1600H T4F CAT User Manual en-US 02250225-985 R01

1600H T4F CAT User Manual en-US 02250225-985 R01
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
training@sullair.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
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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
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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
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Notes:
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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.
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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
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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.
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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.
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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.
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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
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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
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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.
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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.
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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.
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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.
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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
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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
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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
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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
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1600H T4F CAT User Manual
Notes:
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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.
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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
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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).
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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
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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)
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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
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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.
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2: Description
24
2.10 Wiring diagram
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2: Description
25
02250220-244 R06 (sh2)
1600H T4F CAT User Manual
2.10 Wiring diagram
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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
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2: Description
27
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02250221-721 R01 (sh1)
2: Description
28
2.11 Piping & instrumentation, compressor system
Key Description
Component connections
Component Description
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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
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2: Description
30
2.12 Piping & instrumentation, engine system
Key Description
Key Description
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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
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2: Description
32
2.13 ID, DTQ aftercooled
Drawing notes
1
DIMENSIONS ARE IN INCHES. [ ] DIMENSIONS ARE IN MILLIMETERS.
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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
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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.]
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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.
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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.
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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
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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.
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3: Specifications
1600H T4F CAT User Manual
Notes:
40
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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.
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4: Installation
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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
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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.
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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”.
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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.
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5: Operation
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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
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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
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6: Controller
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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
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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.
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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.
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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.
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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
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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.
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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.
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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.
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7: Maintenance
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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.
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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
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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).
7.6.3.1 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-
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7: Maintenance
pressed air as this may introduce dust downstream of the filter.
7.6.3.2 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.
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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
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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.
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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
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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
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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.
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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.
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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.
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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.
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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:
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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:
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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:
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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
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A: Acronyms and Abbreviations
Notes:
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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.
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