USER MANUAL Portable Air Compressor 1600H Tier 4 Final Caterpillar PART NUMBER: 02250225-985 R01 SAFETY WARNING Users are required to read the entire User Manual before handling or using the product. WARRANTY NOTICE Failure to follow the instructions and procedures in this manual, or misuse of this equipment, will void its warranty. The information in this manual is current as of its publication date and applies to compressor models indicated on this cover with serial number: 201612120000 and all subsequent serial numbers. Publication date: 1/12/2017 Copyright © 2016 – 2017 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions. Air Care Seminar Training Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Portable compressors are offered at regular intervals throughout the year at Sullair’s training facility located in Michigan City, Indiana. Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact: Sullair Training Department 1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com email@example.com - Or Write Sullair, LLC 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department. Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual Table of Contents Table of Contents Section 1: Safety.......................................................................................................1 1.1 1.2 1.3 1.4 1.5 1.6 General....................................................................................................... 1 Personal protective equipment ................................................................... 1 Pressure release ........................................................................................ 1 Fire and explosion ...................................................................................... 2 Moving parts ............................................................................................... 3 Hot surfaces, sharp edges and sharp corners............................................ 4 1.7 1.8 1.9 1.10 1.11 1.12 1.13 Toxic and irritating substances ................................................................... 4 Electrical shock........................................................................................... 5 Lifting .......................................................................................................... 6 Entrapment ................................................................................................. 6 Implementation of lockout/tagout................................................................ 6 Jump starting .............................................................................................. 7 Towing1 ...................................................................................................... 8 1.6.1 Tier 4 emissions module—if equipped...................................................................4 1.13.1 Preparing to tow.....................................................................................................8 1.13.2 Towing .................................................................................................................10 1.13.3 Parking or locating compressor ...........................................................................10 1.14 1.15 California proposition 65........................................................................... 11 Symbols and references........................................................................... 12 Section 2: Description............................................................................................17 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 Introduction............................................................................................... 17 Description of components ....................................................................... 17 Sullair compressor unit, functional description ......................................... 17 Cooling and lubrication system, functional description............................. 19 Discharge system, functional description ................................................. 19 Control system, functional description...................................................... 22 Air inlet system, functional description ..................................................... 22 Engine control module, functional description .......................................... 22 Electrical system, functional description................................................... 23 Wiring diagram ......................................................................................... 24 Piping & instrumentation, compressor system ......................................... 28 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. i Table of Contents 1600H T4F CAT User Manual 2.12 2.13 2.14 2.15 2.16 Piping & instrumentation, engine system.................................................. 30 ID, DTQ aftercooled .................................................................................. 32 ID, DLQ aftercooled .................................................................................. 34 Aftercooler air system, functional description ........................................... 36 Engine exhaust aftertreatment, functional description .............................. 36 Section 3: Specifications....................................................................................... 37 3.1 3.2 3.3 3.4 Specifications—1600H Tier 4 Final Caterpillar .........................................37 Lubrication guide—compressor ................................................................ 39 Lubrication guide—engine ........................................................................ 39 Application guide....................................................................................... 39 Section 4: Installation ............................................................................................ 41 4.1 4.2 4.3 4.4 Locating the package................................................................................ 41 Ventilation and cooling.............................................................................. 41 Service air and condensate piping............................................................ 41 Remote fuel connections .......................................................................... 41 Section 5: Operation .............................................................................................. 43 5.1 5.2 5.3 5.4 5.5 General ..................................................................................................... 43 Purpose of controls ...................................................................................43 Startup procedure ..................................................................................... 44 Operation procedure ................................................................................. 45 Shutdown procedure................................................................................. 45 Section 6: Controller .............................................................................................. 47 6.1 6.2 6.3 6.4 Controller layout........................................................................................ 47 Home display ............................................................................................ 48 User options.............................................................................................. 50 Service options ......................................................................................... 51 6.4.1 6.5 Service options: Setup ........................................................................................ 52 Help........................................................................................................... 54 Section 7: Maintenance ......................................................................................... 55 7.1 7.2 7.3 7.4 General ..................................................................................................... 55 Daily operation and maintenance ............................................................. 55 Engine coolant requirements .................................................................... 56 Recommended maintenance intervals...................................................... 57 7.4.1 ii Maintenance after initial 50 hours of operation ................................................... 57 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual Table of Contents 7.4.2 7.4.3 7.4.4 7.5 7.6 Engine maintenance................................................................................. 57 Parts replacement and adjustment procedures........................................ 57 7.6.1 7.6.2 7.6.3 7.6.4 7.6.5 7.6.6 7.6.7 7.6.8 7.6.9 7.6.10 7.7 Maintenance every 250 hours .............................................................................57 Maintenance every 500 hours .............................................................................57 Maintenance every 1500 hours ...........................................................................57 Compressor fluid change procedure....................................................................57 Main fluid filter servicing ......................................................................................58 Air filter maintenance ...........................................................................................58 Control system adjustment ..................................................................................59 Separator element replacement ..........................................................................61 Running gear—brake shoe maintenance and adjustment...................................61 Brake cleaning and inspection.............................................................................62 Brake lubrication ..................................................................................................62 Bearing lubrication—grease ................................................................................62 Axle bearing adjustment ......................................................................................63 Troubleshooting........................................................................................ 64 Section 8: Noise Control........................................................................................67 8.1 8.2 8.3 Noise emissions warranty......................................................................... 67 Tampering with the noise control system is prohibited............................. 67 Noise emissions maintenance and maintenance record log .................... 68 Appendix A: Acronyms and Abbreviations .........................................................71 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. iii Table of Contents 1600H T4F CAT User Manual Notes: iv 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety Section 1 Safety Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace as required. NOTE 1.2 Personal protective equipment Operator is required to read entire instruction manual. 1.1 General Sullair designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. Read the AEM Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator’s Manual. Failure to follow the instructions, procedures and safety precautions in 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 a known unsafe condition. Tag the air compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements. DO NOT modify the compressor except with written factory approval. Each day, walk around the air compressor and inspect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recommended daily maintenance. A. Prior to installing or operating the compressor, owners, employers and users should become familiar with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local codes, standards, and regulations relative to personal protective equipment, such as eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields and barriers and electrical protective equipment, as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment. 1.3 Pressure release A. Inspect the pressure relief valve at least weekly to make sure it is not blocked, closed, obstructed or otherwise disabled. B. To make sure the pressure relief valve is working properly, open the pressure relief valve at least once a year or more frequently as required by any applicable Federal, State and Local codes, standards and regulations. C. Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throttle) valve, when an air hose exceeding 1/2″ (13 mm) inside diameter is to be connected to the shutoff (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302 (b) (7) or any applicable Federal, State and Local codes, standards and regulations. D. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2″ (13 mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1 1: Safety 1600H T4F CAT User Manual E. Provide an appropriate flow-limiting valve for each additional 75 feet (23 m) of hose in runs of air hose exceeding 1/2″ (13 mm) inside diameter to reduce pressure in case of hose failure. cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve accordingly. R. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty. F. G. DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items. H. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. I. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. J. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound. K. Vent all external pressure (pressure downstream of the machine) before disconnecting any air tools, hoses, fittings, etc. or performing any maintenance procedures. L. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge. M. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes, standards and regulations. N. DO NOT engage in horseplay with air hoses as death or serious injury may result. O. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure. P. If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure. Q. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen 2 S. If a manual blowdown valve is provided on the receiver, open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air/fluid system. 1.4 Fire and explosion WARNING Do not attempt to operate the compressor in any classification of hazardous environment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty. A. Refuel at a service station or from a fuel tank designed for its intended purpose. If this is not possible, ground the compressor to the dispenser prior to refueling. B. Clean up spills of lubricant or other combustible substances immediately, if such spills occur. C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries, checking or adding fluid, checking diesel engine ether starting aid systems, replacing cylinders, or when refilling air line anti-icer systems antifreeze compound. D. DO NOT permit fluids, including air line anti-icer system antifreeze compound or fluid film, to accumulate on, under or around acoustical material, or on any external surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety replaced immediately to prevent accumulation of liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes. E. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure, if any. F. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight. G. Turn off battery charger before making or breaking connections to the battery. H. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made. J. Remove any acoustical material or other material that may be damaged by heat or that may support combustion and is in close proximity, prior to attempting weld repairs. K. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine. N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas. O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160°F (71°C). Remove ether cylinder from the compressor when operating in ambient temperatures above 60°F (16°C). P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result. Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result. R. Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use systems and refill with compound only in well-ventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150°F (66°C). Vapors from the antifreeze compound are heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas. DO NOT store containers of antifreeze compound in direct sunlight. S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression systems and detectors if so equipped. T. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. U. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty. 1.5 Moving parts WARNING Disconnect and lock out all power at source and verify at the compressor that all circuits are deenergized to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjustments. This is especially important when compressors are remotely controlled. A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other moving parts. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 3 1: Safety 1600H T4F CAT User Manual B. DO NOT attempt to operate the compressor with the fan, coupling or other guards removed. C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts. D. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it. E. When adjusting the controls, it may require operation of the equipment during adjustment. DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM. Make all other adjustments with the engine shut off. When necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment. F. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the possibility of slips and falls. 1.6 Hot surfaces, sharp edges and sharp corners A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. T4—WARNING Increased DPF skin temperature and exhaust gas temperature may occur in the event of an unexpected engine/aftertreatment failure. An unexpected failure of the engine/aftertreatment may increase temperature at the DPF as high as 900°C (1652°F) gas temperature and 750°C (1382°F) skin temperature. This may result in fire, burn, or explosion hazards, which may result in personal injury or death. Do not expose flammable material or explosive atmospheres to exhaust gas or exhaust system components during regeneration. The aftertreatment skin temperature and the gas temperature are difficult to measure and/or simulate and are dependent upon many factors including the following: the nature of the engine/aftertreatment failure, the design and packaging of the aftertreatment, the engine speed/load conditions, the condition of the aftertreatment and ambient conditions. Therefore, the potential temperatures are provided as a guideline even under conditions of unexpected engine and/or aftertreatment failure. B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases. 1.7 Toxic and irritating substances C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local codes or regulations. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection. 1.6.1 Tier 4 emissions module—if equipped General Guidelines: Thermal Protection. The main exhaust piping routes exhaust gas from the engine to the exhaust aftertreatment. Normal operating temperatures can reach up to 530°C (986°F). Regeneration of the Diesel Particulate Filter (DPF) can create temperatures above normal engine exhaust temperatures. Gas temperatures during the regeneration period can reach 750°C (1382°F). 4 DANGER Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or adequately ventilated areas. D. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor. E. Fuels, fluids and lubricants used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to the specific fluid. F. Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems. G. Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, immediately flush with large quantities of water. H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting and call a physician immediately. I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze compound to air line anti-icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourself and other personnel. J. If air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for fifteen minutes. A physician, preferably an eye specialist, should be contacted immediately. K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operator’s cabs or in other similar confined areas. L. The antifreeze compound used in air line antifreeze systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. M. If your compressor is equipped with Diesel Emissions Fluid (DEF), when handling DEF wear protective clothing. Tools and clothing that come in contact with DEF must be cleaned. IMPORTANT It is very important that all electrical connectors are protected from coming in contact with DEF. If not, there is a risk that DEF will cause oxidation in the wiring that is not possible to clean. The resulting oxidation will result in a wiring/connection failure. Water and compressed air fail to remove DEF. If a connector has been in contact with DEF, it must be changed immediately to prevent the chemical from further migrating into the wiring cable harness, which happens at a speed of 0.6 m/h. WARNING In case of DEF contact with eyes or skin, the affected area must be thoroughly rinsed with lukewarm water. If you breathe any fumes, make sure and breathe fresh air. 1.8 Electrical shock A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10 feet (3 m) from power lines and buried cables. B. Stay clear of the compressor during electrical storms! It can attract lightning. C. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. D. Attempt repairs in clean, dry and well lighted and ventilated areas only. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 5 1: Safety 1600H T4F CAT User Manual 1.9 Lifting A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local, State, Military and Federal regulations that may apply. B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight of water, snow, ice, mud, stored tools, and equipment. If your are unsure of the weight, then weigh compressor before lifting. ments, inform other personnel before doing so, or else secure the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. 1.11 Implementation of lockout/tagout The energy control procedure defines actions necessary to lockout a power source of any machine to be repaired, serviced or set-up, where unexpected motion, or an electrical or other energy source, would cause personal injury or equipment damage. The power source on any machine shall be locked out by each employee doing the work except when motion is necessary during setup, adjustment or trouble-shooting. A. The established procedures for the application of energy control shall cover the following elements and actions and shall be initiated only by Authorized Persons and done in the following sequence: 1. Review the equipment or machine to be locked and tagged out. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail. 2. Alert operator and supervisor of which machine is to be worked on, and that power and utilities will be turned off. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. 3. Check to make certain no one is operating the machine before turning off the power. 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 additional 10% allowance for the weight of water, snow, ice, mud, stored tools, and/or equipment. K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disengaging the lifting hook. 1.10 Entrapment A. Make sure all personnel are out of compressor before closing and engaging enclosure doors. B. If the compressor is large enough to hold a man and if it is necessary to enter it to perform service adjust- 6 4. Turn off the equipment using normal shutdown procedure. 5. Disconnect the energy sources: a. Air and hydraulic lines should be bled, drained and cleaned out. There should be no pressure in these lines or in the reservoir tanks. Lockout or tag lines or valves. b. Any mechanism under tension or pressure, such as springs, should be released and locked out or tagged. c. Block any load or machine part prior to working under it. d. Electrical circuits should be checked with calibrated electrical testing equipment and stored energy and electrical capacitors should be safely discharged. 6. Lockout and/or Tagout each energy source using the proper energy isolating devices and tags. Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each person performing work. Each person shall be provided with their own padlock and have possession of 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety the only key. If more than one person is working on a machine each person shall affix personal lock and tag using a multi-lock device. 7. Tagout devices shall be used only when power sources are not capable of being locked out by use of padlocks and lockout hasp devices. The name of the person affixing tag to power source must be on tag along with date tag was placed on power source. 8. Release stored energy and bring the equipment to a “zero mechanical state”. 9. Verify Isolation: Before work is started, test equipment to ensure power is disconnected. B. General Security 1. The lock shall be removed by the “Authorized” person who put the lock on the energy-isolating device. No one other than the person/persons placing padlocks and lockout hasps on power shall remove padlock and lockout hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it his/her Supervisor may remove padlock/padlocks and lockout hasps and restore power only if it is first: B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away. C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid-resistant apron and face shield when attempting to jump start the compressor. D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells. E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance-free batteries). F. DO NOT attempt to jump start if fluid is frozen or slushy. 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 clean dampened cloths before attempting to jump start. b. verified that the “Authorized” person who applied the device is not in the facility. H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result. c. I. a. verified that no person will be exposed to danger. noted that all reasonable efforts to contact the “Authorized” person have been made to inform him or her that the lockout or tagout device has been removed. d. ensured that the “Authorized” person is notified of lock removal before returning to work. 2. Tagout System—Tags are warning devices affixed at points of power disconnect and are not to be removed by anyone other that the person placing tag on power lockout. Tags shall never be by-passed, ignored, or otherwise defeated. 1.12 Jump starting A. Observe all safety precautions mentioned elsewhere in this manual. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle. J. Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels. K. Place the starting vehicle in neutral or park, turn off all non-essential accessory electrical loads and start its engine. L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current. M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition. N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 7 1: Safety 1600H T4F CAT User Manual adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign. O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the positive (POS) (+) terminal of the ungrounded battery. P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor when jump starting 24V compressors, to the positive (POS) (+) terminal of the ungrounded battery in the compressor. Q. Connect one end of the other jumper cable to the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with 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 a 24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V to one 12V battery in the compressor. S. Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening and the battery. T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking. U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two (2) 12V batteries connected in series. 1 8 V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps. 1.13 Towing1 1.13.1 Preparing to tow WARNING Do NOT tow the compressor should its weight exceed the rated limit of the tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator's Manual, and review its instructions and other requirements for safe towing. A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment, checking for (I) signs of excessive wear or corrosion, (II) parts that are cracked, bent, dented or otherwise deformed or degraded, and (III) loose nuts, bolts or other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected. B. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor. C. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar with the jack to engage coupling device or otherwise couple the compressor to the towing vehicle. WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands. 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. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety D. Make sure the coupling device is fully engaged, closed and locked. CAUTION E. If chains are provided, pass each chain through its point of attachment on the towing vehicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under the front of drawbar before passing them through points of attachment on towing vehicle to support the front of drawbar in case it should accidentally become uncoupled. F. Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. Make sure that the coupling device and adjacent structures on the towing vehicle (and also, if utilized, chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain. G. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render them inoperative. WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. H. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack, and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full upright position. Rotate the screw jack to its stowed position, 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 specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques. J. If provided, make sure all dual stop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional. K. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided. L. Make sure all access doors and tool box covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 9 1: Safety 1600H T4F CAT User Manual M. Make sure parking brakes in towing vehicle are set, or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided. N. Make sure the compressor wheels are not chocked or blocked, and that all tie-downs, if any, are free. O. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail. P. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor. Q. DO NOT load this equipment with accessories or tools such that it is unbalanced from side to side or front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result. 1.13.2 Towing A. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed). B. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions: C. Two axle four-wheel or three axle six-wheel steerable models: 15 mph (24 km/h). D. All other models: 55 mph (88 km/h). E. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, U-turns or other maneuvers. Such maneuvers can cause the compressor to tip, roll over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without warning. U-turns especially should be made slowly and carefully. F. Avoid grades in excess of 15° (27%). ing forward or backing up, regardless of the terrain being traversed. I. DO NOT permit personnel to ride in or on the compressor. J. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction. K. DO NOT permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle. 1.13.3 Parking or locating compressor A. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade so the compressor does not tend to roll downhill. DO NOT park or locate compressor on grades exceeding 15° (27%). B. Make sure compressor is parked or located on a firm surface that can support its weight. C. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to excessive dust from the work site. D. On steerable models, park compressor with front wheels in straight-ahead position. E. Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake 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, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting. H. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has sufficient load bearing capability to support the weight of the compressor. G. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain. H. Maneuver in a manner that will not exceed the freedom of motion of the compressor’s drawbar and/ or coupling device, in or on the towing vehicle’s coupling device and/or adjacent structure whether tow- 10 WARNING This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety CAUTION Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. I. If a caster wheel is provided on the screw jack, it is part of the screw jack and cannot be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar and reinsert the pin. Make sure the jack is secured in place prior to towing. J. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the drawbar or if hinged, to raise it to the upright position by hand, if the weight is more than you can safely handle. Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others. K. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is parked on or adjacent to public roads. Park so as not to interfere with traffic. NOTE While not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted portable air compressors as well. 1.14 California proposition 65 WARNING California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. Battery posts, terminals and related accessories contain lead and other compounds known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 11 1: Safety 1600H T4F CAT User Manual 1.15 Symbols and references The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols. DIESEL FUEL HEARING PROTECTION ROTARY COMPRESSOR HARD HAT TEST RUN DRAIN SAFETY GLASSES HIGH PRESSURE HOOK HERE SHUT-OFF VALVE W/ SAFETY DO NOT REMOVE MANUAL NO ENGINE DO NOT BREATHE COMPRESSED AIR COMPRESSOR DO NOT STAND ON SERV. VALVE ENGINE OIL DO NOT OPERATE W/ DOORS OPEN ENGINE COOLANT WATER DO NOT OPEN OIL DO NOT STACK ELECTRICAL SHOCK DO NOT CLOSED MECHANICAL AIR FLOW FUSE HOT SURFACE LOW PRESSURE PRESSURIZED VESSEL READ MANUAL BRAKES 12 PRESSURIZED COMPONENT SAFETY SYMBOLS 1 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety ENGINE START DANGEROUS OUTLET ENGINE ECM REMOTELY CONTROLLED READ/WRITE DATA CORROSIVE INTAKE AIR EXHAUST GAS WARNING FAN GUARD DO NOT MAINTENANCE BELOW TEMPERATURE BELT GUARD DO NOT TOW SERVICE POINT BAR/PSI LOW TEMPERATURE BATTERY BATTERY DISCONNECT STD AIR OFF A/C AIR ON 24 HOURS RESET BELTS FILTER NO FORKLIFT STRAINER FORK LIFT HERE SAFETY SYMBOLS 2 DIRECTION OF ROTATION 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 13 1: Safety 1600H T4F CAT User Manual RADIATOR HOUR METER AIR-CIRCULATING FAN COMPRESSOR AIR PRESSURE AIR-COOLED OIL COOLER START CONTROL LIQUID-COOLED OIL COOLER ENGINE PREHEAT LOW TEMP AID LUBRICATION ENGINE WARNING TRAILER TOWING MODE FUEL LEVEL AXEL ENGINE RPM LUBRICANT GREASE EXAMINE, CHECK ENGINE OIL PRESSURE CRUSH/PINCH POINT ENGINE COOLANT TEMPERATURE FUNCTIONAL ARROW COMPRESSOR TEMPERATURE DO NOT MIX COOLANTS ENGINE INTAKE AIR FILTER AFTERCOOLER BYPASS VALVE PRESSURE CONTROL INLET VALVE SPRING DRAIN HEATER INTERNAL FUEL BATTERY HEATER EXTERNAL FUEL COMPRESSOR OIL HEAT SIDE DOOR T-LATCH STACKING LIMIT BY NUMBER SAFETY SYMBOLS 3 14 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 1: Safety DO NOT OPERATE WHILE STACKED WATER DRAIN PRESSURIZED SPRING SEVER (FAN) DO NOT MIX FLUIDS DEF FLUID ONLY AUTO START/STOP RUN FLUID DRAIN LOW FUEL DPF: DIESEL PARTICULATE FILTER HEST: HIGH EMISSIONS SYSTEM TEMPERATURE DPF REGEN. INHIBIT EMISSIONS MALFUNCTION INDICATION SAFETY SYMBOLS 4 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 15 1: Safety 1600H T4F CAT User Manual Notes: 16 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 2: Description Section 2 Description 2.1 Introduction Sullair portable air compressor models offer superior performance and reliability while requiring only minimal maintenance. The compressor is equipped with a Sullair rotary screw compressor unit. Compared to other compressors, Sullair’s compressor is unique in mechanical reliability and compressor durability. No inspection is required of the working parts within the compressor unit. As you continue reading this manual and come to learn how the compressor operates and is cared for, you will see how surprisingly easy it is to keep a Sullair compressor in top operating condition. Read Section 7: Maintenance to keep your compressor in top operating condition. Should any problem or question arise which cannot be answered in this manual, contact your nearest Sullair representative or the Sullair Service Department. cooler (which is mounted adjacent to the radiator). As air passes through the cooler, the heat of compression is removed from the fluid. The same fan also cools the engine intake air supply (which is mounted adjacent to the fluid cooler). As air passes through the air to air aftercooler heat is removed which was introduced by the engine’s turbo charger. The engine is coupled to the compressor unit with a non-lubricated, vulcanized rubber disk and a drive flange-type coupling. 2.3 Sullair compressor unit, functional description Sullair compressors feature the Sullair compressor unit, a single-stage, positive displacement, flood lubricated-type compressor. This unit provides continuous compression to meet your needs. NOTE 2.2 Description of components Refer to Figure 2-1 on page 18. The components and assemblies of the Sullair portable air compressor models are clearly shown. The package includes a compressor, diesel engine, engine exhaust aftertreatment, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical system. The machine is also supplied with sound deadening insulation to lower noise emissions to meet EPA and/or any Federal, State, or Local noise requirement. The Sullair compressor unit is driven by an industrial engine designed to provide enough horsepower for more than adequate reserve at rated conditions. Refer to the Engine Operator’s Manual for a more detailed description of the engine. The engine cooling system is comprised of a radiator, high capacity fan and thermostat. The high capacity fan pushes air through the radiator, keeping the engine at the proper operating temperature. The same fan also cools the fluid in the compressor cooling and lubrication system through the compressor fluid With a Sullair compressor, there is no maintenance or inspection of the internal parts of the compressor unit permitted in accordance with the terms of the warranty. Sullair compressors are factory-filled with Sullair AWF® lubricant. For more information on fluid fill, refer to Section 3: Specifications. Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three basic functions: • As coolant, it controls the rise of air temperature normally associated with the heat of compression. • Seals the clearance paths between the rotors and the stator and also between the rotors themselves. • Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 17 2: Description 1600H T4F CAT User Manual 1. Compressor inlet valve 13. Battery disconnect switch 2. Compressor fluid thermal valve 14. Fuel tanks 3. Pressure regulator valve 15. Engine CEM module 4. Engine coolant fill 16. Discharge air water separator and filters† 5. Fuel cooler 17. Compressor fluid filter † 6. Aftercooler 18. Engine & compressor air intake filters 7. Engine charge air cooler 19. Discharge air service valves 8. Engine radiator 20. Diesel exhaust fluid (DEF) tank 9. Compressor fluid cooler 21. Fuel fill 10. Receiver tank 22. Minimum pressure check valve 11. E-stop button 23. External fuel connections 12. Manual box 24. Fuel selection valve †If equipped. Figure 2-1: Main components of 1600H Tier 4 Final compressors 18 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 2: Description After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows through a separator and an aftercooler (if provided) then to the service line while the fluid is being cooled in preparation for reinjection. 2.4 Cooling and lubrication system, functional description Refer to Figure 2-2 on page 20. The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. In addition to the cooler and fan, the system consists of a main 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, the fluid temperature is cool, and routing to the cooler is not required. The fluid first enters the thermal valve and then flows on to the compressor unit, bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and the thermal valve element begins to shift. This forces a portion of the fluid to the fluid cooler. The cooler is a radiator-type that works in conjunction with the engine fan. The fan pushes air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve. Before the temperature of the fluid reaches the valve set point, cooled fluid is mixed with warmer fluid. When the temperature of the fluid reaches 190°F (86.1°C), the thermal element shifts completely causing all fluid to flow to the cooler. The thermal valve incorporates a pressure relief valve, which allows fluid to bypass the cooler, if the cooler becomes plugged or frozen. This helps assure that fluid will continue to be provided to the compressor for lubrication. After the fluid passes through the thermal valve it is then directed through the main fluid filter. There, the fluid is filtered in preparation for injection into the compression chamber and bearings of the compressor unit. The filter has a replaceable element and a builtin bypass valve which allows the fluid to flow even when the filter element becomes plugged and requires changing or when the viscosity of the fluid is too high for adequate flow. The filter housing includes a pressure differential gage to monitor the cleanliness of the compressor oil filter. Please refer to Section 7.6.2: Main fluid filter servicing on page 58 for further details. After the fluid is properly filtered, it then flows on to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and gears. The fluid stop valve functions on shutdown when it shuts off the fluid supply to the compressor unit. The fluid stop valve is held open by a pressure signal from the compressor discharge. At shutdown, the pressure signal is lost and the fluid stop valve closes, isolating the compressor unit from the cooling system. This prevents oil from pooling into the compressor unit. 2.5 Discharge system, functional description Refer to Figure 2-3 on page 21. The Sullair compressor unit discharges compressed air/fluid mixture into the receiver tank. The receiver tank has three functions: • It acts as a primary fluid separator. • Serves as the compressor fluid storage sump. • Houses the final fluid separator. The compressed air/fluid mixture enters the receiver tank and is directed against the tank side wall. By change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the receiver tank. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid collects on the element’s surface, the fluid descends to the bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator element is returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet. An orifice (protected by a strainer) is included in this return line to help assure proper flow. The receiver tank is code rated. A minimum pressure/ check valve, located downstream from the receiver, helps assure a minimum receiver pressure of 65 psig (4.5 bar) during all conditions. This pressure is necessary for proper air/fluid separation and proper fluid circulation. A minimum pressure/check valve is also used to prevent compressed air in the service line from bleeding back into the receiver on shutdown when the compressor is being run in parallel with other compressors tied to a large air system. A pressure relief valve (located on the wet side of the separator) is set to ensure the receiver tank pressure will not exceed its rated pressure. A temperature switch will shut down the compressor if the discharge temperature reaches 250°F (121°C). 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 19 2: Description 1600H T4F CAT User Manual 1. Fluid cooler 4. Oil stop valve 2. Thermal valve 5. Receiver tank 3. Fluid filter 6. Air compressor Figure 2-2: Cooling and lubrication system 20 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 2: Description 1. Receiver tank 6. Water separator 2. Minimum pressure check valve 7. Service air valve 3. Pressure relief valve 8. Aftercooler air valve 4. Aftercooler assembly 9. Standard air valve 5. Aftercooled air filters 10. Moisture drain valve Figure 2-3: Discharge system (with optional aftercooler and discharge filter) 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 21 2: Description 1600H T4F CAT User Manual Fluid is added to the receiver tank via a capped fluid filler. A fluid level sight glass enables the operator to visually monitor the receiver tank fluid level. WARNING Do not remove caps, plugs, and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal pressure before doing so. 2.6 Control system, functional description Refer to Section 2: Piping & instrumentation, compressor system on page 28 and Figure 7-3: Pneumatic control system on page 60. The purpose of the control system is to regulate the amount of air intake in accordance with the amount of compressed air demand. The control system consists of an inlet valve, pressure regulator, a blowdown valve, the controller and a LOAD button. Startup and warm up—0 to 65 psig (0 to 4.5 bar) Push OFF/ON/START switch to ON position to initialize the controller. Once the Controller says “READY” on the display, press OFF/ON/START switch to the START position. In the START position, the start/run solenoid valve is de-energized and the inlet valve is held closed by pressure built up in the receiver tank. Air pressure is contained in the receiver tank by the minimum pressure valve which has a set point of 65 psig (4.5 bar). After engine has warmed up the machine automatically transfers to “READY FOR AIR” mode. Running mode - 80 to 150 psig (5.5 to 12.4 bar) With the controller in “READY FOR AIR” mode, compressor is now ready for use by pressing and holding the LOAD button for one second and opening the service valve. The machine is now in the “AIR AVAILABLE” mode where the start/run valve is energized allowing the inlet valve to open and the engine speed to increase to high idle (1800 rpm). As air demand decreases, service pressure and control pressure will rise. This is accompanied by a corresponding decrease in engine speed along with closing of the inlet valve. Ultimately, the compressor will unload and remain at low idle (1400 rpm) until an increase in air demand. Shutdown and opening the blowdown valve. The controller will display “STOP INITIATED” and the machine enters a cooldown period and the time remaining for cooldown will be displayed. After completion of the cooldown period, the engine will stop and the controller will remain powered and display “MONITORING PRESSURES”. Once system pressures are less than 10 psig, the controller will be powered off. 2.7 Air inlet system, functional description The inlet system consists of two air filters, a compressor air inlet valve and interconnecting piping to the engine and compressor. Also, nylon tubing and air filter restriction indicator gauges are provided. The air filters are a 2-stage unit with a safety element dry element-type filter. This filter is capable of cleaning extremely dirty air. However, in such cases, frequent checks of the air filter will be required. The compressor is equipped with restriction switches on both the engine and compressor inlet filters. When the set point is exceeded, the controller will display a message indicating it is time to replace the elements. At this time, change the air filter element. Refer to Section 7.2: Daily operation and maintenance on page 55. The compressor air inlet valve controls the amount of air intake of the compressor in response to the air demand. 2.8 Engine control module, functional description Diagnostic fault codes are provided to indicate an electrical or electronic problem has been detected by the ECM (Engine Control Module). In some cases, the engine performance can be affected when the condition causing the code exists. More frequently, however, the operator cannot detect any difference in the engine performance. The controller indicates an engine performance problem has occurred whenever the engine warning lamp is flashing. The diagnostic code may indicate the cause of the problem, and should be corrected. If the controller does not indicate a problem with the engine performance, but a diagnostic code is logged by the ECM, an abnormal condition was detected that did not affect performance. If there is an error the controller will display the Failure Mode Indicator (FMI) and Suspect Parameter Number When the OFF/ON/START switch is set to OFF position, the start/run valve is de-energized closing the inlet valve 22 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 2: Description (SPN) on the Engine Diagnostics page within the Service menu. NOTE Only active diagnostic codes can be read in this manner. Logged diagnostic codes must be retrieved with an electronic service tool. Refer to the Engine Operators Manual for explanation and troubleshooting of active diagnostic and event codes. 2.9 Electrical system, functional description Refer to Section 2.10: Wiring diagram. The electrical system is comprised of not only the necessary equipment required to operate the compressor, but also a system to shut it down in the event of a malfunction. The components of the electrical system are an engine starter (with an integral solenoid), battery, an alternator with a built-in voltage regulator, a compressor discharge temperature switch (which will shut down the compressor should the compressor temperature exceed 250°F [121°C]), a low coolant shutdown switch, low DEF shutdown, and low fuel shutdown protection. The engine coolant level detector is located in the radiator for the engine cooling system. It will shut the compressor down or prevent it from being started if the engine coolant level drops too low. In addition, there is a starter protection relay which prevents accidental starter engagement after the engine is running or whenever there is pressure in the receiver tank. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 23 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250220-244 R06 (sh1) 2: Description 24 2.10 Wiring diagram 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 2: Description 25 02250220-244 R06 (sh2) 1600H T4F CAT User Manual 2.10 Wiring diagram 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250220-244 R06 (sh3) 2: Description 26 2.10 Wiring diagram Drawing notes 1 ALL WIRE TYPES: GXL (MAY REPLACE WITH TXL) 2 ALL WIRE COLORS: WHITE UNLESS OTHERWISE SPECIFIED: e.g BB1.2 AND BB1.3 SEE 02250223-499 3 WIRE CROSSINGS WITHOUT A DOT ARE DISCONNECTED 4 WIRE CROSSINGS WITH A DOT ARE CONNECTED 5 CN36 AND CN37 MUST HAVE CAN TERMINATING (REGISTOR) MATING CONNECTOR (DT006-3S-P006) 02250226-702. 1600H T4F CAT User Manual 2.10 Wiring diagram 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 2: Description 27 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250221-721 R01 (sh1) 2: Description 28 2.11 Piping & instrumentation, compressor system Key Description Component connections Component Description 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 01 FILTER, AIR 02 GAUGE, AIR FILTER RESTRICTION P1 DRY SIDE PRESSURE 03 INLET VALVE P2 CONTROL PRESSURE 04 COMPRESSOR P3 WET SIDE PRESSURE 05 VALVE, RELIEF P4 AFTERCOOLER FILTER DISCHARGE PRESSURE 06 SWITCH, TEMPERATURE T1 COMPRESSOR DISCHARGE TEMPERATURE (CDT) 07 SENSOR, TEMPERATURE T2 RECIEVER TANK TEMPERATURE (RTT) 08 SENSOR, PRESSURE T3 AFTERCOOLER DISCHARGE TEMPERATURE 09 VALVE, DISCHARGE CHECK 10 RECEIVER, AIR/OIL 11 GLASS, SIGHT OIL LEVEL 12 VALVE, MINIMUM PRESSURE 13 VALVE, BALL 14 COOLER, AIR 15 SEPARATOR, MOISTURE 16 TRAP, DRAIN 17 ORIFICE 18 VALVE, SOL 3WNO 19 STRAINER 20 SIGHTGLASS, ORIFICE BLOCK 21 VALVE, THERMAL BYPASS 22 COOLER, OIL 23 FILTER, OIL 24 VALVE, OIL STOP 25 VALVE, REGULATOR BACKPRESSURE 26 VALVE, BLOWDOWN N.C. 27 VALVE, CHECK SEPERATOR, ELEMENT 29 FILTER, AIR W/AUTOFLOAT 30 VALVE, ATMOSPHEREIC DRAIN 31 VALVE, PRESSURE DIFF. BYPASS 32 VALVE, CONTROL PRESSURE REGULATOR 33 MANIFOLD, OIL FILTER/THERMALVALVE 29 2: Description 28 1600H T4F CAT User Manual 2.11 Piping & instrumentation, compressor system 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250221-721 R00 (sh2) 2: Description 30 2.12 Piping & instrumentation, engine system Key Description Key Description 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 01 TURBOCHARGER, ENGINE 31 FILTER, AIR 02 COOLER, CHARGE AIR 32 TANK, FUEL 03 MUFFLER, ENGINE 33 PAN, ENGINE OIL 04 SENDER, FUEL LEVEL 34 GAUGE, FILTER RESTRICTION 05 DEARATION TANK 35 SENSOR, INLET AIR TEMPERATURE 06 FILTER, FUEL W/ WATER SEPARATOR 36 VALVE, RELIEF (INTEGRAL TO ENGINE) 07 PUMP, FUEL (INTERNAL TO ENGINE) 37 VALVE, AIR STOP (OPTIONAL) 08 PUMP, FUEL HAND OPERATED PRIMING 38 EXHAUST, DIESEL PARTICULATE FILTER 09 FILTER, FUEL 39 VALVE, 3 WAY 10 VENTILATOR 40 PUMP, FUEL ASSIST 11 CAP, TANK FILL 41 PUMP, CAT PRIMING/ARD 12 THERMOSTAT, THERMOCORD(OPTIONAL) 42 GLASS, SIGHT COOLANT LEVEL 13 KIT, ETHER ASSEMBLY 43 CAP, COOLANT SYSTEM FILL 14 PUMP, OIL (INTEGRAL TO ENGINE) 44 THERMOSTAT, DEF 15 BY-PASS VALVE (INTERNAL TO ENGINE) 45 SENSOR, DEF LEVEL 16 COOLER, OIL (INTERNAL TO ENGINE) 46 CONTROL, DEF MODULE 17 FILTER, OIL 47 INJECTOR, DEF 18 PUMP, WATER (INTEGRAL TO ENGINE) 19 RADIATOR, ENGINE 20 ENGINE THERMO (INTEGRAL TO ENGINE) 21 SENSOR, INLET AIR PRESS(TURBO BOOST) L1 COOLANT LEVEL 22 SWITCH, COOLANT LEVEL L2 FUEL LEVEL 23 SENSOR, FUEL PRESSURE L3 OIL LEVEL (DIPSTICK) 24 SENSOR, FUEL TEMPERATURE P5 INLET MANIFOLD AIR PRESSURE 25 SENSOR, COOLANT TEMPERATURE P6 FUEL PRESSURE 26 SENSOR, ENGINE OIL PRESSURE P7 OIL PRESSURE 27 SENSOR, CAM SPEED TIMING T7 INLET AIR TEMPERATURE 28 SENSOR, CRANK SPEED TIMING T8 FUEL TEMPERATURE 29 HEATER, WATER JACKET (OPTIONAL) T9 COOLANT TEMPERATURE OIL LEVEL (DIPSTICK) S1 CAM SPEED S2 CRANK SPEED Component connections Component Description 31 2: Description 30 1600H T4F CAT User Manual 2.12 Piping & instrumentation, engine system 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250223-002 R00 2: Description 32 2.13 ID, DTQ aftercooled Drawing notes 1 DIMENSIONS ARE IN INCHES. [ ] DIMENSIONS ARE IN MILLIMETERS. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. ALL DOORS REQUIRE 39" [969 MM] CLEARANCE. ALL DOORS ARE PAD/KEY LOCKABLE. APPROX. WET WEIGHT = 19,085 LBS. [8657 KG.], APPROX. DRY WEIGHT = 17,269 LBS. [7834 KG.] ENGINE COOLANT DRAIN ENGINE OIL DRAIN COMPRESSOR OIL DRAIN WATER CONDENSATE DRAIN (DO NOT PLUG) (ONLY REQ'D ON AFTER-COOLED MACHINES) FILTER/H2O TRAP ACCESS LIFTING BAIL ACCESS COVER TIEDOWN (4-PLACES) FORK LIFT POCKET INSTRUMENT PANEL DOOR EMERGENCY STOP BUTTON OVERALL HEIGHT OVERALL LENGTH OVERALL WIDTH A14 A15 A16 A17 A18 AIR EXHAUST ENGINE FUEL FILL ENGINE COOLANT FILL ENGINE FUEL CONNECTION PORTS AIR INTAKE (4-PLACES) A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 2" NPT AIR DISCHARGE (HP) 3" NPT AIR DISCHARGE (LP) 3/4" NPT AIR DISCHARGE (LP ONLY) BATTERY ACCESS AIR FILTER ELEMENT ACCESS (2-PLACES) AIR/OIL SEPARATOR ELEMENT ACCESS SAFETY CHAINS TRACK WIDTH WHEEL CHOCKS BLOCK HEATER INLET (OPTIONAL) STROBE LIGHT JACK AFTERTREATMENT ACCESS DEF ACCESS EYE HEIGHT 21.25 [539.8] TO 39.25 [997.0]. 2: Description 33 2 3 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 1600H T4F CAT User Manual 2.13 ID, DTQ aftercooled 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 02250219-966 R00 2: Description 34 2.14 ID, DLQ aftercooled Drawing notes: 1 DIMENSIONS ARE IN INCHES. [ ] DIMENSIONS ARE IN MILLIMETERS. 2 ALL DOORS REQUIRE 39" [969 MM] CLEARANCE. ALL DOORS ARE PAD/KEY LOCKABLE. 3 APPROX. WET WEIGHT = 17,577 LBS. [7973 KG.], APPROX. DRY WEIGHT = 15,761 LBS. [7149 KG.] 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. A1 ENGINE COOLANT DRAIN A2 ENGINE OIL DRAIN A3 COMPRESSOR OIL DRAIN A4 WATER CONDENSATE DRAIN (DO NOT PLUG) (ONLY REQ'D ON AFTER-COOLED MACHINES) A5 FILTER/H20 TRAP ACCESS A6 LIFTING BAIL ACCESS COVER A7 TIEDOWN (4-PLACES) A8 FORK LIFT POCKET A9 INSTRUMENT PANEL DOOR 1600H T4F CAT User Manual 2.14 ID, DLQ aftercooled A10 EMERGENCY STOP BUTTON A11 OVERALL HEIGHT A12 OVERALL LENGTH A13 OVERALL WIDTH A14 AIR EXHAUST A15 ENGINE FUEL FILL A16 ENGINE COOLANT FILL A17 ENGINE FUEL CONNECTION PORTS A18 AIR INTAKE (4-PLACES) A19 2" NPT AIR DISCHARGE (HP) A20 3" NPT AIR DISCHARGE (LP) A21 3/4" NPT AIR DISCHARGE (LP ONLY) A22 BATTERY ACCESS A23 AIR FILTER ELEMENT ACCESS (2-PLACES) A24 AIR/OIL SEPARATOR ELEMENT ACCESS A26 STROBE LIGHT A27 AFTERTREATMENT ACCESS A28 DEF ACCESS 35 2: Description A25 BLOCK HEATER INLET (OPTIONAL) 2: Description 1600H T4F CAT User Manual 2.15 Aftercooler air system, functional description Refer to Figure 2-3 on page 21. The purpose of the aftercooler air system is to operate the air compressor in conditions when compressed air temperatures are required to be 10 to 25°F (5 to 13°C) over ambient temperature. This compressor has one main discharge valve. The discharge plumbing within the compressor allows the user to switch between standard air to aftercooled and filtered air through a set a valves. These valves are labeled on the machine to help assist the user to select the proper valve orientation with respect to the type of air that is required for the application. Depending upon the application, the compressed air can be by-passed around the aftercooler for unprocessed air or it can be routed through the aftercooler for cooling. The ambient air, which is drawn through the aftercooler by the engine fan, cools the compressed air as it passes through the aftercooler core. Cooled air enters the moisture separator where condensate is removed and discharged. This condensate does carry some oil and it should be disposed of properly in accordance with local regulations. From the moisture separator the compressed air goes to the compressor service valve. NOTE Aftercooler system should not be operated in ambient conditions below 32°F (0°C). To operate in the non-aftercooled mode, close the aftercooler valve completely and open nonaftercooler valve. 2.16 Engine exhaust aftertreatment, functional description The compressor is equipped with exhaust aftertreatment equipment to meet U.S. EPA Tier 4 Final and EU Stage IV emissions requirements. Major components include 36 the Clean Emissions Module (CEM) and Pump Electronics Tank Unit (PETU). The CEM is an integrated assembly containing the Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), Selective Catalytic Reduction (SCR) and all required connections and control components. The PETU contains and controls injection of diesel exhaust fluid (DEF) into the CEM. These parts in conjunction with the rest of the engine systems are responsible for reducing particulate and Oxides of Nitrogen (NOx) to meet regulations. On a periodic basis, the CEM will undergo an active regeneration event. This event is controlled in one of two ways: 1. Automatically controlled by engine ECM, or 2. Requested by end user via controller. During this event, diesel fuel and air is added and ignited in the CEM resulting in elevated temperatures. Tier 4 Final regeneration strategy differs greatly from Tier 4 Interim. The primary reason for active regeneration in Tier 4 Interim was to reduce soot load accumulation in the DPF. For Tier 4 Final, passive regeneration is primarily responsible for soot reduction. Active regeneration can still occur in the following conditions/frequency: • Cold start-up regeneration: Upon cold start-up (coolant temp < 104°F [40°C]). • DPF soot level: As required to reduce soot load. Infrequent in this installation. • Maintenance: To cycle fuel in regeneration system. Approx. every 25 hours.) WARNING Regenerated exhaust gases can reach temperatures of up to 1800°F (982°C). Do not come into direct contact with these gases. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 3: Specifications Section 3 Specifications 3.1 Specifications—1600H Tier 4 Final Caterpillar Table 3-1: Package specifications Model series 1600H Package DTQ (tandem axle) DLQ (less running gear) DTQ (tandem axle) DLQ (less running gear) lbs (kg) 19085 (8657) 17577 (7973) Weight (dry) lbs (kg) 17269 (7833) 15761 (7149) Length in (mm) 239 (6071) 208 (5283) Width in (mm) 88 (2235) 88 (2235) Height in (mm) 101 (2565) 89 (2261) Package Weight (working) †‡ †‡ Track width Maximum towing speed Axle rating in (mm) 79.2 (2012) N/A mph (km/h) 65 (104) N/A lbs (kg) 9000 (4091) N/A 215/75R17.5 N/A Tire size Tire pressure psi (bar) 125 (8.6) N/A 17.5 N/A 300 (407) N/A Wheel size Lug nut torque lbf ft (N m) †Weight is for an aftercooled and filtered machine. A standard air machine reduces weight by 360 lbs (163 kg). ‡Weight is approximate and varies by options installed. Table 3-2: Compressor specifications Model series 1600H Type Rotary screw Actual delivery cfm (L/s) 1600 (755) Rated pressure psig (bar) 150 (10.3) Pressure range, min. psig (bar) 80 (5.5) Pressure range, max. (unloaded) psig (bar) 175 (12.0) Service valves 1 (3" NPT) Service valves, auxiliary 2 (.75" NPT) Cooling Pressurized compressor fluid AWF® Lubricating compressor fluid Compressor fluid capacity gal (L) Operating tilt (maximum) Sound level (U.S. EPA) † Electrical system, instrument †Sound 40 (151) 15° dBA 76 voltage 24 VDC level measured per US 40 CFR Ch.1 Part 204. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 37 3: Specifications 1600H T4F CAT User Manual Table 3-3: Engine specifications Model 1600H Type Diesel Make Caterpillar Model C15 Emissions level Displacement U.S. EPA Tier 4 Final in3 (L) 928 (15.2) Cylinders 6 Cycles 4 Operating speed rpm 1800 Minimum idle speed1 rpm 1400 Available power, SAE bhp (kW) 540 (403) Electrical system, engine voltage 24 VDC 1700 CCA @ 32°F(0°C) Battery rating (2) CCA Alternator amp 95 Radiator capacity gal (L) 21.6 (81.8) Engine water shutdown temperature °F(°C) 219 (104) Lubricating system (8D) 1400 CCA @ 0°F (-18°C) Full pressure fluid Type of motor oil See Engine Operator’s Manual Engine oil capacity gal (L) 19 (72) Fuel tank capacity gal (L) 249 (943) DEF capacity gal (L) 12.8 (48.4) 1Do not allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor is equipped with a low speed shutdown system that will shut down the compressor if engine speed falls below 1100 rpm. 38 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 3: Specifications 3.2 Lubrication guide—compressor Fluid type Sullair AWF®† † Ambient temperature range Change period, hours 1500 °F °C -20 to 120 -29 to 49 Sullair AWF part numbers: 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon/208 liter drum). 3.3 Lubrication guide—engine Refer to the Engine Operator’s Manual for engine oil specifications. 3.4 Application guide Sullair portable air compressors are filled with Sullair AWF®. Sullair AWF is a heavy-duty, multi-viscosity, allweather fluid suitable to a wide variety of conditions, including conditions that can cause severe fluid oxidation. In high ambient temperature and high humidity conditions, condensed moisture can emulsify with the fluid (indicated by the fluid turning a “milky” color). Change the fluid if this condition develops. Do not mix different types or brands of fluid. Mixing different types or brands of fluids can lead to operational problems such as foaming, plugged filters, blocked orifices or lines, or even severe problems like a plugged cooler or a locked air end. Contact your Sullair representative for fluid recommendations if operating conditions require the use of an extended life fluid (for example, the ambient temperature is outside the recommended temperature range for Sullair AWF). 1. Receiver/tank 2. Fluid fill port 3. Sight glass Figure 3-1: Fluid fill location Sullair encourages users to participate in a fluid analysis program. The analysis might indicate a need for change intervals different from those recommended in this manual (for example, to maximize the life of the machine in dirty environments). Contact your Sullair representative for details. NOTE Proper compressor fluid level visible halfway in fluid sight glass when checked on a level surface with the compressor not running. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 39 3: Specifications 1600H T4F CAT User Manual Notes: 40 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 4: Installation Section 4 Installation 4.1 Locating the package Position the compressor on a level surface, if possible. If unable to locate the compressor on a level surface, position the compressor on a grade surface which will not allow the compressor to slide downhill. Do not locate compressor on surface grades exceeding 15 degrees. The compressor package should be placed on a surface or foundation capable of supporting 10% more than the compressor weight. Take into consideration additional weight allowances for stored tools, rainwater, snow, ice and mud. No piping loads or moments should be transmitted to the air and fuel connections provided with the package. Locate compressor so the wind, if any, will help carry the exhaust fumes and package heat away from the compressor air inlet openings. The compressor coolers should not be exposed to excessive dust from the worksite. Contaminants on the coolers will directly affect the packages ability to run in high ambient temperatures. 4.2 Ventilation and cooling Select a location that allows an unrestricted flow of free ventilation air through the package. Avoid any recirculation or ingestion of heated gases. Compressor and engine intakes are located on the double set of doors on the engine and compressor side. Engine and compressor cooling air intake is also taken from the double set of doors while aftercooler cooling air intake has a dedicated opening. Canopy discharge (for cooling air) and engine exhaust is located on the roof at the rear of the package. Maintain a 6 ft. (1.8 m) minimum separation between the package and any surrounding walls. If ductwork is installed, the total restriction on intake must not exceed 0.1 inches H20 (25 pascals). The total restriction on the outlet must not exceed 0.1 inches H20 (25 pascals). 4.3 Service air and condensate piping A shut-off valve is included to isolate the package from the supply line as required. No piping loads or moments should be transmitted to the air connections provided with the package. Condensate drains shall be connected to a non-pressurized gravity feed drain. If the compressor drains are manifolded together, care should be taken to ensure that this drain is not pressurized when the machine condensate drains (both automatic and manual) are in operation. All condensate should be disposed of in accordance with local governing laws. 4.4 Remote fuel connections This compressor is provided with a fuel selector valve and quick disconnect fittings to allow connection to a remote fuel tank. Supply and return connections as well as selector valve position are shown in Figure 4-1 and Figure 4-2 on page 42. External fuel connecting hose length is limited to 25 ft. of ¾" hose to provide sufficient fuel pressures to the engine and avoid damage to the fuel pump. When operating with an external fuel tank and an empty on-board tank, it is necessary to select “External Tank” on the controller to avoid low fuel warnings and shutdowns. Refer to Section 6: Controller for details on this setting. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 41 4: Installation 1600H T4F CAT User Manual 1. Fuel return 2. Fuel supply Figure 4-1: External fuel connections 1. External tank 2. On-board tank Figure 4-2: Fuel tank selector valve positions 42 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 5: Operation Section 5 Operation 5.1 General While Sullair has built into this compressor a comprehensive array of controls and indicators to assure you that it is operating properly, you will want to recognize and interpret the readings which will call for service or indicate the beginning of a malfunction. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators—their purpose, location and use. 5.2 Purpose of controls Control or indicator Purpose The engine switch is used to both energize the compressor’s electrical system and engage the engine/starter. It also has a built-in antirestart device that protects the starter from engaging while the engine is running. The switch must be turned back to the “off” position before the engine can be re-started. OFF/ON Switch / START Switch (Up)† NOTE When restarting the compressor, the controller will not allow restart until system pressure falls below 10 psig (0.7 bar) or less. More than 10 psig (0.7 bar) can put extra load on the starter. Voltmeter† Monitors the condition of the batteries and the charging circuit. The normal reading is 24 to 28 volts. Service Air Pressure† Continually monitors the pressure inside the receiver tank at various load and unload conditions. Engine Temperature† Monitors the temperature of the engine water. The normal operating temperature should read approximately 160°F to 210°F (71°C to 99°C). Controller† Depicts system related diagnostics. Can be used for system performance monitoring. Compressor Temperature† Monitors the temperature of the air/fluid mixture leaving the compressor unit. 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 is shutdown. † Indicates item is part of the compressor controller. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 43 5: Operation 1600H T4F CAT User Manual Control or indicator Purpose Receiver Tank Temperature Switch Opens the electrical circuit to shut down the compressor when the receiver tank temperature reaches 250°F (121°C). Control Regulating Valve Provides an air signal to the inlet valve and engine to close the inlet valve and reduce engine speed to control air delivery according to demand. Minimum Pressure/Check Valve Maintains a minimum of 65 psig (4.5 bar) in the compressor receiver tank. This valve restricts receiver air discharge from receiver/ receiver tank when pressure falls to 65 psig (4.5 bar). Also prevents back flow into the receiver tank during upload conditions and after shutdown. Pressure Relief Valve Opens receiver tank pressure to atmosphere should pressure inside the receiver tank exceed the pressure relief valve setting. Air Inlet Valve Regulates the amount of air allowed to enter the compressor. This regulation is determined by the amount of air being used at the service line. Thermal Valve Regulates flow of fluid to and around the fluid cooler. Designed to maintain a minimum operating temperature; used for fast warm-up at start-up and to eliminate condensation during operation. Blowdown Valve Vents surplus receiver tank pressure during operation and shutdown. Engine Coolant Level Switch Shuts the compressor down and/or prevents it from being started if the engine coolant level drops too low. † Indicates item is part of the compressor controller. 5.3 Startup procedure . 1. Turn on the system power supply by turning the battery disconnect switch to the ON position. • For the location of the battery disconnect switch, see Figure 2-1 on page 18 and Figure 5-1 on page 46. 2. Toggle the <OFF/ON/START> switch, located on the controller, to the ON position. • The controller will power up and initialize. Also, a communication link will be established with the engine ECU. When the system has successfully initialized, the controller status will read “READY”. 3. Toggle the <OFF/ON/START> switch to the START position. • You do not have to hold the switch in the START position. The controller status will read “ENGINE CRANKING” 44 WARNING If the machine does not start successfully when starter disengages, the starter will automatically engage up to three times (total) after brief pauses to try and start the machine. • Once the compressor has started, the unit will enter a warm-up phase and the controller status will read “WARM UP CYCLE”. At this point, the unit is not producing usable compressed air and the service valve should still be closed. • Once the proper operating conditions are met, the machine will be ready to deliver air and the controller status will display “READY FOR AIR”. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 5: Operation 5.4 Operation procedure 1. Once ready to use air, press the <LOAD> button and the machine will begin to deliver usable air. • The controller status will display “AIR AVAILABLE”. 2. At the same time, the service valve should be opened and set to maintain the desired operating pressure. NOTE Fully opening the service valve can result in low service pressure and an overflow condition. This overflow condition can result in excessive oil carry-over in addition to reduced air delivery as the compressor slows to low idle rpm. 5.5 Shutdown procedure WARNING The E-Stop (emergency stop switch) should be used only in the event of an emergency. Refrain from using the E-Stop to shut the machine down during normal operations or equipment damage can occur. All usage of the E-Stop is logged in permanent memory for use by service technicians when troubleshooting a machine. Non-emergency use of E-Stop is considered equipment abuse and could void the manufacturer’s warranty. • The controller will stay powered up while displaying a status of “MONITORING PRESSURES”. • The controller will continue to monitor the system pressures and will not power down until all pressures drop below 2 psi (0.14 bar). This final process may take 3 to 5 minutes. Operator interaction is not necessary during this time as the controller will automatically disconnect power to all systems so that the battery is not inadvertently drained after shutdown. WARNING Following engine shutdown, the exhaust aftertreatment will initiate a purge procedure to clear remaining DEF from the lines. This is necessary to prevent damage to the DEF injector from flooding or freezing. A light is provided near the battery disconnect to notify the user when the purge cycle is active (see Figure 5-1 on page 46). Do not turn battery disconnect switch to off when this lamp is lit or damage to the aftertreatment could occur and an engine fault code may be triggered. 4. Turn off the system power supply by turning the battery disconnect switch to the OFF position. • For the location of the battery disconnect switch, see Figure 2-1 on page 18 and Figure 5-1 on page 46. 1. Slowly close the service valve. 2. Place the <OFF/ON/START> switch in the OFF position. • The controller status will read “STOP INITIATED” and the compressor will enter the cooldown period. 3. The unit will continue to run at low idle rpm, though it will not produce usable air. At the end of the cool down cycle, the engine will be shut down. WARNING It is a good practice to engage the battery disconnect after use. The engine and the compressor controller systems continually draw power after the controller is powered down. Over time, this will deplete the batteries. If the batteries are left on per application requirements, like remote start applications, a battery maintainer should be used to keep the batteries fully charged. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 45 5: Operation 1600H T4F CAT User Manual 5. Vent all external pressure (pressure downstream of the machine) before disconnecting any air tools, hoses, fittings, etc. WARNING Pressure hazard Failure to vent external pressure can result in serious injury. Vent all external pressure (pressure downstream of the machine) before disconnecting any air tools, hoses, fittings, etc. or performing any maintenance procedures. 1. Purge lamp 2. Battery disconnect switch Figure 5-1: Purge lamp location 46 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 6: Controller Section 6 Controller 6.1 Controller layout Key Description Function 1. ON/OFF/START switch Used to turn controller on and start or stop machine. 2. Display Touch screen display. Used to display operating parameters and machine information. Also used to access additional machine functions. 3. LOAD button When machine is in “Ready for Air” state, the button is pressed and held for one second to begin delivering usable air. Can also be used to unload machine during periods of no air demand. 4. HELP button Calls up a menu with machine operating instructions, troubleshooting and QR code. 5. INFO button Calls up a screen showing compressor and engine operating parameters. 6. MENU button Calls up a sub-menu with User Options, Service Options and the Help menu. 7. HOME button Returns to home screen. Figure 6-1: Controller layout and button functions 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 47 6: Controller 1600H T4F CAT User Manual 6.2 Home display 1. Indicator lamps 5. Diesel exhaust fluid (DEF) level gauges 2. Service pressure gauges 6. Message bar 3. Status bar 7. Diesel fuel level gauges 4. Information bar Figure 6-2: Home display layout 48 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 6: Controller Table 6-1: Home display items and functions Key Description Function 1 Indicator lamps Displays status and malfunction indicator lamps. See Section 1.15: Symbols and references on page 12 for definitions of symbols. 2 Service pressure gauges Displays service (tank) pressure. Displays current operating status of compressor: READY: Controller is initialized and compressor is ready to start. ENGINE CRANKING: Starter is engaged and cranking engine. WARM UP CYCLE: Engine is started and compressor is in warm-up state. 3 READY FOR AIR: Warm-up cycle is complete and machine is ready to deliver air. Status bar AIR AVAILABLE: LOAD button has been pressed, air is being delivered and compressor is operating in automatic mode. STOP INITIATED: Switch has been turned to off and compressor is in cool-down period. MONITORING PRESSURES: Engine is stopped and controller is monitoring pressures until less than 2 psig (0.14 bar) before controller is turned off. 4 Information bar Displays compressor and engine parameters. Left and right arrows can be used to scroll through parameters. Can also be accessed by pressing INFO button. 5 Diesel exhaust fluid (DEF) level gauges Displays remaining level of DEF. A warning message will be provided on low DEF level. Engine de-rate and shutdowns will occur if DEF is not refilled. 6 Message bar Displays service reminders and warning/fault messages. 7 Diesel fuel level gauge Displays remaining level of fuel. A warning message will be provided on low fuel level. The controller will shut the compressor off on very low fuel level in order to protect the engine. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 49 6: Controller 1600H T4F CAT User Manual 6.3 User options Figure 6-3: User options layout User options are accessed via the physical MENU button on the front of the controller. The icon next to the setting provides a brief description. Note that some settings can be locked out by the renter of the equipment and may not be available to the end user. • FORCED REGEN: This is used to (a) cancel and inhibit and put regeneration into automatic control (via engine ECM) and (b) actively force a regeneration event. A regeneration event will only commence if certain engine conditions are met. • PRESSURE: Provides for selection between high and low operating pressure mode. Move toggle to high or low depending on need. May not be available on all models. • FUEL TANK: Includes toggle for selecting between internal and external fuel tank. If external fuel tank is selected, fuel gauge is no longer displayed and low fuel level faults and warnings are not active. • INHIBIT REGEN: Can be used to inhibit regeneration of the engine aftertreatment if high exhaust temperatures are a concern. Press and hold to inhibit. Excessive use of the inhibit function can result in engine de-rate/shutdowns and ultimately damage to engine aftertreatment components. 50 • LANGUAGE: Select display language. • UNIT: Select English or metric units of measurement. • CLEAN DISPLAY: When this is selected, touch screen selections are temporarily disabled allowing the screen to be cleaned. Screen may be cleaned with mild soap and water. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 6: Controller 6.4 Service options Figure 6-4: Service options layout Service option sub-menus are accessed via the physical MENU button on the front of the controller and the SERVICE OPTION soft key. • CALIBRATE SENSORS: This feature is utilized to calibrate machine pressure transducers and temp sensors to known calibrated instrumentation. Sensor calibration is best left to experienced personnel and should not be needed under typical operating conditions. • SETUP: Includes option for enabling/disabling remote start and auto sleep. This menu also includes remote start and auto sleep setting options. • ENGINE DIAGNOSTICS: Displays any active engine codes. • SHUTDOWN HISTORY: A log is provided of all abnormal shutdowns due to any fault conditions. This also includes shutdowns where the emergency stop button was used to stop the machine. • I/O DIAGNOSTICS: Displays state of digital inputs and outputs of the controller as well as analog sensor data to be used as a troubleshooting tool. • FLEET OPTIONS: Includes settings for rental fleet managers to customize available features by job. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 51 6: Controller 6.4.1 1600H T4F CAT User Manual Service options: Setup Figure 6-5: Setup options—remote start enabled Figure 6-6: Setup options—auto sleep enabled 52 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 6: Controller You can access Setup options by pressing the SETUP icon soft key under the Service menu. Pressing the next to each setting displays a brief description of that setting. Note that the renter of the equipment can lock out some settings, making them unavailable to the end user. • REMOTE START: When enabled, allows a connection to the remote start input to start the compressor. • CYCLE MODE: Determines how the compressor startup/shutdown cycles are controlled: • Controlled: When CYCLE MODE is set to Controlled, the connection to the remote start input controls the compressor’s startup/shutdown cycle. • Single: When CYCLE MODE is set to Single, the SET POINT and TIME AT SET POINT settings control the compressor’s shutdown cycle. For the compressor to restart, the remote start input signal must be re-sent. • SET POINT: When the compressor is in Remote Start, Single Cycle mode, SET POINT determines the pressure the compressor must reach before the TIME AT SET POINT timer begins its countdown. • TIME AT SET POINT: When the compressor is in Remote Start, Single Cycle mode, TIME AT SET POINT determines how long the SET POINT pressure must be maintained before the compressor will shut down. • AUTO SLEEP: Enables or disables the controller display sleep mode. If enabled, the controller display will shut off after the AUTO SLEEP DELAY time has expired. A button or screen press will awaken the display. • AUTO SLEEP DELAY: With AUTO SLEEP enabled, this is the delay time that must pass prior to the display shutting off. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 53 6: Controller 1600H T4F CAT User Manual 6.5 Help Figure 6-7: Help display Help menu is accessed via the physical HELP button on the front of the controller or the HELP soft key in the main menu. This menu contains a QR code which when 54 scanned will take the user to the product manuals. Additionally, there is a soft key for an operational guide and brief troubleshooting section. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7: Maintenance Section 7 Maintenance 7.1 General A good maintenance program is the key to long compressor life. Below is a program that when adhered to, should keep the compressor in top operating condition. For engine maintenance requirements, refer to the Engine Operator's Manual for a detailed description of service instructions. Refer to Section 7.6: Parts replacement and adjustment procedures on page 57 for a detailed description of specific compressor system components. Prior to performing maintenance, read the CIMA Safety Manual, if applicable. WARNING Do not remove caps, plugs, and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal pressure before doing so. “Excessive Compressor Fluid Consumption” for a probable cause and remedy. NOTE True system oil level can only be determined after the compressor has warmed up to operating temperature and run for a short period of time. This releases trapped oil within the oil cooling system. Short running periods may trap additional oil within the plumbing. Awareness of how the compressor operated and shutdown will help keep the system from being over filled. • Drain water from the fuel/water separator. • Check the fuel level in the fuel tank. • Check the engine oil level. • Check the engine coolant level. • Check the DEF level. 7.2 Daily operation and maintenance Prior to starting the compressor, it is necessary to perform a daily inspection. Perform the following maintenance operations to prevent unnecessary problems. • Check the fluid level in the compressor receiver tank. Should the level be low, simply add the necessary amount. • If the addition of fluid becomes too frequent, a simple problem has developed which is causing this excessive loss. Refer to Table 7-3: Troubleshooting guide on page 64 under • Check for proper tire inflation. Refer to tire sidewall for tire manufacturer’s recommendations. After a routine start has been made, it is necessary to perform an inspection to ensure all operations are performing correctly. Perform the following inspections to prevent unnecessary problems. • Observe the instrument panel gauges and be sure they monitor the correct readings for their particular phase of operation. • After the compressor has warmed up, it is recommended that a general check on the overall compressor and instrument panel be made to assure that the compressor is running properly. • If equipped, check aftercooler condensate drain system functionality. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 55 7: Maintenance 1600H T4F CAT User Manual 7.3 Engine coolant requirements WARNING Not following the recommendations of the coolant requirements may induce cooling system inefficiencies which may result in engine overheating. Non-recommended coolant can drastically reduce the life expectancy of the cooling circuit and engine. This machine is factory filled with Mobil Delvac Extended Life Coolant. It is an ethylene glycol based, OAT inhibited coolant. This coolant is able to protect the cooling system from freezing, extend the boiling point, provide corrosion protection for all metals within the cooling system; especially for systems with aluminum radiators, provide liner cavitation protection for heavy duty diesel engines, and be safe to use with all seals/gasket materials. This coolant should never be mixed with a different coolant type, color, or brand. If radiator coolant is to be added, for any reason, be sure that the coolant added is the same as what is in the cooling system, as well as what is recommended. must be cleaned with a commercial cleaning agent (such as CAT Cooling System Cleaner p/n 4C-4611) and then completely flushed and filled with water (preferably distilled) several times to remove all traces of cleaner and old coolant. Finally, fill the system with the recommended coolant using only one brand/type. Cross contamination, which is caused by adding different types of engine coolants, may result in the depletion or dropout of coolant additives; thus leaving cooling system surfaces unprotected against corrosion. Corrosion to radiator surfaces may reduce cooling efficiency and radiator life expectancy. It is extremely important to evacuate/purge all air within the cooling system before replacing the radiator cap. Engine coolant must not only maintain proper freeze protection levels but also maintain proper corrosion inhibitor levels. Please contact the coolant manufacture for specifics on testing methods and suggested coolant maintenance intervals. Table 7-1: Coolant service life Coolant type Service life Mobil Delvac EXTENDED LIFE Coolant/Antifreeze 6 years/12,000 hours† Caterpillar ELC 6 years/12,000 hours† †Using manufacturer's extender additive to system at 3 years or 6000 hours. The engine coolant type should follow these recommended specifications: CAUTION • Organic acid technology (OAT) • Premixed coolant pH range of 8.0 to 9.5. • Contains no silicates, phosphates, borates, nitrates and amines • Solution states that it is formulated for use in heavy duty diesel applications • Protects all standard metals within the cooling system (i.e. brass, copper, steel, solder, cast iron, and aluminum.) • Meets specification requirements of current industry standards which include ASTM D 3306 and Cat EC-1. • Meets or exceeds performance requirements of current industry standards which include ASTM D 6210, John Deere H24A2 and H24C2. If you are not sure of the coolant that is installed originally or want to change to a different type, the cooling system 56 The radiator and engine cooling system must be drained and flushed periodically. Refer to the OEM Engine Manual for more information. Replace the coolant with a solution of 50% ethylene glycol and 50% water or as required for your geographic location. Do not use a leak sealing type of antifreeze. Should a 100% water solution be used, a non-chromate rust inhibitor must be added. Do not mix coolant types. NOTE Dispose of fluids in accordance with applicable federal, state and local regulations. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7: Maintenance 7.4 Recommended maintenance intervals 7.4.1 Maintenance after initial 50 hours of operation After the initial 50 hours of operation, a few simple maintenance routines can rid the system of any possible foreign materials, if any. Perform the following maintenance operations to prevent unnecessary problems. • Clean the receiver tank return line (or scavenge tube) orifice and strainer. 7.4.4 • Replace separator element. Depending on operating environment, replacement could by required earlier. In this case, it will be indicated by the controller. • (If equipped) Replace the discharge air filter elements. • Concerning compressor models with running gear and brakes: • Change compressor fluid filter • Depending on the compressor’s working environment and the amount of travel it encounters, the braking system may require more frequent adjustment which is left to the discretion of the end-user. See Section 7.6.7 through Section 7.6.10. • Inspect and check fan belt tension. If necessary, adjust the tension to 145 ± 10 lbf (645 ± 62 N) while cold. • Check Engine Operator’s Manual for required engine service. 7.4.2 Maintenance every 250 hours Maintenance every 1500 hours • Change the compressor fluid and replace the fluid filter element. • Check Engine Operator’s Manual for required engine service. • Change fuel system filters. • Inspect and check fan belt tension. If necessary, adjust the tension to 145 ± 10 lbf (645 ± 62 N) while cold. • Clean the radiator, oil cooler and aftercooler exterior. Depending on how contaminated the atmosphere may be, more frequent cooler and radiator cleaning may be necessary in dusty conditions. 7.5 Engine maintenance Check Engine Operator’s Manual for required engine service. 7.6 Parts replacement and adjustment procedures • Clean the return line orifice and strainer. 7.6.1 • Change compressor fluid filter. Warm-up the compressor for 5 to 10 minutes to warm the fluid. Shut the compressor off and relieve all internal pressure before proceeding. Drain the fluid by opening the valves that are bulkhead mounted to the frame (see ID drawing under Section 2.13 on page 32 for location of drain port). Change the compressor fluid and replace the fluid filter element. For element replacement see procedure for servicing the fluid filter in this section. Fill the receiver tank with fluid according to Section 7.6.2: Main fluid filter servicing. • Check the battery level and fill with water if necessary. • Check Engine Operator’s Manual for required engine service. 7.4.3 Maintenance every 500 hours • Change engine oil and filter. • Check Engine Operator’s Manual for required engine service. Compressor fluid change procedure 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 57 7: Maintenance 7.6.2 1600H T4F CAT User Manual Main fluid filter servicing 8. Inspect bowl seal and replace if necessary. 9. Replace bowl. Rotate clockwise and handtighten. 10. Replace drain plug. Torque to 15 to 20 lbf ft. (20 to 27 N m). 7.6.3 1. Fluid filter bypass 4. Element 2. Filter head 5. Bowl 3. Bowl seal (O-ring) 6. Fluid stop valve Figure 7-1: Main fluid filter assembly Refer to Figure 7-1. The main fluid filter is located schematically in the coolant line between the receiver tank and the compressor unit. The main filter element is replaceable. For installation of the filter element, follow the procedure explained below. 1. The compressor must be shut off and system pressure must be relieved. 1. Access cover 4. Secondary element‡ 2. Vacuator™ valve 5. Air cleaner housing 3. Primary †Primary element† replacement element, P/N 02250155-691 (qty 2) ‡Secondary replacement element, P/N 02250155-692 (qty 2) Figure 7-2: Air filter assembly 3. Rotate bowl counterclockwise and remove. Refer to Figure 7-2. Maintenance should be performed when indicated by the controller. Both air filters are twostage with a primary element and secondary element each. 4. Remove element and O-ring from housing and discard (this element is not cleanable). 188.8.131.52 Primary element removal 2. Drain by removing drain plug at bottom of bowl and catching drainage in a container. 5. Make sure mounting surface of filter head is clean. 6. Apply a light film of compressor oil to O-ring and place it in its proper position. 7. Place new, clean element in bowl, over center-perforated tub. 58 Air filter maintenance 1. Clean the exterior of the air filter housing. 2. Unlatch and remove the service cover. Make certain the latches are folded back. 3. Remove the primary filter from the housing. 4. Clean the interior of the housing by using a damp cloth. Do not blow out dirt with com- 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7: Maintenance pressed air as this may introduce dust downstream of the filter. 184.108.40.206 Secondary element removal The secondary element serves as a safety element. The secondary element must be replaced after every third primary element change. 1. Gently pull the element off the outlet tube and out of the housing. 2. Carefully wipe the inside of the outlet tube with a clean cloth. 7.6.4 Control system adjustment Refer to Figure 7-3. Prior to adjusting the control system, it is necessary to determine the desired operating pressure range as well as the maximum pressure at which the machine is to operate. This pressure is stamped on the machine serial number plate. Follow the procedure below for setting up the pressure regulator. 1. Start the machine and let it warm-up and press the LOAD button. 2. Open service valve slightly until engine tries to speed up, then slowly close the service valve. 3. With service valve closed and the engine at low idle (1400 rpm), adjust the pressure regulator until the service pressure is approximately 20 – 25 psi (1.4 – 1.7 bar) above the desired operating pressure. • For example, if the desired service pressure is 150 psig (10.3 bar), the regulator should be adjusted to 170 – 175 psig (11.7 – 12.1 bar) at 1400 rpm. Open the service valve to load the compressor to maintain 150 psig (10.3 bar) or desired discharge pressure. Operating speed should be 1800 rpm on the instrument panel. If not, repeat step, but adjust the unload service pressure up or down as needed until 150 psig (10.3 bar) is maintained when engine speed is 1800 rpm. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 59 7: Maintenance 1600H T4F CAT User Manual 1. Compressor inlet valve 5. Strainer 2. Pressure regulator 6. Start/run solenoid valve 3. Control pressure transducer 7. System pressure transducer 4. Blowdown valve 8. Discharge temperature switch Figure 7-3: Pneumatic control system 60 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7.6.5 7: Maintenance Separator element replacement CAUTION To assist with the removal of the tank lid, Sullair has provided a jack bolt at the bottom of the lid pivot shaft. Simply jack the lid up and rotate out of the way. 2. Remove the element from the tank. An access panel in the roof is provided and the element is equipped with lifting provisions. 3. Scrape the old gasket material from the tank flange and lid of tank. Do not allow gasket material to fall into separator tank. 4. Reinsert new element with gaskets attached. Take care not to damage the element against the side of the tank. • Do not remove grounding staples. • Do not use anti-seize compound on gaskets. 5. Install, lubricate and torque bolts to 200 lbf ft (271 N m). • Perform a continuity check between element flange and tank body and lid after torquing bolts. 6. Reconnect all piping making sure the return line tube is ¼" above the bottom of the separator element. 1. Receiver tank 2. Separator element 3. Capscrew 7. Clean or replace fluid return line strainer and return line orifice. 7.6.6 Running gear—brake shoe maintenance and adjustment 4. Spring lock washer 5. Lid davit support WARNING Figure 7-4: Separator element assembly Refer to Figure 7-4. Use the following procedure for separator replacement. 1. Remove the air receiver tank lid by removing the hex head capscrews and washers. Before proceeding, park or locate the compressor on flat stable ground. Block or chock both sides of all wheels. Use proper personal protection equipment when performing these tasks described below. The electric brakes have a self-adjusting feature. Should manual adjusting be needed, use the following procedure: 1. Jack up compressor and secure on adequate capacity jack stands. Make sure the wheel and drum rotates freely. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 61 7: Maintenance 1600H T4F CAT User Manual 2. If equipped, remove the adjusting hole cover form the adjusting slot on the bottom of the brake backing plate. 3. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn. 4. Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag. for any loose or worn parts, stretched or deformed springs and replace as necessary. CAUTION Potential asbestos dust hazard Some older brake linings may contain asbestos dust, which has been linked to serious or fatal illnesses. Certain precautions need to be taken when servicing brakes: • Avoid creating or breathing dust. 5. Replace the adjusting hole cover and lower the wheel to the ground. • Avoid machining, filing or grinding the brake linings. 6. Repeat the above procedure on all brakes. For best results, the brakes should all be set at the same clearance. 7.6.7 • Do not use compressed air or dry brushing for cleaning (dust can be removed with a damp brush). Brake cleaning and inspection 7.6.8 WARNING Before proceeding, park or locate the compressor on flat stable ground. Block or chock both sides of all wheels. Use proper personal protection equipment when performing these tasks described below. Brake lubrication Before reassembling, apply a light film of grease or antiseize compound on the brake anchor pin, the actuation arm bushing and pin, and the areas on the backing plate that are in contact with the brake shoes and magnet lever arm. Apply a light film of grease on the actuating block mounted on the actuating arm. CAUTION Your brake system must be inspected and serviced immediately if a loss of performance is indicated. With normal use, servicing at one year intervals is usually adequate. With increased usage, maintenance should be performed more frequently as required. Magnets and shoes must be changed when they become excessively worn or scored, a condition which can reduce vehicle braking. Clean the backing plate, magnet arm, magnet, and brake shoes. Make certain that all the parts removed are replaced in the same brake and drum assembly. Inspect Do not get grease or oil on the brake linings, drums or magnets. 7.6.9 Bearing lubrication—grease CAUTION Do not mix lithium, calcium, sodium or barium complex greases due to possible compatibility problems. When changing from one type of grease to another, it is necessary to ensure all the old grease has been removed. Grease should be replaced every 12,000 miles or 12 months. Prior to repacking bearings, all old grease should be removed from the wheel hub cavity and bearings. Bearings should be packed by a packing machine, if possible. If a packing machine is unavailable, packing by 62 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7: Maintenance the hand method is acceptable. The method to pack bearing cones is as follows: 1. Place a quantity of grease onto the palm of your hand. 2. Press a section of the widest end of the bearing into the outer edge of the grease pile closest to the thumb forcing grease into the interior of the bearing between two adjacent rollers. 3. Repeat this while rotating the bearing from roller to roller. 4. Continue this process until you have the entire bearing completely filled with grease. 5. Before reinstalling, apply a light coat of grease onto the bearing cup mating surface. Table 7-2: Wheel bearing lubrication, grease— specifications† Specification Requirements Viscosity 80 Minimum † Source: Dexter Axle Company 9,000 – 15,000 Lbs. Capacity Operation Maintenance Service Manual 7.6.10 Axle bearing adjustment 1. Install the bearing and washer into the hub. Thread on the inner nut, rotate the hub and tighten the nut to 100 lbf ft (136 N m) of torque. 2. Loosen the nut to remove the pre-load torque. Do not rotate the hub. 3. Hand tighten the nut, then back it off ¼ to ⅜ turn. 4. Place the tang washer on the spindle and bend two tangs inward over the nut. This will keep the inner nut from turning while torque is applied to the outer nut. 5. Install the outer nut and torque it to 150 – 175 lbf ft (136 – 233 N m). Insure that the inner nut does not turn. Bend two tangs from the tang washer over the outer nut flats to secure. 6. Install cap with the O-ring and plug installed. Rotate the hub and check the bearing adjustment. The allowable end play is .001" – .010". CAUTION Figure 7-5: Packing a bearing Table 7-2: Wheel bearing lubrication, grease— specifications† Specification Requirements Thickener Type Lithium Complex Dropping Point 215°C (419°F) Minimum Consistency NLGI No.2 Additives EP, Corrosion & Oxidation Inhibitors †Source: Failure to back off the inner adjusting nut could cause bearing and axle spindle overheating or damage, which could result in the wheel locking up or coming off during vehicle operation and lead to an accident, injuries or death. CAUTION Failure to torque the outer locknut properly could cause the wheel end to come off during operation which could result in an accident, injuries or death. Dexter Axle Company 9,000 – 15,000 Lbs. Capacity Operation Maintenance Service Manual 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 63 7: Maintenance 1600H T4F CAT User Manual 7.7 Troubleshooting Table 7-3 is based on both the data obtained from actual tests conducted at our factory and real applied situations. It contains symptoms and usual causes for the described problems. However, do not assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component 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 burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or Sullair. Table 7-3: Troubleshooting guide Symptom Probable cause No fuel Plugged fuel filter Battery Compressor will not start Plugged air filter Engine problems may have developed Electrical control fault No fuel Compressor discharge temperature switch is open Compressor shuts down with air demand present Electrical control fault Low DEF level Exhaust aftertreatment fault 64 Remedy Check fuel level and add fuel if necessary. Replace the fuel filter element(s). Check electrolyte level and add distilled water and recharge if necessary. Loose battery cables; tighten cables. Dirty battery cables; clean thoroughly. Replace the air filter element. Check active engine codes and refer to Engine Operator’s Manual. Refer to the controller message bar for details. Check fuel gauge and add fuel if necessary. Cooling air flow is insufficient; clean cooler and check for proper ventilation. Low fluid sump level; add fluid. Dirty compressor fluid filter; change element. Thermostatic element is not functioning properly; change the thermostatic element. Defective discharge temperature switch; check for a short or open circuit to the engine fuel solenoid. Should this check out normal, it could be possible that the temperature switch itself is defective. Refer to the controller message bar for details. Check DEF level gauge and add if necessary. Check active engine codes and refer to Engine Operator’s Manual. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 7: Maintenance Table 7-3: Troubleshooting guide Symptom Probable cause Air demand is too great Service valve fully open Dirty air filter Compressor will not build up full discharge pressure Pressure regulator out of adjustment Defective pressure regulator Defective air inlet valve Engine is in de-rate due to fault condition Fluid charge lost from spring chamber on inlet valve Improper unloading with an excessive pressure buildup causing pressure relief valve to open Pressure regulator valve set too high or defective Leak in control system causing loss of pressure signal Restriction in the control system Defective pressure relief valve Plugged air filter Plugged air/fluid separator Insufficient air delivery Defective or incorrectly set pressure regulator Leaks in discharge system or service hoses/lines. Engine is in de-rate due to fault condition Remedy Check service lines for leaks of open valves. Set service valve to achieve desired service pressure. Check the controller for service recommendation. Adjust regulator according to control adjustment instructions in the Section 7.6.4. Check diaphragm and replace if necessary (kit available). Replace inlet valve. Check active engine codes and refer to Engine Operator’s Manual. Add fluid to inlet valve spring chamber by removing plugs in the top of the spring chamber and filing with compressor fluid. Adjust or repair. Check control lines. Worn seals in inlet valve. Replace seals (kit available). Check all control lines and components. Ice and other contaminants could cause restrictions. Replace pressure relief valve. Replace. Replace separator element and also change compressor fluid and fluid filter at this time. Adjust or repair. Check for leaks and repair. Check active engine codes and refer to Engine Operator’s Manual. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 65 7: Maintenance 1600H T4F CAT User Manual Table 7-3: Troubleshooting guide Symptom Probable cause Clogged return line Leak in the lubrication system Excessive compressor fluid consumption Separator element damaged or not functioning properly Defective minimum pressure/check valve Fluid receiver tank overfilled Low operating service pressure Compressor overheating Engine overheating 66 Loose or broken fan belt Dirty fluid cooler core Faulty thermostat element Low receiver tank fluid level Plugged compressor fluid filter Loose or broken fan belt Dirty radiator core Low water level Plugged radiator Defective engine thermostat Remedy Clean orifice and strainer. Check all pipes, connections and components Change separator element. Repair or replace. Drain to proper level. Adjust service valve to maintain desired service pressure. Tighten or change belt Clean core thoroughly. Change thermostat element. Refill. Change element. Tighten or change belt. Clean thoroughly. Refill. Clean and flush thoroughly. Replace engine thermostat. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 8: Noise Control Section 8 Noise Control 8.1 Noise emissions warranty Sullair warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. E.P.A. and/or any Federal, State or Local noise control regulations. This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design, assembly, or in any part, component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal standards are covered by this warranty for the life of the air compressor. control prior to its sale or delivery to the ultimate purchaser or while it is in use. 2. The use of the compressor after such device or element of design has been removed or rendered inoperative by any person. Among those acts included in the prohibition against tampering are the acts listed below: 1. Removal or rendering inoperative any of the following: • Engine exhaust system or parts thereof • Compressor air intake system or part thereof • Enclosure of part thereof 2. Removal of any of the following: 8.2 Tampering with the noise control system is prohibited Federal Law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise • Vibration isolators • Control silencer • Floor panel • Fan shroud • Acoustical materials including fiberglass foam or foam tape 3. Operation with canopy doors open for any purpose other than starting, stopping, adjustment, repair, replacement of parts or maintenance. 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 67 8: Noise Control 1600H T4F CAT User Manual 8.3 Noise emissions maintenance and maintenance record log The following instructions and maintenance record log book, for the proper maintenance, use and repair of this compressor, is intended to prevent noise emission degradation. Table 8-1: Annual muffler and exhaust system inspection At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints and connections are tight, and that the muffler is in good condition. Do not operate compressor with defective exhaust system. Remove and replace any defective parts by ordering with part numbers indicated in the Parts List. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Table 8-2: Annual air filter(s) and air inlet system inspection In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight, that there are no other leaks in the system, and that the filter element(s) are intact. Do not operate compressor with defective air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts List. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: 68 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual 8: Noise Control Table 8-3: Annual engine vibration mount inspection At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. Do not operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbers indicated in Parts List. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Table 8-4: 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 deformed members, including all hinged doors, covers and their fastening devices. Do not operate compressor with defective frame, canopy and parts. Remove and replace defective parts by ordering with part numbers indicated in Parts List. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 69 8: Noise Control 1600H T4F CAT User Manual Table 8-5: Annual acoustical materials inspection At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material missing or damaged (refer to Parts List). Clean or replace, if necessary. Do not operate compressor with defective acoustical material. Remove and replace defective parts by ordering with part numbers indicated in the Parts List. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Table 8-6: 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 systems are operating properly and that engine runs at rated speed and pressure. Do not operate malfunctioning or improperly adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required. Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: Maintenance performed: By: Location: Date: 70 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual A: Acronyms and Abbreviations Appendix A: Acronyms and Abbreviations CEM—Clean Emissions Module DEF—Diesel Exhaust Fluid DOC—Diesel Oxidation Catalyst DPF—Diesel Particulate Filter ECU—Engine Control Unit NOx—Oxides of Nitrous (NO and NO2) PETU—Pump Electronic Tank Unit SCR—Selective Catalytic Reduction 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 71 A: Acronyms and Abbreviations Notes: 72 02250225-985 R01 Subject to EAR, ECCN EAR99 and related export control restrictions. 1600H T4F CAT User Manual Subject to EAR, ECCN EAR99 and related export control restrictions. Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.