known leaks in the fuel system.Tag the compressor and render it inoperative untilrepair can be made.

J. Remove any acoustical material or other material thatmay be damaged by heat or that may supportcombustion prior to attempting weld repairs. Removediesel engine ether starting aid cylinders and air lineanti-icer system components containing antifreezecompound, prior to attempting weld repairs in anyplace other than the fuel system. DO NOT weld on ornear the fuel system.

K. Keep a suitable, fully charged class BC or ABC fireextinguisher or extinguishers nearby when servicingand operating the compressor.

L. Keep oily rags, trash, leaves, litter or othercombustibles out of and away from the compressor.

M. Open all access doors and allow the enclosure toventilate thoroughly prior to attempting to start theengine.

N. DO NOT operate compressor under low overhangingleaves or permit such leaves to contact hot exhaustsystem surfaces when operating the compressor inforested areas.

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O. Ethyl ether used in diesel engine ether starting aidsystems is extremely flammable. Change cylinders, ormaintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame orsparks. DO NOT install, store or otherwise exposeether cylinders to temperatures above 160˚F (71˚C).Remove ether cylinder from the compressor whenoperating in ambient temperatures above 60˚F (16˚C).

P. DO NOT attempt to use ether as a starting aid ingasoline engines or diesel engines with glow plugs asserious personnel injury or property damage mayresult.

Q. DO NOT spray ether into compressor air filter or intoan air filter that serves both the engine and thecompressor as serious damage to the compressor orpersonal injury may result.

R. Antifreeze compound used in air line anti-icer systemscontains methanol which is flammable. Use systemsand refill with compound only in well-ventilated areasaway from heat, open flames or sparks. DO NOTexpose any part of these systems or the antifreezecompound to temperatures above 150˚F (66˚C).Vapors from the antifreeze compound are heavierthan air. DO NOT store compound or dischargetreated air in confined or unventilated areas. DONOT store containers of antifreeze compound in directsunlight.

S. Store flammable fluids and materials away from yourwork area. Know where fire extinguishers are and howto use them, and for what type of fire they are intended.Check readiness of fire suppression systems anddetectors if so equipped.

1.5 MOVING PARTSA. Keep hands, arms and other parts of the body and also

clothing away from belts, pulleys and other movingparts.

B. DO NOT attempt to operate the compressor with thefan or other guards removed.

C. Wear snug-fitting clothing and confine long hair whenworking around this compressor, especially whenexposed to hot or moving parts inside the enclosure.

D. Keep access doors closed except when makingrepairs or adjustments, performing service or whenstarting or stopping the compressor.

E. Make sure all personnel are out of and clear of thecompressor prior to attempting to start or operate it.

F. Shut off engine before adding fuel, fluid, coolantlubricants, air line antifreeze compound or batteryelectrolyte, or before replacing ether starting aidcylinders.

G. Disconnect the grounded negative battery connectionto prevent accidental engine operation prior toattempting repairs or adjustments. Tag the batteryconnection so others will not unexpectedly reconnectit.

H. When adjusting the controls, it may require operationof the equipment during adjustment. DO NOT comein contact with any moving parts while adjusting thecontrol regulator and setting the engine RPM. Makeall other adjustments with the engine shut off. Whennecessary, make adjustment, other than settingcontrol regulator and engine RPM, with the engineshut off. If necessary, start the engine and checkadjustment. If adjustment is incorrect, shut engine off,readjust, then restart the engine to recheckadjustment.

I. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water, antifreeze orother liquids to minimize possibility of slips and falls.

1.6 HOT SURFACES, SHARP EDGESAND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant, hotsurfaces and sharp edges and corners.

B. Keep all parts of the body away from all points of airdischarge and away from hot exhaust gases.

C. Wear personal protective equipment including glovesand head covering when working in, on or around thecompressor.

D. Keep a first aid kit handy. Seek medical assistancepromptly in case of injury. DO NOT ignore small cutsand burns as they may lead to infection.

1.7 TOXIC AND IRRITATINGSUBSTANCES

A. DO NOT use air from this compressor forrespiration (breathing) except in full compliance withOSHA Standards 29 CFR 1920 and any other Federal,State or Local codes or regulations.

DANGER

INHALATION HAZARD!Death or serious injury can result frominhaling compressed air withoutusing proper safety equipment. SeeOSHA standards and/or anyapplicable Federal, State, and Localcodes, standards and regulations onsafety equipment.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utilizationequipment and DO NOT discharge air from thesesystems into unventilated or other confined areas.

SECTION 1


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C. Operate the compressor only in open or well-ventilated areas.

D. If the compressor is operated indoors, dischargeengine exhaust fumes outdoors.

E. Locate the compressor so that exhaust fumes are notapt to be carried towards personnel, air intakesservicing personnel areas or towards the air intake ofany portable or stationary compressor.

F. Fuels, fluids, coolants, lubricants and batteryelectrolyte used in the compressor are typical of theindustry. Care should be taken to avoid accidentalingestions and/or skin contact. In the event ofingestion, seek medical treatment promptly. DONOT induce vomiting if fuel is ingested. Wash withsoap and water in the event of skin contact.

G. Wear an acid-resistant apron and a face shield orgoggles when servicing the battery. If electrolyte isspilled on skin or clothing, immediately flush with largequantities of water.

H. Ethyl ether used in diesel engine ether starting aidsystems is toxic, harmful or fatal if swallowed. Avoidcontact with the skin or eyes and avoid breathing thefumes. If swallowed, DO NOT induce vomiting, but calla physician immediately.

I. Wear goggles or a full face shield when testing etherstarting aid systems or when adding antifreezecompound to air line anti-icer systems. Keep openingsof valve or atomizer tube of ether starting aid systempointed away from yourself and other personnel.

J. If ethyl ether or air line anti-icer system antifreezecompound enters the eyes or if fumes irritate the eyes,they should be washed with large quantities of cleanwater for 15 minutes. A physician, preferably any eyespecialist, should be contacted immediately.

K. DO NOT store ether cylinders or air line anti-icersystem antifreeze compound in operator's cabs or inother similar confined areas.

L. The antifreeze compound used in air line anti-icersystems contains methanol and is toxic, harmful orfatal if swallowed. Avoid contact with the skin or eyesand avoid breathing the fumes. If swallowed, inducevomiting by administering a tablespoon of salt in eachglass of clean warm water until vomit is clear, thenadminister two tablespoons of baking soda in a glassof clean water. Have patient lay down and cover eyesto exclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCKA. Keep the towing vehicle or equipment carrier,

compressor hoses, tools and all personnel at least 10feet (3 m) from power lines and buried cables.

B. Keep all parts of the body and any hand-held tools orother conductive objects away from exposed live partsof electrical system. Maintain dry footing, stand oninsulating surfaces and DO NOT contact any otherportion of the compressor when making adjustmentsor repairs to exposed live parts of the electricalsystem.

C. Attempt repairs only in clean, dry and well-lighted andventilated areas.

D. Stay clear of the compressor during electrical storms!It can attract lightning.

1.9 LIFTINGA. If the compressor is provided with a lifting bail, then lift

by the bail provided. If no bail is provided, then lift bysling. Compressors to be air lifted by helicopter mustnot be supported by the lifting bail, but by slingsinstead. In any event, lift only in full compliance withOSHA Standards 29 CFR 1910 subpart N or any otherLocal, State, Military and Federal regulations that mayapply.

B. Inspect lifting bail and points of attachment for crackedwelds and for cracked, bent, corroded or otherwisedegraded members and for loose bolts or nuts prior tolifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condition andhas a rated capacity of at least the net weight of thecompressor plus an additional 10% allowance forweight of snow, ice, mud or stored tools andequipment. If your are unsure of the weight, then weighcompressor before lifting.

D. Make sure lifting hook has a functional safety latch orequivalent, and is fully engaged and latched on thebail.

E. Use guide ropes or equivalent to prevent twisting orswinging of the compressor once it has been liftedclear of the ground.

F. DO NOT attempt to lift in high winds.G. Keep all personnel out from under and away from the

compressor whenever it is suspended.H. Lift compressor no higher than necessary.I. Keep lift operator in constant attendance whenever

compressor is suspended.J. Set compressor down only on a level surface capable

of supporting at least its net weight plus an additional10% allowance for the weight of snow, ice, mud orstored tools and equipment.

K. If the compressor is provided with parking brakes,make sure they are set, and in any event, block orchock both sides of all running wheels beforedisengaging the lifting hook.

SAFETY


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1.10 ENTRAPMENTA. Make sure all personnel are out of compressor before

closing and latching enclosure doors.B. If the compressor is large enough to hold a man and if

it is necessary to enter it to perform serviceadjustments, inform other personnel before doing so,or else secure the access door in the open position toavoid the possibility of others closing and possiblylatching the door with personnel inside.

1.11 JUMP STARTINGA. Observe all safety precautions mentioned elsewhere

in this manual.B. Batteries may contain hydrogen gas which is

flammable and explosive. Keep flames, sparks andother sources of ignition away.

C. Batteries contain acid which is corrosive andpoisonous. DO NOT allow battery acid to contacteyes, skin, fabrics or painted surfaces as seriouspersonal injury or property damage could result. Flushany contacted areas thoroughly with waterimmediately. Always wear an acid-resistant apron andface shield when attempting to jump start thecompressor.

D. Remove all vent caps (if so equipped) from the batteryor batteries in the compressor. DO NOT permit dirt orforeign matter to enter the open cells.

E. Check fluid level. If low, bring fluid to proper levelbefore attempting to jump start (not applicable tomaintenance-free batteries).

F. DO NOT attempt to jump start if fluid is frozen orslushy. Bring batteries up to at least 60˚F (16˚C)before attempting to jump start or it may explode.

G. Cover open cells of all compressor batteries with cleandampened cloths before attempting to jump start.

H. Attempt to jump start only with a vehicle having anegative ground electrical system with the samevoltage, and is also equipped with a battery orbatteries of comparable size or larger than supplied inthe compressor. DO NOT attempt to jump start usingmotor generator sets, welders or other sources of DCpower as serious damage may result.

I. Bring the starting vehicle alongside the compressor,but DO NOT permit metal to metal contact betweenthe compressor and the starting vehicle.

J. Set the parking brakes of both thecompressor (if provided) and the starting vehicle orotherwise block both sides of all wheels.

K. Place the starting vehicle in neutral or park, turn off allnon-essential accessory electrical loads and start itsengine.

L. Use only jumper cables that are clean, in goodcondition and are heavy enough to handle the startingcurrent.

M. Avoid accidental contact between jumper cableterminal clips or clamps and any metallic portion ofeither the compressor or the starting vehicle tominimize the possibility of uncontrolled arcing whichmight serve as a source of ignition.

N. Positive battery terminals are usually identified by aplus (+) sign on the terminal and the letters POSadjacent to the terminal. Negative battery terminalsare usually identified by the letters NEG adjacent tothe terminal or a negative (-) sign.

O. Connect one end of a jumper cable to thepositive (POS) (+) battery terminal in the startingvehicle. When jump starting 24V compressors and ifthe starting vehicle is provided with two (2) 12Vbatteries connected in series, connect the jumpercable to the positive (POS) (+) terminal of theungrounded battery.

P. Connect the other end of the same jumper cable to thepositive (POS) (+) terminal of the starter motor batteryin the compressor, or when jump starting 24Vcompressor, to the positive (POS) (+) terminal of theungrounded battery in the compressor.

Q. Connect one end of the other jumper cable to thegrounded negative (NEG) (-) terminal of the battery inthe starting vehicle. When jump starting 24Vcompressors and if the starting vehicle is providedwith two (2) 12V batteries connected in series,connect the jumper cable to the negative (NEG) (-)terminal of the grounded battery.

R. Check your connections. DO NOT attempt to start a24V compressor with one 12V battery in the startingvehicle. DO NOT apply 24V to one 12V battery in thecompressor.

S. Connect the other end of this same jumper cable to aclean portion of the compressor engine block awayfrom fuel lines, the crank case breather opening andthe battery.

T. Start the compressor in accordance with normalprocedure. Avoid prolonged cranking.

U. Allow the compressor to warm up. When thecompressor is warm and operating smoothly at normalidle RPM, disconnect the jumper cable from theengine block in the compressor, then disconnect theother end of this same cable from the groundednegative (NEG) (-) terminal of the battery in the startingvehicle. Then disconnect the other jumper cable fromthe positive (POS) (+) terminal of the battery in thecompressor, or if provided with two (2) 12V batteriesconnected in series, from the ungrounded battery inthe compressor, and finally, disconnect the other endof this same jumper cable from the positive (POS) (+)terminal of the battery in the starting vehicle or fromthe positive (POS) (+) terminal of the ungroundedbattery in the starting vehicle, if it is provided with two(2) 12V batteries connected in series.

SECTION 1


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V. Remove and carefully dispose of the dampenedcloths, as they may now be contaminated with acid,then replace all vent caps.

1.12 CALIFORNIA PROPOSITION 65 WARNING

CALIFORNIA PROPOSITION 65WARNING

Diesel engine exhaust and some of itsconstituents are known to the State ofCalifornia to cause cancer, birthdefects and other repoductive harm.Battery posts, terminals and relatedaccessories contain lead and othercompounds known to the State ofCalifornia to cause cancer and birthdefects and other reproductive harm.Wash hands after handling.

SAFETY


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SECTION 1



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2.1 INTRODUCTIONSullair Portable Air Compressor models offer superiorperformance and reliability while requiring only minimalmaintenance.The compressor is equipped with a Sullair rotary screwcompressor unit. Compared to other compressors, theSullair is unique in mechanical reliability and compressordurability. No inspection is required of the working partswithin the compressor unit.As you continue reading this manual and come to learnhow the compressor operates and is cared for, you will seehow surprisingly easy it is to keep a Sullair compressor intop operating condition.Read Maintenance on page 39 to keep your compressorin top operating condition. Should any problem or questionarise which cannot be answered in this text, contact yournearest Sullair representative or the Sullair CorporationService Department.

2.2 DESCRIPTION OF COMPONENTSRefer to Figure 2-1. The components and assemblies ofthe Sullair Portable Air Compressor models are clearlyshown. The package includes a compressor, dieselengine, compressor inlet system, compressor cooling andlubrication system, compressor discharge system,

capacity control system, instrument panel and electricalsystem. The machine is also supplied with sounddeadening insulation to lower noise emissions to meetEPA and/or any Federal, State, or local noise requirement.The Sullair compressor unit is driven by an industrialengine designed to provide enough horsepower for morethan adequate reserve at rated conditions. Refer toEngine Operator's Manual for a more detaileddescription of the engine.The engine cooling system is comprised of a radiator, highcapacity fan and thermostats. The high capacity fan drawsair through the radiator, keeping the engine at the properoperating temperature.The same fan also cools the fluid in the compressorcooling and lubrication system. While passing through theradiator, the fan air also passes through the compressorfluid cooler (which is mounted adjacent to the radiator). Asair passes through the cooler, the heat of compression isremoved from the fluid.The same fan also cools the engines intake air supply.While passing through the radiator and oil cooler, the fanair passes through an air to air aftercooler. As air passesthrough the air to air aftercooler heat is removed which wasintroduced by the engine's turbo charger. The engine iscoupled to the compressor unit with a non-lubricated,vulcanized rubber disk and a drive flange-type coupling.All compressor models are supplied with a fuel tank largeenough to keep the compressor running through a full shift.

®SULLAIR®

Section 2DESCRIPTION


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SU_0000145

SECTION 2


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SU_0000146

1. Moisture Separator2. Thermal Valve3. Regulator Valves4. Engine Coolant Fill5. Fluid Cooler6. Aftercooler7. Engine Charge Air-Cooler

8. Engine Radiator9. Discharge Air Filter10. Air/Fluid Separator11. E-Stop12. Engine Muffler13. Manual Enclosure14. Battery Disconnect Switch

Figure 2-1: Compressor

DESCRIPTION


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2.3 SULLAIR COMPRESSOR UNIT,FUNCTIONAL DESCRIPTION

Sullair compressors feature the Sullair compressor unit, asingle-stage, positive displacement, flood lubricated-typecompressor. This unit provides continuous compressionto meet your needs.

NOTEWith a Sullair compressor, there is nomaintenance or inspection of theinternal parts of the compressor unitpermitted in accordance with theterms of the warranty.

Sullair compressors are factory-filled with Sullair AWFlubricant. For more information on fluid fill, refer toApplication Guide on page 33.

Fluid is injected into the compressor unit hoses and mixesdirectly with the air as the rotors turn, compressing the air.The fluid flow has three basic functions:1. As coolant, it controls the rise of air temperature

normally associated with the heat of compression.2. Seals the clearance paths between the rotors and the

stator and also between the rotors themselves.3. Acts as a lubricating film between the rotors allowing

one rotor to directly drive the other, which is an idler.After the air/fluid mixture is discharged from thecompressor unit, the fluid is separated from the air. At thistime, the air flows through an aftercooler and separatorthen to your service line while the fluid is being cooled inpreparation for reinjection.

SECTION 2


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2.4 COMPRESSOR COOLING ANDLUBRICATION SYSTEM,FUNCTIONAL DESCRIPTION

Refer to Figure 2-2, Figure 2-3 and Figure 2-4. Thecompressor cooling and lubrication system is designed toprovide adequate lubrication as well as maintain theproper operating temperature of the compressor. Inaddition to the cooler and fan, the system consists of amain filter and thermal valve.Fluid is used in the system as a coolant and a lubricant.The fluid is housed in the receiver tank. Upon start-up, thetemperature of the fluid is cool and routing to the fluidcooler is not necessary. The fluid, taking the path of leastresistance, flows to the thermal valve.As previously stated, upon start-up, the fluid temperatureis cool, and routing to the cooler is not required. The fluidfirst enters the thermal valve and then flows on to thecompressor unit, bypassing the cooler. As the compressorcontinues to operate, the temperature of the fluid rises andthe thermal valve element begins to shift. This forces aportion of the fluid to the fluid cooler. The cooler is a

radiator-type that works in conjunction with the engine fan.The fan draws air through the cooler removing the heat ofcompression from the fluid. From the cooler, the fluid isrouted back to the thermal valve.Before the temperature of the fluid reaches the valve setpoint, cooled fluid is mixed with warmer fluid. When thetemperature of the fluid reaches 170°F (77°C), the thermalelement shifts completely causing all fluid to flow to thecooler. The thermal valve incorporates a pressure reliefvalve, which allows fluid to bypass the cooler, if the coolerbecomes plugged or frozen. This helps assure that fluidwill continue to be provided to the compressor forlubrication. After the fluid passes through the thermal valveit is then directed through the main fluid filter. There, thefluid is filtered in preparation for injection into thecompression chamber and bearings of the compressorunit. The filter has a replaceable element and a built-inbypass valve which allows the fluid to flow even when thefilter element becomes plugged and requires changing orwhen the viscosity of the fluid is too high for adequate flow.After the fluid is properly filtered, it then flows on to thecompressor unit where it lubricates, seals and cools thecompression chamber as well as lubricates the bearingsand gears.

DESCRIPTION


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SU_0000143

SECTION 2


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SU_0000144

1. Service Air Outlet2. Minimum Pressure Check Valve3. Receiver tank

4. Fluid Cooler5. Thermal Valve6. Fluid Filler

Figure 2-2: Discharge, Cooling and Lubrication – All Models

DESCRIPTION


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2.5 CONTROL SYSTEM,FUNCTIONAL DESCRIPTION

Refer to Figure 2-3 and Figure 2-4. The purpose of thecontrol system is to regulate the amount of air intake inaccordance with the amount of compressed air demand.The control system consist of an inlet valve, a controlregulator, a reducing regulator, a blowdown valve, arecirculating valve, a START/RUN selector switch, aHIGH/LOW selector switch (150 psig [10.3 bar]compressors only) and tubing connecting the variouscomponents together.The functional descriptions of the control system are givenbelow in three distinct phases of operation. Thesedescriptions will apply to all control systems.Start - 0 to 65 psig (0 to 4.5 bar)2.5.1 Cold StartRefer to Compressor Start-up Procedure on page 37 forcomplete starting instructions. "B" section goes here. Theinlet valve is kept in the closed position by the main controlsprings. This helps assure minimum load on the engineduring starting. After starting, system pressure will riseslowly to 25 psig (1.7 bar).After sufficient machine warm-up is achieved, turn warm-up valve to "RUN" position. This directs regulated air-pressure behind the inlet valve piston, opening the inletvalve, and behind the engine speed control piston, to bringthe engine to full operating speed.Normal Operation - 80 to 100psig (5.5 to 6.9 bar)When the receiver tank pressure rises above 65 psig(4.5 bar), the minimum pressure/check valve opens anddelivers compressed air to the service line. The START/RUN switch is in the "RUN" position. On dual-pressure(150 psig [10.3 bar]) compressors, the pressure selectorswitch is in the "LOW" pressure position.60 psig (4.1 bar) regulated pressure is maintained behindthe inlet valve piston and behind the engine speed controlcylinder. to keep the inlet valve open and the engine at fullrated speed for maximum air output.Modulation - 100 to 115 psig (6.9 to 7.9 bar)Should less than the rated capacity of air be used, theservice line pressure will rise above 100 psig (6.9 bar). Thecontrol pressure regulator (labeled "High" in Figure 2-3)

gradually opens, applying pressure to the spring side ofthe inlet valve piston and speed control cylinder. Thiscauses the inlet valve to partially close, and reduces thespeed of the engine. With the service line closed and noair demand, the control pressure regulator opens fully,closing the inlet valve, reducing engine speed to idle andopening a recirculation valve. The recirculation valvebleeds high-pressure air back to the compressor inlet toprevent entrapment of fluid in the rotors.When air demand then increases, the receiver tankpressure will fall below 115 psig (7.9 bar). The controlpressure regulator valve will close, which causes therecirculating valve to close, the inlet valve to open and theengine speed to increase to full rated speed. Thecompressor will then be operating at full load condition.Dual Pressure – 150 psig (10.3 bar) modelsand 175 psig (12.1 bar) "HH" modelsThe high pressure "H" compressors are equipped with adual-pressure system consisting of a second controlpressure regulator , a pressure selector switch andconnecting lines (Figure 2-3). The standard controlregulator is set up to 150 psig (10.3 bar) on "H"compressors and up to 175 psig (12.1 bar) on "HH"compressors. The second control regulator is set for 100psig (6.9 bar). The pressure selector switch (located onthe instrument panel) is open allowing a pressure signal tothe low pressure control regulator for low pressureoperation. Moving the selector switch to the "HIGH"pressure position closes the selector switch, cutting off theair signal to the low pressure regulator, allowing the highpressure regulator to take control of the system.ShutdownThe blowdown valve is normally closed. When thecompressor is shutdown, system pressure backs up to theinlet valve causing the check spring in the inlet valve toclose the air inlet valve. This sends a pressure signal to theblowdown valve causing it to open and vent the pressurein the system. After the pressure is vented, the blowdownvalve spring returns the blowdown valve to the closedposition.

SECTION 2


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Manifold Valve – Control SystemManifold Valve – Control System

6FluidAirAir Fluid

5 4

3

2

1

1311

12

10

9

8

7

A B C D ESU_0000203

1. Blowdown Valve2. P2 Pressure Switch3. High Pressure Bypass Regulator4. Low Pressure Bypass Regulator5. HI/LO Solenoid6. Recirculating Solenoid7. Recirculating Valve

8. P1 Pressure Switch9. Reducing Regulator10. RUN/START Solenoid11. Start Orifice12. Check Valve13. Run Orifice


DESCRIPTION


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Control SystemControl System

A B C D E

1

2

3

4

5

6

7

8

9

10

11

12

14

13

15

1716

18

19

SU_0000204

1. Compressor Air Filter2. Engine Air Filter3. Engine4. Compressor Unit5. Service Air (Aftercooled)6. Discharge Air Filters7. Air Inlet Valve8. Moisture Separator9. Aftercooler10. Relief Valve

11. Fluid Cooler12. Thermal Valve/Fluid Filter Assembly13. Receiver Tank14. Fluid Level Sight Gauge15. Final Fluid Separator Element16. Ball Valve17. P3 Pressure Switch18. Service Air (Non-Aftercooled)19. Minimum Pressure Check Valve


SECTION 2


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2.6 COMPRESSOR DISCHARGESYSTEM, FUNCTIONALDESCRIPTION

Refer to Figure 2-2, Figure 2-3 and Figure 2-4. The Sullaircompressor unit discharges compressed air/fluid mixtureinto the receiver tank.The receiver tank has three functions:1. It acts as a primary fluid separator.2. Serves as the compressor fluid storage sump.3. Houses the final fluid separator.The compressed air/fluid mixture enters the receiver tankand is directed against the tank side wall. By change ofdirection and reduction of velocity, large droplets of fluidseparate and fall to the bottom of the receiver tank. Thefractional percentage of fluid remaining in the compressedair collects on the surface of the final separator element asthe compressed air flows through the separator. As moreand more fluid collects on the element's surface, the fluiddescends to the bottom of the separator. A return line(or scavenge tube) leads from the bottom of the separatorelement to the inlet region of the compressor unit. Fluidcollecting on the bottom of the separator element isreturned to the compressor by the pressure differencebetween the area surrounding the separator element andthe compressor inlet. An orifice (protected by a strainer) isincluded in this return line to help assure proper flow.

The receiver tank is ASME code rated. A minimumpressure/check valve, located downstream from theseparator, helps assure a minimum receiver pressureduring all conditions. This pressure is necessary for properair/fluid separation and proper fluid circulation.A minimum pressure/check valve at the outlet of thereceiver is installed to prevent compressed air in theservice line from bleeding back into the receiver onshutdown when the compressor is being run in parallelwith other compressors tied to a large air system.The compressor unit discharges compressed air/fluidmixture through a discharge check valve into the receivertank. The discharge valve is located on the rear of thecompressor unit at the end opposite the driveshaft. Thedischarge check valve prevents discharged air fromreturning to the compression chamber after shutdown.Fluid is added to the receiver tank via a capped fluid filler.A fluid level gauge glass enables the operator to visuallymonitor the receiver tank fluid level.

WARNINGDO NOT remove caps, plugs, and/orother components when compressoris running or pressurized.Stop compressor and relieve allinternal pressure before doing so.

DESCRIPTION


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2.7 AIR INLET SYSTEM,FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The compressor inlet system consistsof one air filter, a compressor air inlet valve andinterconnecting piping to the engine and compressor.Also, nylon tubing and air filter restriction indicator gaugeson the instrument panel are provided.The air filter is a 2-stage unit with a safety element dryelement-type filter. This filter is capable of cleaningextremely dirty air. However, in such cases, frequent

checks of the air filter will be required. Referring to theinstrument panel, the engine air filter restriction gauge orthe compressor air filter restriction gauge will indicatewhen restriction of the air passing through the filterbecomes too high.At this time, change the air filter element. Refer toAir Filter Maintenance on page 43. These indicatorsshould be checked daily, after start-up under normalconditions.The compressor air inlet valve controls the amount of airintake of the compressor in response to the air demand.

SU_0000152

1. Engine Air Filter2. Compressor Air Filter3. Air Inlet Valve

4. Compressor5. Engine Inter-Cooler

Figure 2-5: Air Inlet System

SECTION 2


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2.8 INSTRUMENT PANEL GROUP,FUNCTIONAL DESCRIPTION

Refer to Compass Controller Manual, Sullair Part No.02250167-454.

1

2

3 4

5

6

7

02250159-203R03

1. HI/LO Switch2. Diagnostic Service Port3. Reset Switch4. Pressure Gauge5. Temp/Tach/Fuel Gauge6. Warning Bank7. START/ON/OFF Switch

Figure 2-6: Instrument Panel Group

2.9 ENGINE CONTROL MODULE,FUNCTIONAL DESCRIPTION

Diagnostic Fault Codes are provided to indicate anelectrical or electronic problem has been detected by theECM (Engine Control Module). In some cases, the engine

performance can be affected when the condition causingthe code exists. More frequently, however, the operatorcannot detect any difference in the engine performance.The Compass Controller indicates a performance problemhas occurred whenever the Engine Warning Lamp isflashing. The diagnostic code may indicate the cause ofthe problem, and should be corrected.If the Compass Controller does not indicate a problem withthe engine performance but a diagnostic code is loggedby the ECM, the ECM detected an abnormal condition thatdid not affect performance.If this is the case, unless there are several occurrences ofthe code in a very short period of time, or, the ECM isindicating an Active Code at the present time, there is mostlikely nothing wrong with the system.The diagnostic FLASH CODE may be retrieved using thislamp.The lamp is not required for engine operation, however, itcan be useful to determine Active diagnostic codes. Thelamp will illuminate (ON) at initial ECM power-up to test thelamp operation (self test).Count the first sequence of flashes to determine the firstdigit. After a two-second pause, count the secondsequence of flashes to determine the second digit. Anyadditional flash code diagnostics will follow(after a pause) and will be displayed in the same manner.In addition to the flash codes described above, theCompass Controller should display a brief verbal messagein the LCD of the master gauge. This message helps topinpoint the source of the problem and aid introubleshooting the compressor.

NOTEOnly Active diagnostic codes can beread in this manner. Loggeddiagnostic codes must be retrievedwith an Electronic Service Tool.

Refer to Table 2-1 on page 24 for possible performanceof active diagnostic codes.

DESCRIPTION


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TABLE 2-1 POSSIBLE PERFORMANCE OF ACTIVE DIAGNOSTIC CODESFlashCode

Description Of Code CID-FMICode

SPN-FMICode

EngineMisfires

LowPower

ReducedEngineSpeed

EngineShutdown

12 Incorrect crank-without-inject inputs 266-02 266-02 13 Fuel temperature open/short to +batt 174–03 174–03

Fuel temperature short to ground 174–04 174–04 21 5-Volt sensor DC power supply short to

+batt262-03 620-03

5-Volt sensor DC power supply short toground

262-04 620-04

Digital sensor supply short to +batt 262–03 678-03 Digital sensor supply short to ground 263-04 678-04

24 Engine oil pressure open/short to +batt 100-03 100-03 Engine oil pressure open/short to ground 100-04 100-04

25 Turbo outlet pressure above normal 273-00 102-00 x Turbo outlet pressure open/short to +batt 273-03 102-03 x Turbo outlet pressure short to ground 273-04 102-04 x

26 Atmospheric pressure open/short to +batt 274-03 108-03 Atmospheric pressure short to ground 274-04 108-04

27 Engine coolant temperature open/short to+batt

110-03 110-03 x x x

Engine coolant temperature short to ground 110-04 110-04 x x x 28 Throttle position calibration required 91-13 91-03 x x 32 Throttle position signal abnormal 91-08 91-08 x x 34 Speed/timing sensor loss of signal 320-02 190-02 x x (I)

Speed/timing sensor mechanical failure 320-11 190-11 x x (I)Loss of secondary engine speed signal 342-02 723-02 x x (I)Secondary engine speed sensormechanical failure

342-11 723-11 x x (I)

35 Engine overspeed shutdown 004 0190-16 Engine overspeed warning 190 0190-00

37 Fuel pressure open/short to +batt 94-03 94-03 Fuel pressure short to ground 94-04 94-04 Engine oil temperature open/short to +batt 175-03 175-03 Engine oil temperature short to ground 175-04 175-04

38 Intake manifold air temp open/short to +batt 172-03 172-03 x x x Intake manifold air temp short to ground 172-04 172-04 x x x

42 Engine timing calibration required 261-13 228-13 x x x x46 Low engine oil pressure warning 100 0100-17

Low engine oil pressure derate 039 0100-18 Low engine oil pressure shutdown 040 0100-01 x (I) x (I) x (I)

51 System voltage intermittent/erratic 168-02 168-02 x x x(I) The engine will shut down if both speed/timing sensors are lost.(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier

SECTION 2


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FlashCode

Description Of Code CID-FMICode

SPN-FMICode

EngineMisfires

LowPower

ReducedEngineSpeed

EngineShutdown

53 Electronic Control Module error 254-12 No code x x x x56 Personality Module mismatch 253-02 234-02 x (II)

Check programmable parameters 268-02 111-02 x x 58 J1939 Data Link communications 247-09 639-09 61 High engine coolant temperature derate 015 0110-16

High engine coolant temperature shutdown 016 0110-00 High engine coolant warning 017 0110-15

62 Fuel filter restriction derate 005 0094-15 Fuel filter restriction shutdown 006 0094-16 Fuel filter restriction warning 095 0094-00 High fuel pressure 096 0094-00

64 High inlet temperature derate 025 0172-16 High inlet temperature warning 027 0172-15

65 High fuel temperature derate 054 0174-16 High fuel temperature shutdown 055 0174-00 High fuel temperature warning 056 0174-15

72 Injector cylinder #1 fault 1-11 651-11 x x Injector cylinder #2 fault 2-11 652-11 x x



00 Either start relay open/short to +batt 545-05 545-05 Either start relay short to ground 545-06 545-06

(I) The engine will shut down if both speed/timing sensors are lost.(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier

2.10 ELECTRICAL SYSTEM,FUNCTIONAL DESCRIPTION

Refer to Figure 2-7. The electrical system is comprised ofnot only the necessary equipment required to operate thecompressor, but also a system to shut it down in the eventof a malfunction. The components of the electrical systemare an engine starter (with an integral solenoid), battery,an alternator with a built-in voltage regulator, a compressordischarge temperature switch (which will shut down thecompressor should the compressor temperature exceed

250°F [121°C]), a low coolant shutdown switch and lowfuel shutdown switch. This compressor also incorporatesan engine coolant level detector. This device is located inthe top of engine radiator. It will shut the compressor downor prevent it from being started if the engine coolant leveldrops too low. In addition, there is a starter protection relaywhich prevents accidental starter engagement after theengine is running or whenever there is pressure in thereceiver tank. Also, should fuel supply level drop near thebottom of the fuel tank, the Compass Controller will shutdown the machine before the engine actually runs out offuel.

DESCRIPTION


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2.11 ELECTRICAL SYSTEM

26

25

24

65

4

3

21

02250163-092R03-1

7

A1 A2

SECTION 2


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711 12

13

14

15

109

02250163-092R03-2

17

19

18

23

22

2120

8

6

16

1. Air Shutoff Relay2. 15-Amp Breaker3. Alternator4. Battery Disconnect5. Engine Ground Stud6. Manifold Block Connector7. Battery8. Remote Start Input9. Starter Relay10. Starter Solenoid11. 2-Amp Breaker12. Ether Start Solenoid13. Starter

14. Engine Filter Minder15. E-Stop16. Shutter Solenoid17. Compass Controller18. Ambient Temperature Sensor19. Fuel Sensor20. P3 Pressure Switch21. P1 Pressure Switch22. RTT23. CDT24. Coolant Sensor25. Engine ECM26. Transistor ResistorA1 To air shutoffA2 To battery +

Figure 2-7: Electrical System

DESCRIPTION


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2.12 AFTERCOOLER AIR SYSTEM,FUNCTIONAL DESCRIPTION

Refer to Figure 2-8. The purpose of the aftercooler airsystem is to operate the air compressor in conditions whencompressed air temperatures are required to be 10 to 25˚F(5 to 13˚C) over ambient temperature. Two dischargevalves are provided on all aftercooled compressormodels. One valve is labeled standard air and one valveis labeled aftercooled air. Closing the standard air (non-aftercooled) valve completely forces the air flow from thereceiver tank to the aftercooler. The ambient air, which isdrawn through the aftercooler by the engine fan, cools thecompressed air as it passes through the aftercooler core.Cooled air enters the moisture separator wherecondensation is removed from the cooler air anddischarged. This condensation does carry some oil and it

should be disposed of properly in accordance with localregulations. From the moisture separator the compressedair goes to the compressor service valve.

NOTEAftercooler system should not beoperated in ambient conditions below32˚F (0˚C). If it is necessary to operatein these conditions, Sullair can supplyoptional equipment to accommodatethis requirement.To operate in the non-aftercooledmode, close the aftercooler servicevalve completely and open non-aftercooler valve.

SU_0000141

1. Receiver Tank2. Minimum Pressure Check Valve3. Air Valve4. Aftercooler

5. Moisture Separator6. Discharge Filters7. Pneumatic Valve

Figure 2-8: Aftercooler Air System

SECTION 2


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3.1 TABLE OF SPECIFICATIONS – 600H, 600HH, 750, 750H, 750HHTABLE 3-1 OVERALL SPECIFICATIONS - 600H, 600HH, 750, 750H AND 750HH

Model Series Length (I)in (mm)

Widthin (mm)

Height (II)in (mm)

Weight (wet)lb (kg)

DTQ (Tandem) 191 (4851) 87 (2210) 89.75 (2280) 10045 (4554)DWQ (4–Wheel) 204 (5182) 87 (2210) 97 (2464) 10195 (4662)DLQ (LRG) 131 (3372) 87 (2210) 80 (2032) 9870 (4474)(I) Length including drawbar where applicable.(II) Over lifting bail.

TABLE 3-2 COMPRESSOR SPECIFICATIONSCompressor 600H/750H 750 600HH/750HHType Rotary Screw Rotary Screw Rotary ScrewDelivery @ Operating Pressure 600/750 750 600/750Maximum Operating Pressure 150 psig (10.3 bar) 125 psig (8.6 bar) 175 psig (12.0 bar)Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid Pressurized Compressor FluidLubricating Compressor See

Lubrication Guide –Compressor on page 33

SeeLubrication Guide –Compressor on page 33


Receiver Tank Capacity 21 U.S. gallons (80 liters) 21 U.S. gallons (80 liters) 21 U.S. gallons (80 liters)Operating Tilt (maximum) 15° 15° 15°Electrical System Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt

Instrument System – 24 Volt Instrument System – 24 Volt Instrument System – 24 VoltBattery (2) 1000 CCA @ 0°F (-18°C) 1000 CCA @ 0°F (-18°C) 1000 CCA @ 0°F (-18°C)Alternator 35 Amp 35 Amp 35 AmpSound Level 76 dBA @ 23 ft (7 m) 76 dBA @ 23 ft (7 m) 76 dBA @ 23 ft (7 m)

®SULLAIR®

Section 3SPECIFICATIONS


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TABLE 3-3 ENGINE SPECIFICATIONSEngine 600H/750H 750 600HH/750HHMake Caterpillar Caterpillar CaterpillarType C9 C9 C9Rated Speed 1800 RPM 1800 RPM 1800 RPMHorsepower, SAE 275 HP (205 kW) / 300 HP (224

kW)275 HP (205 kW) / 300 HP (224kW)

275 HP (205 kW) / 300 HP (224kW)

Cylinders 6 6 6Cycles 4 4 4Bore x Stroke 4.41 x 5.87 in (112 x 149 mm) 4.41 x 5.87 in (112 x 149 mm) 4.41 x 5.87 in (112 x 149 mm)Displacement 538 cu.in (8.8 liters) 538 cu.in (8.8 liters) 538 cu.in (8.8 liters)Lubricating System Full Pressure Fluid Full Pressure Fluid Full Pressure FluidType Of Motor Oil See Engine Operator's Manual See Engine Operator's Manual See Engine Operator's ManualFuel Tank Capacity 120 U.S. gallons (454 liters) 120 U.S. gallons (454 liters) 120 U.S. gallons (454 liters)Engine Cooling SystemCapacity

6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters)

Idle Speed 1400 RPM 1400 RPM 1400 RPM

TABLE 3-4 TRAILER SPECIFICATIONSTrailer DTQ DWQTrack Width 77 in (1956 mm) 79.5 in (2019 mm)Tire Size (Load Range) 9.50 x 16.5 LT (E) 8.75 x 16.5 LTTire Pressure 100 psig (7 bar) 60 psig (4 bar)Wheel Size 16.5 x 6.75 16.5 x 6.75Wheel Bolt/Lugnut Torque 80 to 90 ft.lbs (108.5 to 122.0 N·m) 80 to 90 ft.lbs (108.5 to 122.0 N·m)

SECTION 3


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3.2 TABLE OF SPECIFICATIONS – 825, 900, 900H, 1050TABLE 3-5 OVERALL SPECIFICATIONS - 825, 900, 900H AND 1050

Model Series Length (I)in (mm)

Widthin (mm)

Height (II)in (mm)

Weight (wet)lb (kg)

DTQ (Tandem) 191 (4851) 87 (2210) 89.75 (2280) 10045 (4554)DWQ (4–Wheel) 204 (5182) 87 (2210) 97 (2464) 10195 (4662)DLQ (LRG) 131 (3372) 87 (2210) 80 (2032) 9870 (4474)(I) Length including drawbar where applicable.(II) Over lifting bail.

TABLE 3-6 COMPRESSOR SPECIFICATIONSCompressor 825 900/1050 900HType Rotary Screw Rotary Screw Rotary ScrewDelivery @ Operating Pressure 825 900/1050 900Maximum Operating Pressure 140 psig (9.7 bar) 125 psig (8.6 bar) 150 psig (10.3 bar)Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid Pressurized Compressor FluidLubricating Compressor See

Lubrication Guide –Compressor on page 33



Receiver Tank Capacity 21 U.S. gallons (80 liters) 21 U.S. gallons (80 liters) 21 U.S. gallons (80 liters)Operating Tilt (maximum) 15° 15° 15°Electrical System Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt

Instrument System – 24 Volt Instrument System – 24 Volt Instrument System – 24 VoltBattery (2) 1000 CCA @ 0°F (-18°C) 1000 CCA @ 0°F (-18°C) 1000 CCA @ 0°F (-18°C)Alternator 35 Amp 35 Amp 35 AmpSound Level 76 dBA @ 23 ft (7 m) 76 dBA @ 23 ft (7 m) 76 dBA @ 23 ft (7 m)

SPECIFICATIONS


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TABLE 3-7 ENGINE SPECIFICATIONSEngine 825 900/1050 900HMake Caterpillar Caterpillar CaterpillarType C9 C9 C9Rated Speed 1800 RPM 1800 RPM 1800 RPMHorsepower, SAE 275 HP (205 kW) / 300 HP (224

kW)275 HP (205 kW) / 300 HP (224kW)

275 HP (205 kW) / 300 HP (224kW)

Cylinders 6 6 6Cycles 4 4 4Bore x Stroke 4.41 x 6.00 in (112 x 152.4 mm) 4.41 x 6.00 in (112 x 152.4 mm) 4.41 x 6.00 in (112 x 152.4 mm)Displacement 550 cu.in (9.0 liters) 550 cu.in (9.0 liters) 550 cu.in (9.0 liters)Lubricating System Full Pressure Fluid Full Pressure Fluid Full Pressure FluidType Of Motor Oil See Engine Operator's Manual See Engine Operator's Manual See Engine Operator's ManualFuel Tank Capacity 120 U.S. gallons (454 liters) 120 U.S. gallons (454 liters) 120 U.S. gallons (454 liters)Engine Cooling SystemCapacity

14.7 U.S. gallons (55.6 liters) 14.7 U.S. gallons (55.6 liters) 14.7 U.S. gallons (55.6 liters)

Idle Speed 1400 RPM 1400 RPM 1400 RPM

TABLE 3-8 TRAILER SPECIFICATIONSTrailer DTQ DWQTrack Width 77 in (1956 mm) 79.5 in (2019 mm)Tire Size (Load Range) 9.50 x 16.5 LT (E) 8.75 x 16.5 LTTire Pressure 100 psig (7 bar) 60 psig (4 bar)Wheel Size 16.5 x 6.75 16.5 x 6.75Wheel Bolt/Lugnut Torque 80 to 90 ft.lbs (108.5 to 122.0 N·m) 80 to 90 ft.lbs (108.5 to 122.0 N·m)

SECTION 3


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3.3 LUBRICATION GUIDE – COMPRESSORFluid Type Change Period, Hours Ambient Temperature Range °F (°C)Sullair AWF (I) 1200 –20 to 120 (–29 to 49)D-A Torque Fluid 300 10 to 110 (-12 to 43)SAE 10W SE, SF, SG, CD 300 0 to 100 (-18 to 38)MIL-L-2104E 10W 300 0 to 100 (-18 to 38)(I) Sullair part numbers for multi-viscosity lubricants are 250030–757 (5 gallons/18.9 liters), 250030–758 (55 gallons/208 liter drum).

3.4 APPLICATION GUIDERefer to Figure 3-1. Sullair Air Compressors are suppliedwith Sullair AWF which is heavy duty multi-viscosity, all-weather fluid. Sullair AWF also allows an extended changeinterval. The fluids in theLubrication Guide – Compressor can be used. Any ofthese oils are suitable under conditions where severe oiloxidations can occur.Water must be drained from the receiver tank periodically.In high ambient temperature and high humidity conditions,condensed moisture may emulsify with the oil forming a"milky" color. ATF or SAE 10W is especially prone to thiscondition. The fluid should be changed if this conditiondevelops.

CAUTIONDO NOT mix types of fluids.Combinations of different fluids maylead to operational problems such asfoaming, filter plugging, orifice or lineplugging.

When ambient conditions exceed those noted or ifconditions warrant use of other extended life lubricants,contact Sullair for recommendations.Sullair encourages the user to participate in a fluid analysisprogram. This could result in a fluid change intervaldiffering from that stated in the manual. Sullair Corporationoffers a fluid analysis program for Sullair AWF. Contactyour local Sullair representative for details.D-A Lubricant® Company Inc. offers an analysis programfor users of D-A products and Sullair AWF. Contact yourD-A Lubricant® supplier or Sullair representative fordetails.

SU_0000142

1

2

1. Sight Glass*2. Fluid Fill Port

Figure 3-1: Sight Glass Location*If fluid is seen in the sight glass when the machine is notrunning, no fluid is needed.

3.5 LUBRICATION GUIDE, ENGINEFor engine oil specifications, refer to the EngineOperator's Manual.

SPECIFICATIONS


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SECTION 3



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4.1 GENERALWhile Sullair has built into this compressor acomprehensive array of controls and indicators to assureyou that it is operating properly, you will want to recognize

and interpret the readings which will call for service orindicate the beginning of a malfunction. Before startingyour Sullair compressor, read this section thoroughly andfamiliarize yourself with the controls and indicators - theirpurpose, location and use.

4.2 PURPOSE OF CONTROLSCONTROL OR INDICATOR PURPOSEOFF/ON/START Switch The engine switch is used to both energize the compressor's

electrical system and engage the engine/starter. It also has a built-in anti-restart device that protects the starter from engaging whilethe engine is running. The switch must be turned back to the "OFF"position before the engine can be re-started.

NOTEWhen re-starting the compressor, theCompass Controller will not allow restartuntil system pressure falls below 10 psig(0.7 bar) or less. More than 10 psig (0.7bar) can put extra load on the starter.

Voltmeter Monitors the condition of the batteries and the charging circuit. Thenormal reading is 24 to 28 volts.

Air Pressure Gauge Continually monitors the pressure inside the receiver tank atvarious load and unload conditions.

Engine Water Temperature Gauge Monitors the temperature of the engine water. The normaloperating temperature should read approximately 160°F to210°F (71°C to 99°C).

Compass Controller Depicts system related diagnostics. Can be used for systemperformance monitoring.

Compressor Discharge Temperature Gauge Monitors the temperature of the air/fluid mixture leaving thecompressor unit. The normal reading should be approximately210°F to 230°F (99°C to 110°C).

System Pressure Switch Prevents starter engagement when the air system is pressurized.Fluid Level Sight Glass Monitors the fluid level in the receiver tank. Proper level is always

visible in the sight glass. Check the level when the compressor isshutdown.

®SULLAIR®

Section 4OPERATION


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CONTROL OR INDICATOR PURPOSECompressor Discharge Temperature Switch Opens the electrical circuit to shut down the compressor when the

discharge temperature reaches 250°F (121°C).Reducing Regulator Valve Provides regulated air pressure to the inlet valve and engine speed

control to open the inlet valve and move engine governor to fullspeed with warm-up valve in the "RUN" position.

Control Regulating Valve Provides an air signal to the inlet valve and engine speed cylinderto close the inlet valve and reduce engine speed to control airdelivery according to demand.

Minimum Pressure/Check Valve Maintains a minimum of 65 psig (4.5 bar) in the compressorreceiver tank. This valve restricts receiver air discharge fromreceiver/receiver tank when pressure falls to 65 psig (4.5 bar). Alsoprevents back flow into the receiver tank during unload conditionsand after shutdown.

HI/LO Selector Switch Select high pressure 150 psig (10.3 bar) or low pressure 100 psig(6.9 bar) at instrument panel to correspond to operator's needs.

Pressure Relief Valve Opens receiver tank pressure to the atmosphere should pressureinside the receiver tank exceeds the pressure relief valve setting.

Pressure Regulator Opens a pressure line between the receiver tank and inlet valveallowing inlet valve to regulate air delivery according to air demand.

Air Inlet Valve Regulates the amount of air allowed to enter the air inlet valve. Thisregulation is determined by the amount of air being used at theservice line.

Blowdown Valve Vents receiver tank pressure to the atmosphere at shutdown.Thermal Valve Regulates flow of fluid to and around the fluid cooler. Designed to

maintain a minimum operating temperature; used for fast warm-upat start-up and to eliminate condensation during operation.

Start Switch Starts unit.Running Blowdown Valve Vents surplus receiver tank pressure to the atmosphere during

operation.Coolant Level Detector Shuts the compressor down and/or prevents it from being started

if the engine coolant level drops too low.Recirculation Valve Normally closed. Open when pressure in the spring chamber

exceeds spring.

SECTION 4


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4.3 COMPRESSOR START-UPPROCEDURE

1. Turn the ON/OFF/START switch, located on theCompass Controller, to the "ON" position. Thecontroller will power up and a self-diagnostic programwill be initiated. During the initiation process, thegauges will wag (the needles on each gauge willsweep through its full scale) to verify all relevantsensors are operational. Also, a communication linkwill be established with the engine ECU. During thistime, several messages will be displayed on the panel.Some of these messages may not be noticed by theoperator because the controller steps through theinitialization phase rather quickly. However, theoperator should see the following messages duringthis step:

&

SU_0000044

When the system has successfully initialized, thefollowing message will be displayed on the LCDGraphic Display:

SU_0000045

2. Turn the OFF/ON/START switch to the "START"position and then let off to start engine. You do nothave to hold the switch in the “START” position. TheLCD panel will show the following message:

SU_0000046

WARNINGIf machine does not start successfullywhen starter disengages, the starterwill automatically engage up to fourmore times after brief pauses to tryand start the machine.

Once the compressor has started, the unit will enter awarm-up phase. At this point, the unit is not producingusable compressed air and the service valve shouldstill be closed. The following message will bedisplayed on the LCD panel:

SU_0000047

Once the proper operating conditions are met, themachine will automatically switch into run mode andprovide pressurized service air.

OPERATION


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4.4 SHUTDOWN PROCEDURE1. Close the service valve.2. Turn Place the OFF/ON/START switch in the “OFF”

position. The following message will be displayed inthe LCD Graphic Display:

SU_0000048

3. The unit will continue to run, though it will not produceusable air. The cool down time is defaulted to fiveminutes. At the end of the cool down, the engine willbe shut down. The controller will stay powered up, anda new message will be displayed:

SU_0000049

The controller will continue to monitor the systempressures and will not power down until all pressuresdrop below 10 PSI (0.7 bar). This final process maytake 3 to 5 minutes. Operator interaction is notnecessary during this time as the controller willautomatically disconnect power to all systems so thatthe battery is not inadvertently drained after shutdown.

WARNINGThe E-Stop (emergency stop switch)should be used only in the event of anemergency. Refrain from using theE-Stop to shut the machine downduring normal operations. All usageof the E-Stop is logged in permanentmemory for use by servicetechnicians when troubleshooting amachine. Non-emergency use ofE-Stop is considered equipmentabuse and could void themanufacturer's warranty.

SECTION 4


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5.1 GENERALA good maintenance program is the key to longcompressor life. Below is a program that when adhered to,should keep the compressor in top operating condition.For engine maintenance requirements, refer to the EngineOperator's Manual for a detailed description of serviceinstructions.Refer to Description of Components on page 11 for adetailed description of specific compressor systemcomponents. Prior to performing maintenance, read theCIMA Safety Manual, if applicable.

CAUTIONDO NOT remove caps, plugs and/orother components when compressoris running or pressurized.Stop compressor and relieve allinternal pressure before doing so.

5.2 DAILY OPERATIONPrior to starting the compressor, it is necessary to checkthe fluid level in the receiving tank. Should the level be low,simply add the necessary amount. If the addition of fluidbecomes too frequent, a simple problem has developedwhich is causing this excessive loss.Refer to Troubleshooting Guide on page 48 underExcessive Compressor Fluid Consumption for a probablecause and remedy. Also check the engine oil level and theradiator coolant level prior to starting.

CAUTIONThe radiator and engine coolingsystem must be drained and flushedevery two (2) years. Replace thecoolant with a solution of 50%ethylene glycol and 50% water or asrequired for your geographic location.DO NOT use a leak sealing type of anti-freeze. Should a 100% water solutionbe used, a non-chromate rust inhibitormust be added.

After a routine start has been made, observe theinstrument panel gauges and be sure they monitor thecorrect readings for their particular phase of operation.After the compressor has warmed up, it is recommendedthat a general check on the overall compressor andinstrument panel be made to assure that the compressoris running properly. Also check the air filter restrictions.Should they indicate restriction, replace the elementsimmediately.Refer to Air Filter Maintenance on page 43.

5.3 MAINTENANCE AFTER INITIAL50 HOURS OF OPERATION

After the initial 50 hours of operation, a few simplemaintenance routines can rid the system of any possibleforeign materials, if any. Perform the followingmaintenance operations to prevent unnecessaryproblems.1. Clean the return line orifice and strainer.2. Change compressor fluid filter.3. Check Engine Operator's Manual for required

service.

®SULLAIR®

Section 5MAINTENANCE


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5.4 MAINTENANCE EVERY 100HOURS

After 100 hours of operation, it will be necessary to performthe following:1. Check the battery level and fill with water if necessary.2. Check Engine Operator's Manual for required

service.


Perform the following after every 250 hours of operation:1. Check fan belt tension and adjust if needed.2. Clean the radiator and cooler exterior. Depending on

how contaminated the atmosphere may be, morefrequent cooler and radiator cleaning may benecessary. To clean between fluid cooler and radiator,the three bolts securing the top of the fluid cooler tothe top mounting bracket should be removed, allowingthe fluid cooler to swing down on its lower hinge. Thiswill allow easier access to clean between the fluidcooler and radiator cores.

3. Check Engine Operator's Manual for requiredservice.


When using Sullair AWF, change the compressor fluid andreplace the fluid filter element.Refer to Main Fluid Filter Servicing on page 42.


When using Sullair AWF, replace the fluid filter elementonly. Refer to Main Fluid Filter Servicing on page 42.


Perform the following after every 1000 hours of operation:1. Clean the return line orifice and strainer.2. Repack the wheel bearings on wheel-mounted units.


When using Sullair AWF, change the compressor fluid andreplace the fluid filter element.Refer to Parts Replacement and Adjustment Proceduresin Section 5.10.

5.10 PARTS REPLACEMENT ANDADJUSTMENT PROCEDURES

Compressor Fluid Change ProcedureWarm-up the compressor for 5 to 10 minutes to warm thefluid. Shut the compressor off and relieve all internalpressure before proceeding. Drain the fluid by removingthe plug at the bottom of the receiver tank. Change thecompressor fluid and replace the fluid filter element. Forelement replacement see procedure for servicing the fluidfilter in this section. Fill the receiver tank with fluidaccording to Application Guide on page 33.Running Gear LubricationRefer to Figure 5-1. An inspection of the running gearshould be made on a routine basis. On four-wheelsteerable running gear models, front-axle pivot joints androd ends are fitted with grease zerks which should belubricated every six months.

SECTION 5


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Running Gear Lubrication

SU_0000079

Figure 5-1: Running Gear Lubrication

MAINTENANCE


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Typical E-Z Lube Axle

1

2

3

76

5

4

SU_0000076

1. Rubber Plug2. Outer Bearing3. Inner Bearing4. Grease Flow

5. Grease Fitting6. Metal End Cap7. Spring-loaded Double Lip Seal

Figure 5-2: Typical E-Z Lube Axle

Wheel Bearing LubricationRefer to Figure 5-2. Proper lubrication is essential to theproper functioning and reliability of your portablecompressor axle. Wheel bearings should be lubricated atleast once every 12 months, or more frequently to helpinsure proper performance. Use wheel bearing grease thatconforms to military specification MIL-G-10924 or a hightemperature wheel bearing grease such as lithiumcomplex NLGI Consistency #2.If your axle is equipped with the E-Z Lube feature, thebearings can be periodically lubricated without removingthe hubs from the axle. This feature consists of axlespindles that have been specially drilled and fitted with agrease zerk in their ends. When grease is pumped into thezerk, it is channeled to the inner bearing and then flowsback to the outer bearing and eventually back out of thegrease cap hole (refer to Figure 5-2). The procedure is asfollows:1. Remove the rubber plug from the end of the grease

cap.2. With a standard grease gun filled with a quality wheel

bearing grease, place the gun onto the grease zerklocated in the end of the spindle. Make sure the greasegun nozzle is fully engaged on the fitting.

3. Pump grease into the zerk. The old, displaced greasewill flow back out of the cap around the grease gunnozzle.

4. When new, clean grease is observed, remove thegrease gun, wipe off any excess, and replace therubber plug in the cap.

Main Fluid Filter ServicingRefer to Figure 5-3. The main fluid filters are locatedschematically in the coolant line between the receiver tankand the compressor unit. The main filter elements arereplaceable. For installation of the filter elements, followthe procedure explained below:1. The compressor MUST be shut off and system

pressure MUST be relieved.2. Position a suitable container beneath the elements to

catch fluid drainage.3. Remove elements using a suitable tool.4. Rotate each element counterclockwise to remove.5. Remove element and discard. These elements are not

cleanable.6. Make certain that the mounting surfaces are of the

filter heads are clean.

SECTION 5


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7. Apply a light film of clean fluid to each element gasketsurface.

8. Center the new elements on filter housing heads andtighten until the filter gaskets make contact with thefilter housing. After gaskets make contact, tighten 1/2to 2/3 of a turn.

9. Run compressor and check for leaks.

Main Fluid Filter Assembly

SU_0000126

1

2

3

4

5

6

7

8

1. Capscrew2. Washer3. Lower Housing4. O-Ring

5. Thermostat Element*6. O-Ring7. Upper Housing8. Filter Elements **

Figure 5-3: Main Fluid Filter Assembly*Repair kit for thermostat element, part number02250087-682**Replacement filter element (2 required), part number250025-526Air Filter MaintenanceRefer to Figure 5-4. Air filter maintenance should beperformed when indicated on instrument panel. The airfilters are both equipped with a primary element andsecondary element each.

CAUTIONDO NOT strike elements against anyhard surface to dislodge dust. Thiswill damage the sealing surfaces andpossibly rupture the elements.

The secondary element must be replaced after every thirdprimary element change. DO NOT reconnect thesecondary element once it is removed.

MAINTENANCE


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Element Removal1. Clean the exterior of the air filter housing.2. Remove the cover/element assembly by loosening

the wingnut securing the cover/element assembly.3. Remove the cover/element assembly from the

housing by unscrewing the wingnut.

4. Clean the interior of the housing by using a damp cloth.DO NOT blow out dirt with compressed air as this mayintroduce dust downstream of the filter.

5. When it becomes necessary to remove the secondaryelement, pull the element out of the housing.

6. Install the new secondary element over the rod.7. With the secondary element in place, replace the

primary element.

1

2

6

5

4

3

SU_0000077

1. Housing2. Secondary Element**3. Dust Collector

4. Primary Element*5. Sealing Washer6. Wing Nut

Figure 5-4: Air Filter Assembly* Primary Filter Element, Part No. 048462** Secondary Filter Element, Part No. 048463Element Inspection1. Place a bright light inside the element to inspect for

damage or leak holes. Concentrated light will shinethrough the element and disclose any holes.

2. Inspect all gaskets and gasket contact surfaces of thehousing. Should faulty gaskets be evident, correct thecondition immediately.

3. If the clean element is to be stored for later use, it mustbe stored in a clean container.

4. After the element has been installed, inspect andtighten all air inlet connections prior to resumingoperation.

Primary Element Replacement1. Place the element in position over the secondary

element.2. Install the cover with clean-out port pointing down.

Clamp in place using all latches located on canister.

SECTION 5


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Control System AdjustmentRefer to Figure 5-5 or Figure 5-6. Prior to adjusting thecontrol system, it is necessary to determine the desiredoperating pressure range as well as the maximumpressure at which the machine is to operate. This pressuremust not exceed the maximum operating pressure whichis stamped on the machine serial number plate. Thefollowing explanation applies to a typical machine with adesired operating range of 100 to 110 psig(6.9 to 7.6 bar). This information will apply to a machinewith any other operating range except for the statedoperating pressure. For high-pressure machines,adjustment pressures are shown in parenthesis:1. Start the machine and let it warm-up. On high-

pressure machines, place pressure selector switch inthe "HIGH" position. Check for leaks aroundconnections.

2. Open service valve slightly. Slowly close the servicevalve, watching the pressure gauge to ensure theunload pressure does not exceed 125 psig (8.6 bar)(170 psig [11.7 bar] for "H” machines) (185 psig [12.8bar] for "HH" machines). If it does, the control regulatorset-screw must be backed out until the compressorwill unload. With service valve closed, adjust thecontrol regulator for a 60 psig (4.1 bar) setting. Withservice valve still closed, adjust the control regulator(high pressure regulator on 150 psig [10.3 bar]machines) to maintain a discharge pressure of 115psig (7.9 bar) on low pressure machines (100 psig [6.9bar]), (160 psig [11.0 bar] on "H" machines) (185 psig[12.8 bar] for "HH" machines). Check the idle speedsetting and adjust the threaded rod in the speedcontrol cylinder to maintain 1400 RPM. Open theservice valve to load the compressor to maintain 100psig (6.9 bar) (150 psig [10.3 bar] on "H" machines)(185 psig [12.8 bar] for "HH" machines) dischargepressure. Check to see that the engine throttle lever isagainst the high-speed stop screw. If it is not, thecontrol regulator setting may have to be raised. Set fullload operating speed to 1800 RPM by adjusting thehigh-speed stop screw.

3. For 150 psig (10.3 bar) and 175 psig (12.1 bar)machines, switch to "LO" position. Close the servicevalve and set the low pressure control regulator tomaintain 115 psig (7.9 bar) discharge pressure. Openthe service valve to maintain 100 psig (6.9 bar) andcheck for 1800 RPM full-load speed. If lower speed isobserved, raise the setting of the low pressure controlregulator until rated speed is achieved.

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Control System Components

SU_0000153

1. Pneumatic Inlet Valve2. Manifold Block3. Compass Controller4. HI/LO Solenoid

5. High Pressure Regulator6. Low Pressure Regulator7. START/RUN Solenloid8. Recirculation Solenoid

Figure 5-5: Control System Components

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Separator Element ReplacementRefer to Figure 5-6. When fluid carry-over is evident afterthe fluid return-line strainer and orifice, as well as theblowdown valve diaphragm, have been inspected andfound to be in satisfactory condition, or if the separatorrestriction gauge reads in excess of 10 psig (0.7 bar),separator element replacement is necessary. Follow theprocedure explained below:1. Remove all piping connected to the receiver tank

cover to allow removal (return line, service line, etc.).2. Remove the fluid return line from the fitting in the

cover.3. Remove the twelve (12) 5/8 x 2.25 in capscrews and

lockwashers and lift the cover from the receiver tankwith the minimum pressure/check valve in place.

4. Remove the separator element.5. Scrape the old gasket material from the cover and the

flange on the receiver tank. Be sure to keep allscrapings from falling inside the tank.

6. Install the gaskets.7. Make sure grounding staples are attached to

separator gasket. DO NOT REMOVE STAPLES.8. Replace the receiver tank cover. Install the

twelve (12) 5/8 x 2.25 in capscrews and lockwashersin finger-tight, then gradually tighten in a criss-crosspattern in 4 to 5 steps. Always tighten the capscrewsalternately at opposite sides of the cover. Nevertighten capscrews adjacent to each other. Torquecapscrews to 112 to 127 ft.lbs (151 to 172 N·m).

9. Reconnect all piping. The fluid return line shouldextend to the bottom of the separator element or nomore than 1/16 in (1.6 mm) up from the bottom. Thiswill assure the proper fluid return flow.

10. Clean the fluid return line strainer and clear the orificeprior to restarting the compressor.

1

2

3

4

5

SU_0000078

1. Capscrew2. Lockwasher3. Cover4. Separator Element5. Receiver Tank

Figure 5-6: Separator Element AssemblyRepair kit, part number 250034-086

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5.11 TROUBLESHOOTING GUIDEThe following Troubleshooting Chart is based on both thedata obtained from actual tests conducted at our factoryand real applied situations. It contains symptoms andusual causes for the described problems. However, DONOT assume that these are the only problems that mayoccur. All available data concerning the trouble should besystematically analyzed before undertaking any repairs orcomponent replacement procedures.

• Check for loose wiring.• Check for damaged piping.• Check for parts damaged by heat or an electrical short

circuit, usually apparent by discoloration or a burntodor.

Should your problem persist after making therecommended check, consult your nearest Sullairrepresentative or the Sullair Corporation.

SYMPTOM PROBABLE CAUSE REMEDYCompressor will not start No fuel Check fuel level and add fuel if necessary.

Plugged fuel filter Replace the fuel filter element.Battery Check electrolyte level and add distilled

water and recharge if necessary.Loose battery cables; tighten cables.Dirty battery cables; clean thoroughly.

Plugged air filter Replace the air filter element.Engine problems may have developed Refer to Engine Operator's ManualInstrument panel problems may havedeveloped

Refer to Compass Controller Manual.Sullair Part No. 02250167-454.

Compressor shuts down with air demandpresent

No fuel Check fuel gauge and add fuel if necessary.Compressor discharge temperature switchis open

Cooling air flow is insufficient; clean coolerand check for proper ventilation.Low fluid sump level; add fluid.Dirty compressor fluid filter; changeelement.Thermostatic element is not functioningproperly; change the thermostatic element.Defective discharge temperature switch;check for a short or open circuit to the enginefuel solenoid. Should this checkout normal,it could be possible that the temperatureswitch itself is defective.

Instrument panel problems may havedeveloped

Refer to Compass Controller Manual.Sullair Part No. 02250167-454.

Compressor will not build up full dischargepressure

Air demand is too great Check service lines for leaks or open valves.Dirty air filter Check the filter gauges on instrument panel

and change element if required.Pressure regulator out of adjustment Adjust regulator according to control

adjustment instructions in theMAINTENANCE section.

Defective pressure regulator Check diaphragm and replace if necessary(kit available).

Defective air inlet cylinder Replace cylinder.

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SYMPTOM PROBABLE CAUSE REMEDYImproper unloading with an excessivepressure build-up causing pressure reliefvalve to open

Fluid charge lost from spring chamber oninlet valve pressure regulating valve is settoo high

Add fluid to inlet valve spring chamber byremoving plugs in the top of the springchamber and filling with compressor fluid.Some fluid may leak from the controlregulator at first but will stop leaking whenfluid level in the spring chamber equalizes.

Running blowdown valve pressureregulating valve set too high

Readjust.

Leak in control system causing loss ofpressure signal

Check control lines.Worn seals in inlet valve. Replace seals(kit available).Defective pressure regulating valves; repairvalves (kits available).

Inlet valve jammed Free or replace valve.Restriction in the control system Check all control lines and components.

Ice and other contaminants could causerestrictions.

Defective pressure relief valve Replace pressure relief valve.Insufficient air delivery Plugged air filter Replace.

Plugged air/fluid separator Replace separator element and alsochange compressor fluid and fluid filter atthis time.

Defective pressure regulator Adjust or repair.Engine speed too low Readjust engine speed.Control air cylinder defective Replace cylinder.

Excessive compressor fluid consumption Clogged return line Clear orifice.Leak in the lubrication system Check all pipes, connections and

components.Separator element damaged or notfunctioning properly

Change separator element.

Defective minimum pressure/check valve Repair or replace.Fluid receiver tank overfilled Drain to proper level.

Compressor overheating Loose or broken fan belt Tighten or change belt.Dirty fluid cooler core Clean core thoroughly.Dirty aftercooler Clean core thoroughly.Dirty radiator core Clean core thoroughly.Faulty thermostat element Change thermostat element.Plugged fluid cooler tube (internal) Clean tube thoroughly.Low receiver tank fluid level Refill.Plugged compressor fluid filter Change element.

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SYMPTOM PROBABLE CAUSE REMEDYEngine overheating Loose or broken fan belt Tighten or change belt.

Dirty radiator core Clean thoroughly.Dirty oil cooler Clean thoroughly.Low water level Refill.Dirty aftercooler Clean thoroughly.Low fluid level Refill.Faulty water pump Change pump.Plugged radiator Clean and flush thoroughly.Defective engine thermostat Replace engine thermostat.

Shutdown panel lights Faulty switch indicated by light Replace the switch.Check engine light Engine safety switch (low coolant) fault Replace the switch (Caterpillar part).Engine warning flashing light Count number of flashes. This will flash

trouble code.Determine trouble code and call CaterpillarService Representative to correct problem.

NOTEAdditional troubleshooting tips areavailable in the Compass ControllerManual. Sullair Part No. 02250167–454

SECTION 5


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6.1 NOISE EMISSIONS WARRANTYSullair Corporation warrants to the ultimate purchaser andeach subsequent purchaser that this air compressor wasdesigned, built and equipped to conform at the time of saleto the first retail purchaser, with all applicable U.S. E.P.A.and/or any Federal, State or Local noise controlregulations.This warranty is not limited to any particular part,component, or system of the air compressor. Defects inthe design, assembly, or in any part, component, orsystem of the compressor which, at the time of sale to thefirst retail purchaser, caused noise emissions to exceedFederal standards are covered by this warranty for the lifeof the air compressor.

6.2 TAMPERING WITH THE NOISECONTROL SYSTEM ISPROHIBITED

Federal Law prohibits the following acts or the causingthereof:1. The removal or rendering inoperative by any persons,

other than for purposes of maintenance, repair, orreplacement, of any device or element of designincorporated into any new compressor for the purposeof noise control prior to its sale or delivery to theultimate purchaser or while it is in use.

2. The use of the compressor after such device orelement of design has been removed or renderedinoperative by any person.

Among those acts included in the prohibition againsttampering are the acts listed below:1. Removal or rendering inoperative any of the following:

a. Engine exhaust system or parts thereofb. Compressor air intake system or part thereofc. Enclosure of part thereof

2. Removal of any of the following:a. Vibration isolatorsb. Control silencerc. Floor paneld. Fan shroude. Acoustical materials including fiberglass foam or

foam tape3. Operation with canopy doors open for any purpose

other than starting, stopping, adjustment, repair,replacement of parts or maintenance.

®SULLAIR®

Section 6NOISE CONTROL


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6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOGThe following instructions and maintenance record logbook, for the proper maintenance, use and repair of thiscompressor, is intended to prevent noise emissiondegradation.

Noise Emission Maintenance and Maintenance Record Log1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTIONAt least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints andconnections are tight, and that the muffler is in good condition. DO NOT operate compressor with defective exhaust system. Removeand replace any defective parts by ordering with part numbers indicated in the Parts List.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTIONIn addition to the instructions in the Maintenance section of the Operator's Manual, the air filter(s) and entire air inlet system shouldbe inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight, that there are noother leaks in the system, and that the filter element(s) are intact. DO NOT operate compressor with defective air inlet system. Removeand replace defective parts by ordering with part numbers indicated in the Parts List.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

SECTION 6


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3. ANNUAL ENGINE VIBRATION MOUNT INSPECTIONAt least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. DO NOToperate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbersindicated in Parts List.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION

At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any missing or deformedmembers, including all hinged doors, covers and their fastening devices. DO NOT operate compressor with defective frame, canopyand parts. Remove and replace defective parts by ordering with part numbers indicated in Parts List.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

5. ANNUAL ACOUSTICAL MATERIALS INSPECTIONAt least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material missing ordamaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate compressor with defective acoustical material. Removeand replace defective parts by ordering with part numbers indicated in the Parts List.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

NOISE CONTROL


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6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.In addition to other instructions in the Operator's Manual, at least annually, operate compressor and inspect to make sure all systemsare operating properly and that engine runs at rated speed and pressure. DO NOT operate malfunctioning or improperly adjustedcompressor. Repair or adjust, per instructions in Operator's Manual, as required.Maintenance PerformedByLocationDate Maintenance PerformedByLocationDate

SECTION 6


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7.1 SERIAL NUMBER PLATE LOCATIONWhen ordering parts, always indicate the Serial Number of the compressor. This can be obtained from the Bill of Ladingfor the compressor or from the Serial Number Plate located on the compressor. Refer to Figure 7-1.

SU_0000054

Figure 7-1: Serial Number Plate

®SULLAIR®

Section 7PARTS LISTS


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Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor waspurchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, phoneor fax numbers listed.

SECTION 7


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PARTS LISTS


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7.2 RECOMMENDED SPARE PARTS LISTKey Description Part Number Note Quantity

1 high temperature shutdown switch 250°f 02250159-102 12 ambient temperature sensor 02250161-276 13 discharge temperature sensor 02250161-277 14 engine coolant level sensor 02250165-908 15 fuel level sender 02250163-524 16 pressure sensor 02250141-442 37 discharge filter monitoring module 02250144-565 18 controller relay 02250146-682 49 controller breaker 50a 02250147-476 1

10 aux fuel quick coupling female 1/2" 02250160-014 111 aux fuel quick coupling female 3/8" 02250160-017 112 aux fuel quick coupling male 1/2" 02250160-020 113 aux fuel quick coupling make 3/8" 02250160-023 114 frame drain hole plug 02250160-013 415 air filter element - primary 048462 216 air filter element - secondary 048463 217 discharge filter element - primary 250030-644 118 discharge filter element - secondary 250030-645 119 separator tank element 250034-086 120 spin-on fluid filter 250025-526 221 thermostat replacement kit 250026-561 122 minimum pressure check valve repair kit 250018-262 123 inlet valve repair kit 02250122-534 124 shaft seal repair kit 600893-001 125 kit, mini filt adapt 850to1315 250024-294 126 manifold rebuild kit - dual pressure 02250166-771 127 manifold rebuild kit - single pressure 02250166-772 128 recirculation solenoid repair kit 02250166-773 129 run/start solenoid repair kit 02250166-774 130 hi/lo solenoid repair kit 02250166-775 1

SECTION 7


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7.2 RECOMMENDED SPARE PARTS LIST (CONTINUED)Key Description Part Number Note Quantity31 solenoid coil repair kit 02250166-777 132 pressure reducing valve repair kit 02250166-779 133 blowdown valve repair kit 02250166-781 134 check valve repair kit 02250166-782 135 cp valve repair kit 02250166-783 136 compressor oil, awf (55 gal/208 ltr) 250030-758 137 compressor oil, awf (5 gal/18.9 ltr) 250030-757 138 operators manual & parts list 02250167-521 139 compass control manual 02250167-454 1

CAUTIONMixing of other lubricants within thecompressor unit will void allwarranties.

PARTS LISTS


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PARTS LISTS


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A WARNINGCALIFORNIA

Proposition 65 WarningDiesel engine exhaust and some ofits constituents are known to theState of California to cause cancer,birth defects and other repoductiveharm.Battery posts, terminals andrelated accessories contain leadand other compounds known to theState of California to cause cancerand birth defects and otherreproductive harm. Wash handsafter handling.

02250118-633

®

WORLDWIDE SALES AND SERVICE

SULLAIR EU R OPE , S.A. Zone Des Granges B P 82 42602 Montbrison Cedex, France T elephone: 33-477968470 Fax: 33-477968499 ww w .sullaireurope.com

SULLAIR CORPOR A TION 3700 East Michigan Boulevard Michigan Cit y , Indiana 46360 U.S.A. ww w .sullai r .com

T elephone: 1-800-SULLAIR (U.S.A. Only) or 1-219-879-5451 Fax: (219) 874-1273 CUSTOMER CARE

for PARTS and SERVICE 1-888-SULLAIR (7855247)

219-874-1835

SULLAIR ASIA , L T D . Sullair Road, No. 1 Chiwan, Shekou Shenzhen, Guangdong P R V . PRC POST CODE 518068 T elephone: 755-6851686 Fax: 755-6853473 ww w .sullair-asia.com

CHAMPION COMPRESSORS , L T D . Princess Highway

Hallam, Victoria 3803Austrailia T elephone: 61-3-9796-4000 Fax: 61-3-9703-8053 ww w .championcompressors.com.au

Printed in the U.S.ASpecifications subject to change

without prior noticeE07KCC

Date post:	18-Apr-2015
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