OPERATOR`S MANUAL AND PARTS LIST

P

ortable

a

ir

C

omPressor

300HH, 375, 375H

and

425

Caterpillar Standard and Aftercooled and Filtered

Part Number:

02250169-726 r01

keeP for future refereNce

©

Sullair corPoratioN

The information in this document is correct at the time of printing for portable compressor serial number

200705010000

and all subsequent serial numbers.

air care SemiNar traiNiNG

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

Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for Rental House,

Contractor Maintenance and Service Personnel.

For detailed course outlines, schedule and cost information contact:

Sullair customer care training Department

:

1-888-SULLAIR or

219-879-5451 (ext. 5363) www.sullair.com

- Or Write -

Sullair corporation

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department

table of coNteNtS contents

1 - SafetY ...........................................................................................................1

General ...........................................................................................................1

Towing (I) ........................................................................................................1

Preparing To Tow ...................................................................................... 1

Towing .....................................................................................................3

Parking Or Locating Compressor ............................................................. 3

Pressure Release ...........................................................................................4

Fire And Explosion ..........................................................................................5

Moving Parts ...................................................................................................6

Hot Surfaces, Sharp Edges And Sharp Corners ............................................. 6

Toxic And Irritating Substances ....................................................................... 6

Electrical Shock ..............................................................................................7

Lifting ..............................................................................................................7

Entrapment .....................................................................................................8

Jump Starting ..................................................................................................8

California Proposition 65 ................................................................................. 9

Implementation of Lockout/Tagout .................................................................. 9 explosive atmosphere ................................................................................... 10

2 - DeScriPtioN ............................................................................................... 11

Introduction .................................................................................................. 11

Description Of Components .......................................................................... 11

Sullair Compressor Unit, Functional Description .......................................... 13

Compressor Cooling And Lubrication System, Functional Description ......... 13

Compressor Discharge System, Functional Description ............................... 14

Capacity ContRol SysTem, Functional Description ....................................... 14

Start – 0 To 40 psig (0 To 2.8 Bar) Cold Start ......................................... 14

Normal Operation – 80 to 100 psig (5.6 to 6.9 bar) or 80 to 150 psig

(5.6 to 10.3 bar) for H machines or 80 to 200 psig (5.6 to 13.8 bar) for

HH machines ..........................................................................................22

Modulation – 100 to 110 psig (6.9 to 7.5 bar) or 150 to 165 psig (10.3 to 11.4 bar) for H machines or 200 to 220 psig (13.8 to 15.2 bar) for

HH machines ..........................................................................................22

Shutdown ...............................................................................................22

Air Inlet System, Functional Description ...................................................... 22

Instrument Panel Group, Functional Description .......................................... 22

375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List

iii

SectioN 7

Wiring Diagram .............................................................................................37

Electrical System, Functional Description ..................................................... 38

Compressor Shutdown & Warning System, Functional Description ............. 38

Aftercooled And Filtered Air System, Functional Description ........................ 39

Listing of Diagnostic Codes .......................................................................... 40

Trouble Codes ........................................................................................40

Operation of the Indicator Lamps .................................................................. 43

Flash Codes ..................................................................................................44

3 - SPecificatioNS .........................................................................................45

Specifications – 300HH and 375 Caterpillar ................................................. 45

Specifications – 375H and 425 Caterpillar .................................................... 46

Lubrication Guide – Compressor .................................................................. 48

Application Guide ..........................................................................................48

Lubrication Guide – Engine ........................................................................... 48

4 - GeNeral ......................................................................................................49

General .........................................................................................................49

Purpose Of Controls .....................................................................................49

Control or Indicator Purpose ................................................................... 49

Initial Startup/Shutdown Procedure .............................................................. 50

Startup ....................................................................................................50

Shutdown ................................................................................................50

Restart Procedure .........................................................................................50

5 - maiNteNaNce .............................................................................................51

General .........................................................................................................51

Daily Maintenance ........................................................................................51

Maintenance After Initial 50 Hours Of Operation .......................................... 52

Maintenance Every 50 Hours ........................................................................ 52

Maintenance Every 100 Hours ...................................................................... 52

Maintenance Every 250 Hours ...................................................................... 52

Maintenance Every 1500 Hours .................................................................... 52

Part Replacement And Adjustment Procedures ............................................ 53

Compressor Fluid Change Procedure .................................................... 53

Compressor Fluid Filter Element Replacement ...................................... 53

Air Filter Maintenance ............................................................................ 53

Air Filter Replacement ............................................................................ 53

Element Inspection ................................................................................. 54

Separator Element Replacement ........................................................... 54

Procedure For Setting Speed And Pressure Controls On Portable

Compressors Equipped With Poppet Valves ......................................... 54

Bearing Lubrication ................................................................................. 56

First and Second Stage Discharge Air Filter Maintenance – Aftercooled &

Filtered Models .......................................................................................57

Trouble Shooting ...........................................................................................58

6 - NoiSe coNtrol .........................................................................................63

Noise Emissions Warranty ............................................................................ 63

Tampering with the Noise Control System is Prohibited ............................... 63

Noise Emission Maintenance and Maintenance Record Log ................. 64

Noise Emissions Maintenance and Maintenance Record Log ...................... 64

Procedure For Ordering Parts ....................................................................... 67

7 - illuStratioNS aND PartS liSt ............................................................ 67

Recommended Spare Parts List ................................................................... 69

Engine, Compressor And Parts ..................................................................... 70

Radiator & Compressor Fluid Cooling System ............................................. 74

Air Inlet System & Exhaust System .............................................................. 78

iv


table of coNteNtS

Control Parts & Discharge Parts - 375 and 425 ............................................ 80

Control Parts & Discharge Parts - 300HH and 375H .................................... 84

Regulator/Blowdown Valve - 375 And 425 .................................................... 88

Regulator/Blowdown Valve - 300HH and 375H ............................................ 90

Control Parts Orifice - 300HH and 375H ....................................................... 92

Service Valves...............................................................................................94

Optional AfterCooler/Filter And Parts ............................................................ 96

Electrical Parts ............................................................................................100

Instrument Panel & Parts ............................................................................ 104

Fuel Tank & Connections ............................................................................ 108

Frame, Axle & Parts And Axle Assembly ..................................................... 110

Axle Assembly ............................................................................................. 114

Canopy, Acoustical Panels & Parts ............................................................. 116

Decals ......................................................................................................... 118

Decal Locations ..........................................................................................130


v

SectioN 7

tHiS PaGe iNteNtioNallY left blaNk

vi


Section 1

SafetY

Note oPerator iS reQuireD to reaD eNtire iNStructioN maNual.

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.

Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace as required.

cautioN

estimated hose life based on a 5-day

8-hour work week is 3 years. these conditions exist on an 8-hour shift only. any other operation of the equipment other than 8-hour shifts would shorten the hose life based on hours of operation.

1.1

GeNeral

Sullair Corporation 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 cima 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 the battery so others who may not know of the unsafe condition will not 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.

1.2 towiNG

Note

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.

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.

1

SectioN 1 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. 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 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.

D. e. f.

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

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 front of drawbar before passing them through points of attachment on towing vehicle to support front of drawbar in case it should accidentally become uncoupled.

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 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


Do Not attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.

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.

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. i.

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.

Make sure tires are in good condition and are the size (load range) specified and are inflated to the type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques.

2

J. k. l. m.

N. o.

or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided.

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

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.

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.

Make sure all service air hoses (not air brake hoses) hose reels, if provided.

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.

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 possibility of tipping, rolling over, jackknifing, etc.

Loss of control of the towing vehicle may result.

Towing

a. b. c.

D. e.

towing this equipment (including those specifying minimum speed).

Do Not

exceed the towing speeds listed below under ideal conditions. Reduce your speed according conditions:

1.

2.

Two axle four-wheel or three axle six-wheel steerable models: 15 MPH (24 km/h).

All other models: 55 MPH (88 km/h).

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.

Avoid grades in excess of 15̊ (27%).

SafetY f.

G.

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 towing forward or backing up, regardless of the terrain being traversed.

Do Not

permit personnel to ride in or on the compressor.

H. i.

compressor is clear of all personnel and obstructions prior to towing in any direction.

Do Not

permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle.

Parking Or Locating Compressor

a.

Park or locate compressor on a level surface, if possible. If not, park or locate compressor across

b. c.

downhill. Do Not park or locate compressor on grades exceeding 15̊ (27%).

Make sure compressor is parked or located on a firm surface that can support its weight.

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. e. f.

G.

Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake connections, if provided.

Block or chock both sides of all wheels.

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.

3

SectioN 1

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.

warNiNG


Do Not attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. i.

J.

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.

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 secured in place prior to towing.

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. l.

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

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 skid- mounted portable air compressors as well.

1.3

a. b.

PreSSure releaSe

Open the pressure relief valve at least weekly to otherwise disabled.

Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throttle)

c.

D.

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) standards and regulations.

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.

Provide an appropriate flow-limiting valve for each additional 75 feet (23 m) of hose in runs of air hose

e. f.

Flow-limiting valves are listed by pipe size and rated

CFM. Select appropriate valve accordingly.

Do Not

use tools that are rated below the maximum

G.

H.

pipes, valves, filters and other fittings accordingly. Do

Not exceed manufacturer’s rated safe operating pressures for these items.

Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled.

Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the

4

i.

J. k. l. m.

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 with antifreeze compound.

Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge.

Do Not

use air at pressures higher than 30 psig (2.1 effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) standards and regulations.

Do Not

engage in horseplay with air hoses as death or serious injury may result.

This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief

N. o.

valve is functional. Do Not lift the handle while machine is under pressure.

If the machine is installed in an enclosed area it is structure or to an area of non-exposure.

Do Not

remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure

P.

cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand.

The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under 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.

Q.

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

a.

fire aND exPloSioN

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. c.

Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition when adding fuel, or when checking or adding electrolyte to batteries, or when checking or adding fluid, or when checking diesel engine ether starting air line anti-icer systems antifreeze compound.

SafetY

D. Do Not

permit liquids, including air line anti-icer system antifreeze compound or fluid film, to accumulate on bottom covers or on, under or around

e.

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 replaced immediately to prevent accumulation of flammable solvents for cleaning purposes.

Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning

f.

G.

H. i.

Keep electrical wiring, including the battery terminals and other terminals, 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 clean and tight.

Turn off battery charger before making or breaking connections to the battery.

Keep grounded 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.

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. k. l. m.

N.

may be damaged by heat or that may support combustion prior to attempting weld repairs. Remove diesel engine ether starting aid cylinders and air line anti-icer system components containing antifreeze compound, prior to attempting weld repairs in any place other than the fuel system. Do Not weld on or near the fuel system.

Keep a suitable, fully charged class BC or ABC fire and operating the compressor.

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

Open all access doors and allow the enclosure to engine.

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.

5

SectioN 1 o.

P.

Q. r.

S.

1.5

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).

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.

Do Not

spray ether into compressor air filter or into compressor as serious damage to the compressor or personal injury may result.

Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use systems and refill with compound only in wellventilated 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 compound in direct sunlight.

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 systems and detectors if so equipped.

moViNG PartS

a. b. c.

D. e.

Keep hands, arms and other parts of the body and moving parts.

Do Not

attempt to operate the compressor with the fan or other guards removed.

Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts inside the enclosure.

Keep access doors closed except when making repairs or adjustments, performing service or when starting or stopping the compressor.

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

f.

lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders.

G.

to prevent accidental engine operation prior to attempting repairs or adjustments. Tag the battery connection so others will not unexpectedly reconnect it.

H.

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.

i.

surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibility of slips and falls.

1.6

a.

Hot SurfaceS, SHarP eDGeS aND SHarP corNerS

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

b. c.

D.

Wear personal protective equipment including gloves and head covering when working in, on or around the compressor.

Keep a first aid kit handy. Seek medical assistance and burns as they may lead to infection.

1.7

a.

toxic aND irritatiNG

SubStaNceS

Do Not

use air from this compressor for respiration

(breathing) except in full compliance with OSHA or Local codes or regulations.

DaNGer

b. iNHalatioN HaZarD!

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.

Do Not

use air line anti-icer systems in air lines equipment and Do Not discharge air from these systems into unventilated or other confined areas.

6

c.

D.

Operate the compressor only in open or wellventilated areas.

If the compressor is operated indoors, discharge engine exhaust fumes outdoors.

e. f.

G.

H. i.

J.

apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor.

Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are typical of the industry. Care should be taken to avoid accidental ingestions and/or skin contact. In the event of ingestion, seek medical treatment promptly. Do Not and water in the event of skin contact.

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.

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 call a physician immediately.

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.

If ethyl ether or air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the

k.

clean water for 15 minutes. A physician, preferably any eye specialist, should be contacted immediately.

Do Not

store ether cylinders or air line anti-icer

l.

The antifreeze compound used in air line anti-icer 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 tablespoons of baking soda in a glass to exclude light. Call a physician immediately.

1.8

a.

electrical SHock

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.

SafetY b.

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.

c.

D.

1.9

Stay clear of the compressor during electrical storms!

It can attract lightning.

liftiNG

a. b. c.

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.

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.

Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition

D. e. f.

G.

H. i.

equivalent, and is fully engaged and latched on the bail.

Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground.

Do Not

attempt to lift in high winds.

Keep all personnel out from under and away from the compressor whenever it is suspended.

Lift compressor no higher than necessary.

Keep lift operator in constant attendance whenever compressor is suspended.

J.

the compressor plus an additional 10% allowance for weight of snow, ice, mud or stored tools and equipment. If your are unsure of the weight, then weigh compressor before lifting.

k.

of supporting at least its net weight plus an additional

10% allowance for the weight of snow, ice, mud or stored tools and equipment.

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.

7

SectioN 1

1.10 eNtraPmeNt

a. b.

Make sure all personnel are out of compressor before closing and latching enclosure doors.

If the compressor is large enough to hold a man and if it is necessary to enter it to perform service adjustments, 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

JumP StartiNG

a. b. c.

Observe all safety precautions mentioned elsewhere in this manual.

Batteries may contain hydrogen gas which is other sources of ignition away.

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. e. f.

G.

H. i.

J. k. l.

battery or batteries in the compressor. Do Not permit dirt or foreign matter to enter the open cells.

Check fluid level. If low, bring fluid to proper level maintenance-free batteries).

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.

Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start.

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.

Bring the starting vehicle alongside the compressor, the compressor and the starting vehicle.

Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels.

Place the starting vehicle in neutral or park, turn off all engine.

Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current.

m.

N.

Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to might serve as a source of ignition.

Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS

o.

are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign.

Connect one end of a jumper cable to the positive

(POS) (+) battery terminal in the starting vehicle.

P.

Q. r.

S.

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.

Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor, or when jump starting 24V compressor, to the positive (POS) (+) terminal of the ungrounded battery in the compressor.

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, terminal of the grounded battery.

Check your connections. Do Not attempt to start a

24V compressor with one 12V battery in the starting compressor.

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. u.

Allow the compressor to warm up. When the compressor is warm and operating smoothly at 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.

8

V.

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

1.12 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.

1.13 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.

2.

3.

4.

Alert operator and supervisor of which machine is be turned off.

Check to make certain no one is operating the machine before turning off the power.

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.

SafetY b.

6. c. d.

Block any load or machine part prior to working under it.

Electrical circuits should be checked with calibrated electrical testing equipment and stored energy and electrical capacitors should be safely discharged.

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 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.

8.

9. sources are not capable of being locked out by use of padlocks and lockout hasp devices. Name of person affixing tag to power source must be on source.

Release stored energy and bring the equipment to a “zero mechanical state”.

Verify Isolation: Before work is started, test equipment to ensure power is disconnected.

General Security

1. person who put the lock on the energy-isolating device. No one other than the person/persons placing padlock ad lockout hasp 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 first:

2. a. b. c. verified that no person will be exposed to danger.

verified that the “Authorized” person who applied the device is not in the facility.

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.

Tagout System—Tags are warning devices affixed at points of power disconnect and are not to be removed by anyone other that the person by-passed, ignored, or otherwise defeated.

9

SectioN 1

1.14 exPloSiVe atmoSPHere 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.

10

Section 2

DeScriPtioN

2.1

2.2 iNtroDuctioN

The Sullair 300HH, 375, 375H, and 425 CFM Standard and Aftercooled Portable Air Compressors offer superior performance, reliability and require a minimal amount of maintenance. Compared to other compressors, Sullair’s are unique in terms of reliability and durability. Compressor internal components require no routine maintenance inspections.

DeScriPtioN of comPoNeNtS

Figure 2-1

shows the main components and subassemblies of the Sullair 300HH, 375, 375H, and 425

Standard and Aftercooled Portable Air Compressors.

These packages include a heavy duty rotary screw air

compressor, a diesel engine, fuel tank, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical

system. A low profile canopy offers improved handling and mobility. Large side service doors provide easy access to all serviceable components. This model meets EPA sound level regulations of 76dbA at 7 meters (23 feet). Sullair air compressors have the following delivery capacities:

Model 300HH, 300CFM@ 200 psig (13.8 bar)

Model 375, 375CFM @ 100 psig (6.9 bar)

Model 375H, 375CFM @ 150 psig (10.3 bar)

Model 425, 425CFM @ 100 psig (6.9 bar)


11

SectioN 2

SU_0000673

1.

2.

3.

4.

5.

6.

7.

Radiator/Fluid Cooler Assembly

Radiator/Fluid Cooler Assembly With Air To Air Aftercooler

Lifting Bail

Engine Air Filter

Compressor Air Filter

Fuel Tank

Battery Shutoff Switch

8.

9.

10.

11.

12.

13.

14.

Service Valves

Serial Number Plate Location

Receiver/Sump Tank

Minimum Pressure/Check Valve

Engine Exhaust Muffler

Moisture Separator

Optional Discharge Air Filters

Figure 2-1: Sullair Rotary Screw Portable Air Compressor – Caterpillar Standard and Aftercooled Models

The control system can easily be adjusted for pressures from 80 to 125 psig (5.6 to 8.6 bar) for standard machines, from 80 to 150 psig (5.6 to 10.3 bar) for “H” machines and from 80 psig to 200 psig (5.6 to 13.8 bar) for “HH” machines. The compressor unit is driven by an industrial diesel engine designed to provide enough horsepower to provide an adequate reserve under 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, charge air cooler, high capacity fan, and thermostat. The high capacity fan pushes air through the radiator to maintain the engine’s specified operating temperature. The same fan also cools the fluid in the compressor cooling and lubrication system.

12


DeScriPtioN

The engine radiator, charge air cooler, and the compressor fluid cooler are next to each other allowing the fan air to push through all three simultaneously. As air passes through the fluid cooler, the heat of compression is removed from the fluid. The compressor’s high capacity fuel tank contains enough fuel for one eight hour shift under normal operating conditions.

2.3

Sullair comPreSSor uNit, fuNctioNal DeScriPtioN

Sullair compressors are single-stage, positive displacement, flood lubricated-type compressors that provide continuous (pulse-free) compression to meet various demand loads. Sullair compressors require no routine maintenance or inspection of their internal parts or systems. The compressor works by injecting fluid into the compressor unit where it mixes directly with the air as the rotors turn: the rotor’s rotation compresses the air. The fluid flow has three main functions:

1.

2.

3.

It acts as a coolant, to control the rise of air temperature which is generated by compression (heat of compression).

Seals the leakage paths between the rotors and the stator and also between the rotors themselves.

Lubricates the rotors allowing one rotor to directly drive the other.

After the air fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows to the service line and the fluid is cooled in preparation for re-injection.

2.4 comPreSSor cooliNG aND lubricatioN SYStem, fuNctioNal DeScriPtioN

Refer to Figure 2-2. 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 fluid cooler and interconnecting piping, the system consists also of three other components: a fluid filter, thermal valve, and a fan which perform the following functions:

•

•

•

The fluid filter removes and collects any contaminants in the fluid.

The thermal valve functions as a temperature regulator directing fluid either to the cooler or to the compressor unit.

The fan pushes air through the cooler dissipating the heat resulting from compression of the fluid.

The functions of the lubrication system are explained in more detail below. Fluid is used in the system as a coolant and as a lubricant: the sump serves as the fluid reservoir.

At start-up, fluid flows from the sump to the fluid thermal valve. Fluid circulation is achieved by forcing the fluid from the high pressure region of the sump to a lower pressure area in the compressor unit. A minimum pressure device

(See Compressor Discharge System, Functional

Description on page 14

) is provided to assure adequate fluid flow under all conditions. When entering the thermal valve upon start-up, the fluid temperature is cool and thus it is not necessary to route it through the cooler. The fluid flows through the fluid filter and on to the compressor unit bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and the thermostatic control opens, allowing a portion of the fluid into the cooler.

When the temperature reaches 155°F (68°C), the thermostat is fully open allowing all fluid entering the thermal valve to flow to the cooler.

The cooler is a radiator type that works in concert with the engine fan. The fan pushes air through the cooler removing the heat from the fluid. From the cooler, the fluid is then routed back through the fluid filter. All fluid flowing to the compressor unit passes through this filter. The fluid leaving the filter flows to the compressor unit where it lubricates, seals and cools the compression chamber; and lubricates the bearings and gears.

2

3

1

5

6

4

SU_0000664

1.

2.

3.

4.

5.

6.

Fluid Cooler

Engine

Compressor

Thermal Valve

Fluid Filter

Receiver Tank

Figure 2-2: Compressor Cooling and Lubrication

System


13

SectioN 2

2.5 comPreSSor DiScHarGe

SYStem, fuNctioNal

DeScriPtioN

1.

2.

3.

Refer to Figure 2-3. The Sullair compressor unit discharges a compressed air/fluid mixture into the sump.

The sump has three functions:

It acts as a primary fluid separator.

Serves as the compressor fluid reservoir.

Houses the air/fluid separator.

The compressed air/fluid mixture enters the sump and is directed against the side of the sump. Because of a change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the sump. The small amount of fluid remaining in the compressed air collects on the surface of the separator element as the compressed air flows through the separator. As more fluid collects on the element surface, it then flows 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 assure proper and unobstructed flow. The sump is ASME code rated at 250 psig (17.1 bar) working pressure. A minimum pressure device located downstream from the separator, ensures a minimum receiver pressure of 80 psig (5.5 bar) during all conditions. Keeping this pressure level stable is necessary for proper air/fluid separation and proper fluid circulation. A pressure relief valve (located on the wet side of the separator) is set to open if the sump pressure exceeds 250 psig (17.1 bar).

Fluid is added to the sump through a capped fluid filler.

2.6 caPacitY coNtrol SYStem, fuNctioNal DeScriPtioN

Refer to Figure 2-4, Figure 2-5, Figure 2-6 or Figure 2-7.

The purpose of the control system is to regulate the amount of air intake and match it to the demand (required output) on the compressor. The control system consists of a pressure regulating valve(s), air inlet valve, system blowdown valve, pressure transducer, speed control module, and tubing connecting the various components of the compressor and engine. The functional descriptions of the control system are described by relating them to four distinct phases of operation. They apply to any control system with the exception of those with specified pressures which are dependent on pressure requirements.

The given values apply to a compressor with an operating pressure range of 100 to 110 psig (6.9 to 7.6 bar).

Start – 0 To 40 psig (0 To 2.8 Bar) Cold Start

When the compressor is started, the sump pressure quickly rises from 0 to 40 psig (0 to 2.8 bar). During this period the pressure regulator valve is inactive. At this pressure range the idle warm-up control keeps the inlet valve closed for engine idle operation. Within 30 seconds of starting the compressor (the instrument panel annunciator light goes off after 30 seconds) turn the handle of the warm-up selector valve (located on the instrument panel) from the START to the RUN position.

The inlet valve is fully open due to inlet pressure, and the compressor operates at full capacity. When the compressor operates at full capacity, the engine runs at full speed.

warNiNG

Do Not remove caps, plugs and/or other components when the compressor is running or pressurized. Stop the compressor and relieve all internal pressure before removing these items.

14


DeScriPtioN

STANDARD MODEL

1

2

3

4

8

7

6

5

9

14

15

13

11

AFTERCOOLED MODEL

12

10

5.

6.

7.

8.

1.

2.

3.

4.

Engine

Strainer


Service Air Outlet

Receiver Tank (Sump)

Separator Element

Minimum Pressure Valve

Non-Aftercooled/Aftercooled Service Air Valve

9.

10.

11.

12.

13.

14.

15.

Service Air Outlet

Receiver Tank (Sump)


Moisture Separator

Aftercooler

Air

Fluid/Air

Figure 2-3: Compressor Discharge System – Standard and Aftercooled Models

SU_0000665


15

SectioN 2

1

3

4

5

6

21

7

8

2

16

9

18

19

20

15

10

16

11

14

12

17

13

SU_0000666

5.

6.

7.

8.

1.

2.

3.

4.

9.

10.

11.

Air Pressure Gauge

Instrument Panel

Idle Warm-Up Valve

Inlet Valve

Air Filter

Regulator/Blowdown Valve Manifold

Minimum Pressure Check Valve

Pressure Relief Valve

Fuid Fill/Fluid Level Sight Glass


Optional Moisture Separator

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Optional Aftercooler

Aftercooled Machines ONLY

Fluid Filter

Thermal Valve

Compressor Unit

Fluid Cooler

Air

Fluid/Air

Fluid

Strainer

Figure 2-4: Control System with Piping and Instrumentation - 375 and 425 Models


1

2

5

6

7

8

9

10

4

3

11

12

13

DeScriPtioN

14

15

23

24

25

21

16

17

20

18

22

19

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Compressor Unit

Fluid Fill/Fluid Level Sight Glass


Optional Moisture Separator

Optional Aftercooler

Aftercooled Machines ONLY

Fluid Filter

Thermal Valve

Fluid Cooler

Air

Fluid/Air

Fluid

SU_0000667

5.

6.

7.

8.

1.

2.

3.

4.

9.

10.

11.

12.

13.

Air Pressure Gauge

Idle Warm-Up Control Selector Valve

Low Pressure Regulator Valve

High Pressure Regulator/Blowdown Valve Manifold

Instrument Panel

High/Low Pressure Selector Switch

Air Filter

Orifice

Silencer

Inlet Valve

Strainer



Figure 2-5: Control System with Piping and Instrumentation – 300HH and 375H Models


17

SectioN 2

High

Run

Warm-up

Low

Start

Out In

High Pressure

In Out

Low Pressure

Standard Air

Moisture Drain

18

Figure 2-6: Piping and Instrumentation Diagram

02250169-746R00-1


Aftercooled Air

10. Glass, Sight Oil Level

11.

21.

22.

23.

27.

16.

17.

18.

19.

28.

29.

31.

5.

6.

8.

9.

1.

2.

3.

4.

12.

13.

14.

15.

Filter, Air

Gauge, Filter Restriction (Optional)

Inlet Valve

Compressor

Gauge, Temperature

Switch, Temperature

Valve, Relief

Receiver, Air/Oil

Indicator, Delta-P

Valve, Minimum Pressure/Check

Valve, Ball

Cooler, Air

Separator, Moisture

Trap, Drain

Orifice

Valve, Blowdown N.C.

Strainer

Valve, Thermal Bypass

Cooler, Oil

Filter, Oil

Gauge, Pressure

Valve, Pressure Regulator

Valve, 3-Way Selector

Valve, Check

t1

DeScriPtioN

Compressor Discharge Temperature Switch


19

SectioN 2

Compressor

Air Intake and Exhaust System

Intake Manifold

Internal Relief Valve

Turbine

Fuel System

Injector

Relief Valve

(Filter Head)

Customer Supplied Ether Bottle

John Deere Only

Cooling System

Heads and Cylinder

Lubrication System

Engine Lube System/

Block and Turbo

20

Figure 2-7: Piping and Instrumentation Diagram


02250169-746R00-2

5.

6.

7.

8.

1.

2.

3.

4.

Turbocharger, Compressor

Cooler, Air

Muffler, Engine

Fuel Level Sender

Rain Cap, Exhaust System

Fuel Filter W/ Water Separator

Fuel Transfer Pump (Internal To Engine)

Hand Operated Fuel Priming Pump

9. Filter, Fuel

10. Gauge, Fuel Level

11. Fuel Tank Cap W/Vent

12.

Thermostat, Thermocord (Optional)

13. Kit, Ether Assembly

14. Oil Pump (Integral To Engine)

15. By-Pass Valve (Internal To Engine)

16. Cooler, Oil (Internal To Engine)

17. Filter, Oil

18.

Water Pump (Integral To Engine)

19. Radiator, Engine

20.

Engine Thermostat (Integral To Engine)

21. Inlet Manifold Air Press Sensor (Turbo Boost)

23.

Sensor, Fuel Pressure

24. Sensor, Fuel Temperature

25. Sensor, Coolant Temperature

26. Sensor, Engine Oil Pressure

27. Sensor, Cam Speed Timing

28. Sensor, Crank Speed Timing

29. Jacket Water Heater (Optional)

30.

Oil Level (Dipstick)

31. Filter, Air

32.

Tank, Fuel

33. Engine Oil Pan

34.

Gauge, Filter Restriction

l1 Coolant Level

l2 Fuel Level

l3 Oil Level (Dipstick)

P5 Inlet Manifold Air Pressure

P6 Fuel Pressure

P7 Oil Pressure

t8 Fuel Temperature

t9 Coolant Temperature

S1 Cam Speed

S2 Crank Speed

DeScriPtioN


21

SectioN 2

1

5

2

3

4

SU_0000668

1.

2.

3.

4.

Engine Air Filter

Compressor Air Filter

Air Inlet Valve

Compressor

5.

Engine

Figure 2-8: Air Inlet System – Caterpillar

Normal Operation – 80 to 100 psig (5.6 to 6.9 bar) or 80 to 150 psig (5.6 to 10.3 bar) for H machines or 80 to 200 psig (5.6 to 13.8 bar) for HH machines

When the warm-up control selector valve handle is moved to the RUN position, the sump pressure rises above 80 psig (5.6 bar). At this time, the inlet valve remains fully open for maximum air output. The engine will continue to run at full speed during this phase of operation.

Modulation – 100 to 110 psig (6.9 to 7.5 bar) or 150 to 165 psig (10.3 to 11.4 bar) for H machines or 200 to 220 psig (13.8 to 15.2 bar) for HH machines

If the demand on the compressor is less than its rated capacity, the service line pressure will rise above 100 psig

(6.9 bar) - low or single pressure rating: 150 psig (10.3 bar) for “H” rating or 200 psig (13.8 bar) for “HH” dual or high pressure rating. The pressure regulating valve gradually opens, applying pressure to the inlet valve piston and pressure transducer. This causes the inlet valve to partially close and reduces the engine speed. As the pressure increases, the inlet valve piston will further close the inlet valve and the engine speed will decrease until it reaches its preset idle speed. When the demand on the compressor increases, the sump pressure falls below 110 psig (7.6 bar) or 165 psig (11.4 bar) for “H” machines, or

220 psig (15.2 bar) for “HH” ones. The pressure regulating valve closes, the air inlet valve opens fully, and the engine speed increases to its preset full load rating.

Between the pressure regulating valve and the inlet valve, there is a small orifice that vents a small amount of air into the atmosphere when the pressure regulating valve is open. This allows changes in air output to conform to air demand. This orifice also discharges any accumulated moisture from the regulator.

Shutdown

The blowdown valve is normally closed. At shutdown the back pressure in the compressor inlet signals the blowdown valve to vent the sump pressure into the atmosphere.

2.7 air iNlet SYStem, fuNctioNal DeScriPtioN

Refer to Figure 2-8. The air inlet system consists of two air filters, a compressor air inlet valve and interconnecting piping to the engine and the compressor.

The air filters are three-stage dry element type filters that are capable of cleaning extremely dirty air. However, when operating in dirty environments, the filters should be checked more frequently.

See Air Filter Maintenance on page 61 for Air Filter

Maintenance Procedures.

2.8 iNStrumeNt PaNel GrouP, fuNctioNal DeScriPtioN

Refer to Figure 2-9. The instrument panel group consists of a molded panel containing an: air pressure gauge, compressor temperature gauge (optional), ignition/start switch, PowerView (optional), annunciator light, idle warm-up control, engine shutdown light, engine warning light, and a wait to start light. A high-low pressure selector valve is located on the panel for “H” and “HH” compressors.

22


DeScriPtioN

fig_2-9_cat_t3-r00

1.

2.

3.

4.

5.

6.

Compressor Discharge Temperature Gauge (optional)

System Air Pressure Gauge

Start/Stop Switch

Warm-up Control Switch

High/Low Pressure Selector Switch

Shutdown Indicator

7.

8.

9.

10.

11.

12.

Engine Warning Lamp

Engine Wait to Start Lamp

Engine Stop Lamp

Fuel Level (optional)

Engine PowerView Monitor (optional)

Cold Weather Starting Aid

Figure 2-9: Instrument Panel Group (Optional Full Gauge Panel Shown)

Refer to Figure 2-9 for the locations of the following indicators and controls:

1.

2.

3.

4.

5.

The compressor discharge temperature gauge monitors the temperature of the air/oil mixture in the sump.

The air pressure gauge continuously monitors the sump pressure under various load conditions.

The engine switch energizes the system and starts the compressor. The engine switch is pressed to the ON position to energize the electrical system, and pressed momentarily to the START position to engage the starter and start the compressor.

The idle warm-up control is turned from START to

RUN after sufficient warm-up is achieved for full compressor operation.

The pressure selector valve on “H” compressors allows the selection of the compressor operating pressure range, 80 to 110 psig (5.6 to 7.6 bar) or 80 to

165 psig (5.6 to 11.4 bar) for “H” models, or 80 to 220 psig (5.6 to 15.2 bar) for “HH” models.

6.

7.

8.

9.

10.

The shutdown indicator light indicates engine and compressor safety shutdown status.

The engine warning lamp indicates when an abnormal condition exists. It is not necessary to shutdown the engine immediately, but the problem should be corrected as soon as possible.

The engine wait to start lamp is illuminated when conditions are not right for starting.

The engine stop lamp signals when the engine should be stopped immediately or as soon as possible to prevent engine damage. Correct the problem before restarting.

The fuel level gauge indicates the fluid level in the fuel tank.

11.

12.

The PowerView® is a multifunction tool that allows operators to view a wide range of engine parameters and engine service codes.

The cold weather starting aid can be used to add additional glow plug time in cold weather. Press the

Continued on next page.


23

SectioN 2

button and hold for 10-30 seconds (depending upon ambient temperature). Release the button prior to starting.

The engine ECM (Electronic Control Module) will monitor the engine temperature and automatically power the glow plugs upon starting in cold weather.

When glow plugs are required, when the engine start switch is pressed on the ON position, the amber “Wait to Start” warning lamp will light. Leave the engine switch in the ON position until the warning light for the glow plugs is extinguished. When the “Wait to start” warning light for the glow plugs is extinguished press the engine switch to the START position in order to engage the electric starting motor and crank the engine.

Note

the operating period of the warning light for the glow plugs will change due to the temperature of the engine.

warNiNG

Do Not use aerosol types of starting aids such as ether.

Such use could result in an explosion and personal injury.

if the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again.

Indicator Lamps

The indicator lamps are designed to display the maximum amount of information on the minimum number of lamps. Three lamps are installed; the red

“Stop” lamp, the amber “Warning” lamp and the amber

“Wait to start” lamp. The “Stop” lamp and the

“Warning” lamp can also be used to indicate a diagnostic code by use of the “Flash Code” feature.

The “Flash Code” feature can be used to indicate all active diagnostic codes and logged diagnostic codes.

Functions of the Indicator Lamps

Stop lamp

lamp check - When the engine switch is turned to

ON, the lamp will come on for 2 seconds. The lamp will then go off unless there is an active warning.

flashing - The lamp will be flashing when a derate is active or when a derate is present because of an active diagnostic code. An example of an active diagnostic code is “System Voltage High”.

on - The lamp will be on when the shutdown level in the engine protection strategy has been reached. The

“Warning” lamp will also be on.

warning lamp


ON, the lamp will come on for 2 seconds. The lamp will then go off unless there is an active warning.

flashing - The lamp will be flashing when a “warning” or a “warning and derate” is active. This includes low oil pressure.

on - The lamp will be on when the shutdown level has been reached. The “Stop” lamp will also be on.

wait to Start lamp


ON, the lamp will come on for 2 seconds. The lamp will then go off unless “Wait to Start” is active.

flashing - The lamp is on during a “Wait to Start” period.

24


DeScriPtioN

Using the Optional Diagnostic Gauge to

Access Engine Information

•

•

•

•

•

•

•

•

•

•

•

•

Refer to Figure 2-10. The diagnostic gauge

(Figure 2-10, [1])

displays engine function and trouble codes (DTCs). The display can be set for either English or metric units. It is linked to the electronic control system sensors and allows the operator to monitor engine functions and troubleshoot malfunctions.

Press the menu key (Figure 2-10, [2]) to view various engine functions in sequence. The following is a list of engine parameters the gauge can display:

• Engine hours

Engine rpm

System voltage

Percent engine load at current rpm

Coolant temperature

Oil pressure

Throttle position

Intake manifold temperature

Current fuel consumption

Active service (diagnostic) codes

Stored service (diagnostic) codes from the engine

Set units for display

View the engine configuration parameters

Note

engine parameters that can be displayed depend upon the engine application. Six readout languages are available and can be selected during gauge setup. the diagnostic gauge has a graphical backlit liquid crystal Display (lcD) screen. the display can show a single parameter or four simultaneously (in four quadrants). two arrow keys

(Figure 2-10, [3])

scroll through the engine parameter list and menu items. the enter key (Figure 2-10, [4]) selects items. the red

(Figure 2-10, [5])

and amber

(Figure 2-10, [6])

lights alert the operator to an active trouble code condition.

1.

2.

3.

4.

5.

6.

SU_0000687

Diagnostic Gauge

Menu Key

Arrow Keys

Enter Key

Red STOP ENGINE Indicator Light

Amber WARNING Indicator Light

Figure 2-10: Diagnostic Gauge

Note

when viewing engine codes through the PowerView, the SSam will display a four flash fault code after 30 seconds.


25

SectioN 2

PowerView Menus

PowerView oPeratioN

2

. The first seven items of the “Main Menu” will be displayed.

First Time Start Up

1

. When power is first applied to the PowerView, the "Logo Screen" will be displayed.

Go to 1-uP DiSPlaY eNGiNe coNf

SetuP 1-uP DiSPlaY


Select uNitS aDJuSt backliGHt

26

2

. The "Wait to Start" message will be displayed for engines with a pre-startup sequence. Once the "Wait to Start" message is no longer displayed the operator may start the engine. Note: Displays only when SAE

J1939 message is supported by engine manufacturer.

3

. Depressing the "Arrow Buttons" will scroll through the menu selections.

Go to 1-uP DiSPlaY

StoreD coDeS eNGiNe coNf



Select uNitS aDJuSt backliGHt wait to

Start

PreHeat

4

. Pressing the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

aDJuSt coNtraSt utilitieS

3

. Once the engine has started the display will show the single engine parameter display.

0 1500 3000

1800 rPm eNG rPm cool temP

Main Menu Navigation

1

. Starting at the single or four engine parameter display, depress the

"Menu Button".

98% loaD@rPm

1000 rPm eNG rPm

0 1500 3000


14.2

bat Volt

57 PSi oil PreS

5

. Use the arrow buttons to scroll to the desired menu item or press the

"Menu Button" to exit the Main menu and return to the engine parameter display.

Go to 1-uP DiSPlaY eNGiNe coNf



98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

PV-02124N page 5 of 17


DeScriPtioN

PowerView oPeratioN continued

Stored Fault Codes

1

. Starting at the single or four engine parameter display depress the

"Menu Button".

5

. Press the "Menu Button" to return to the main menu.

1 of x

98% loaD@rPm


SPN110 fmi10

HiGH coolaNt temP

0 1500 eNG rPm

3000

1800 rPm cool temP

14.2

bat Volt

57 PSi oil PreS more HiDe

2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Stored Fault Codes" is highlighted.


StoreD coDeS eNGiNe coNfG




6

. Press the "Menu Button" to exit the Main menu and return to the engine parameter display.

Go to 1-uP DiSPlaY eNGiNe coNfG


SetuP 4-uP DiSPlaY aDJuSt backliGHt

98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

3

. Once the "Stored Fault Codes" menu item has been highlighted press the "Enter Button" to view the "Stored Fault Codes".






Engine Configuration Data

1

. Starting at the single or four engine parameter display press the

"Menu Button".

0 1500 eNG rPm

3000


98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

4

. If the word "MORE" appears above the "Arrow Buttons" there are more stored fault codes that may be viewed. Use the "Arrow Buttons" to scroll to the next Stored Diagnostic Code.

1 of x

SPN110 fmi10

HiGH coolaNt temP more HiDe

2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Engine Configuration" is highlighted.






3

. Once the "Engine Configuration" menu item has been highlighted press the "Enter Button" to view the engine configuration data.







27

SectioN 2


4

. Use the "Arrow Buttons" to scroll through the engine configuration data.

eNGiNe SPeeD Pt 1

1000 rPm

or normal operation an auxiliary gage should fail the single or four parameter screen will be replaced with the "MLink Gage Fault" message.

1 of x more eNGiNe oil PreSSure

GaGe Not reSPoNDiNG

HiDe

5


eNGiNe SPeeD Pt 1

1000 rPm more

3

. To acknowledge and "Hide" the fault and return to the single or four parameter display press the "Enter Button".

1 of x eNGiNe oil PreSSure


HiDe

6





98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

4

. The display will return to the single or four parameter screen.

0 1500 eNG rPm

3000


!

!

98% loaD@rPm

14.2

bat Volt

!


57 PSi oil PreS

!

!

Indicates Auxiliary Gage Fault

Faults and Warnings

Auxiliary Gage Fault

1

. During normal operation the single or four parameter screen will be displayed.

98% loaD@rPm


0 1500 eNG rPm

3000


14.2

bat Volt

57 PSi oil PreS

!

Indicates Derate or Shutdown Condition Fault

5

. Pressing the "Enter Button" will redisplay the hidden fault. Pressing the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display. NOTE: The fault can only be cleared by correcting the cause of the fault condition.

1 of x eNGiNe oil PreSSure


HiDe

2

. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView via a daisy-chained RS-485 port. If at any time during system initialization


28


DeScriPtioN


Active Fault Codes

1


5

. The display will return to the single or four parameter display, but the display will contain the "Active Fault"warning icon. Pressing the "Enter

Button" will redisplay the hidden fault.

0 eNG rPm

1500 3000


98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

0 1500 eNG rPm

3000


!

!

98% loaD@rPm

14.2

bat Volt

!


57 PSi oil PreS

!

2

. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the "Active

Fault Codes" message.

1 of x warNiNG

SPN110 fm

I0


6

. Pressing the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

1 of x warNiNG

SPN110 fm

I0


3

. If the word "MORE" appears above the "Arrow Buttons" there are

Use the "Arrow Buttons" to scroll to the next "Active Fault Code"

1 of x

7

. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.





98% loaD@rPm

14.2

bat Volt

!


57 PSi oil PreS

!

more HiDe

4


1 of x

Shutdown Codes

1


98% loaD@rPm


0 1500 3000


14.2

bat Volt

57 PSi oil PreS more HiDe

2

. When the PowerView receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the

"Shutdown!" message.

1 of x

SHutDowN

SPN110 fmI0




29

SectioN 2

1 of x


3


SHutDowN

SPN110 fm10


2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Adjust Backlight" is highlighted.





Select uNitS

4

. The display will return to the single or four parameter display, but the display will contain the "Shut Down" icon. Pressing the "Enter

Button" will redisplay the hidden fault.

0 1500 3000

1800 rPm eNG rPm cool temP !

!

98% loaD & rPm

14.2

bat Volt

!


57 PSi oil PreS

3

. Once the "Adjust Backlight" menu item has been highlighted press the "Enter Button" to activate the "Adjust Backlight" function.






5

. Pressing the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

1 of x

SHutDowN

SPN110 fm10


4

. Use the "Arrow Buttons" to select the desired backlight intensity.

aDJuSt backliGHt

6

. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

!

0 1500 eNG rPm

3000

1800 rPm cool temP !

98% loaD & rPm

14.2

bat Volt

!


57 PSi oil PreS

!

5


aDJuSt backliGHt

30

Back Light Adjustment

1

. Starting at the single or four engine parameter display press the

"Menu Button".

98% loaD@rPm


0 1500 eNG rPm

3000


14.2

bat Volt

57 PSi oil PreS

6



98% loaD@rPm





14.2

bat Volt

57 PSi oil PreS



DeScriPtioN

0 1500 eNG rPm

3000



Contrast Adjustment

1


"Menu Button".

98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

6






98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until "Adjust Contrast" is highlighted.






Select Units

1


"Menu Button".

98% loaD@rPm


0 1500 eNG rPm

3000


14.2

bat Volt

57 PSi oil PreS

3

. Once the "Adjust Contrast" menu item has been highlighted press the "Enter Button" to activate the "Adjust Contrast" function.




Select uNitS aDJuSt backliGHt aDJuSt coNtraSt

2

. The main menu will pop up on the display. Use the arrow buttons to scroll through the menu until the "Select Units" is highlighted.





Select uNitSD aDJuSt backliGHt

4

. Use the "Arrow Buttons" to select the desired contrast intensity.

aDJuSt coNtraSt

3

. Once the "Select Units" menu item has been highlighted press the

"Enter Button" to access the "Select Units" function.






5


aDJuSt coNtraSt

4

. Use the arrows to highlight the desired units. "English" for Imperial units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC.

eNGliSH metric kPa metric bar

PV-02124N page 10 of 17


31

SectioN 2 eNGliSH metric kPa metric bar


5

. Press the "Enter Button" to select the highlighted units.

3

. Once the "Setup 1-up Display" menu item has been highlighted press the "Enter Button" to access the "Setup 1-up Display" function.






6

. Press the "Menu Button" to return to the "Main Menu".

eNGliSH metric bar

7





98% loaD@rPm

14.2

bat Volt


57 PSi oil PreS

4

. Three options are available for modification of the 1-Up display.

a)

.

Use Defaults

– This option contains a set of engine parameters:

Engine Hours, Engine RPM, System Voltage, Battery Voltage, %

b)

Engine Load at Current RPM, Coolant Temperature, Oil Pressure.

.

Custom Setup

– This option allows for the modification of what parameter, the number of parameters, and the order in which the parameters are being displayed.

c)

.

Automatic Scan

– Selecting the scan function will cause the

1-Up Display to scroll through the selected set of parameters one at a time, momentarily pausing at each.

5

. Use Defaults - To select "Use Defaults" use the arrow buttons to scroll to and highlight "Use Defaults" in the menu display.

uSe DefaultS cuStom SetuP automatic ScaN off

Setup 1-Up Display

1

. Starting at the single engine parameter display press the "Menu Button".

98% loaD@rPm


0 1500 eNG rPm

3000


14.2

bat Volt

57 PSi oil PreS

6

. Press the "Enter Button" to activate the "Use Defaults" function.

uSe DefaultS automatic ScaN off

7

. A message indicating the “Single Engine” parameter display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu.

2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 1-up Display" is highlighted.





Select uNitSD aDJuSt backliGHt reStoreD to

DefaultS

32

PV-02124N page 11 of 17


DeScriPtioN


8

. Custom Setup - To perform a custom setup of the 1-Up Display use the arrow buttons to scroll to and highlight "Custom Setup" on the display.


13

. Press the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.

eNGiNe SPeeD

PerceNt loaD at curreNt rPm 2 eNGiNe oil PreSSure 1 eNGiNe coolaNt temP 3

9

. Pressing the "Enter Button" will display a list of engine parameters.


14

. Continue to scroll and select additional parameters for the custom

1-Up Display. Press the "Menu button" at any time to return to the "Custom

Setup" menu.

10

. Use the "Arrow Buttons" to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).

eNGiNe SPeeD 1

PerceNt loaD at curreNt rPm 3 eNGiNe oil PreSSure 2 eNGiNe coolaNt temPerature

This number indicates the order of display for the parameters and that the parameter is selected for display.

15

. Automatic Scan - Selecting the scan function will cause the 1-

Up Display to scroll through the selected set of parameters one at a time.

Use the "Arrow Buttons" to scroll to the "Automatic Scan" function.

uSe DefaultS cuStom SetuP

16

. Pressing the "Enter Button" toggles the "Automatic Scan" function on.


11

. Press the "Enter Button" to diselect the selected parameter removing it from the list of parameters being displayed on the 1-up display.

eNGiNe SPeeD 1

PerceNt loaD at curreNt rPm 3 eNGiNe oil PreSSure 2 eNGiNe coolaNt temPerature

17

. Pressing the "Enter Button" again toggles the "Automatic Scan" function off.


12

. Use the "Arrow Buttons" to scroll and highlight the desired parameter that has not been selected for display.

eNGiNe SPeeD

PerceNt loaD at curreNt rPm 2 eNGiNe oil PreSSure 1 eNGiNe coolaNt temP

Note that the numbers now indicate the new order of display for the parameters.

PV-02124N page 12 of 17


33

SectioN 2

18

. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set press the "Menu Button" to return to the main menu.



4

. Press the "Enter Button" to activate the "Use Defaults" function. This action will reset the unit to the factory default.


19





0 eNG rPm

1500 3000


5

. The "Use Defaults"screen will be displayed during the reseting period then will automatically return to the "Setup 4-Up Display" menu.

reStoreD to

DefaultS

34

Setup 4-Up Display

1

. From the single or four engine parameter display press the "Menu Button".

98% loaD@rPm


0 1500 eNG rPm

3000


14.2

bat Volt

57 PSi oil PreS

6

. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.


2

. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 4-Up Display" is highlighted.





7

. The quadrent with the backlit parameter value is the current selected parameter. Use the "Arrow Buttons" to highlight the parameter value in the quadrant you wish to place a new parameter.

125°f cool temP

14.2

bat Volt


57 PSi oil PreS

P

3

. Once the "Setup 4-Up Display" menu item has been highlighted press the "Enter Button" to activate the "Setup 4-Up Display" menu.





8

. Press the "Enter Button" and a list of parameters will appear.


14.2

bat Volt


57 PSi oil PreS

P

PV-02124N page 13 of 17


DeScriPtioN


9

. The parameter that is highlighted is the selected parameter for the screen. Use the "Arrow Buttons" to highlight the new parameter to be placed in the quadrent selected in the previous screen.

eNGiNe SPeeD 3 eNGiNe HourS eNGiNe coolaNt temPerature 1 batterY PoteNtial eNGiNe oil temPerature

2 eNGiNe oil PreSSure 4

The number to the right of the parameter indicates the quadrant in which it is displayed.

1. = Upper Left Quadrent

2. = Lower Left Quadrent

3. = Upper Right Quadrent

4.= Lower Right Quadrent

15







125% cool temP

143°f oil temP


57 PSi oil PreS

10

. Press the "Enter Button" to change the selected parameter in the quadrant to the new parameter.

eNGiNe SPeeD 3 eNGiNe HourS eNGiNe coolaNt temPerature 1 batterY PoteNtial 2 eNGiNe oil temPerature eNGiNe oil PreSSure 4

Utilities

(Information and troubleshooting)

1

. Starting at the single or four engine parameter display, press the “Menu button”.

125% cool temP


0

1500 3000


143°f oil temP

57 PSi oil PreS

11

. Use the "Menu Button" to return to the “4-UP Custom Setup” screen.

eNGiNe SPeeD 3 eNGiNe HourS eNGiNe coolaNt temPerature 1 batterY PoteNtial eNGiNe oil temPerature 2 2 eNGiNe oil PreSSure 4

Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location.

2

. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted.




Select uNitS aDJuSt backliGHt utilitieS

12

. The parameter in the selected quadrent has changed to the parameter selected in the previous screen.


143°f oil temP


57 PSi oil PreS

P

3

. Once the “Utilities” menu item has been highlighted, press the “Enter

Button” to activate the “Utilities” functions.





13

. Repeat the parameter selection process until all spaces are filled.

14



143°f oil temP


57 PSi oil PreS

P

4

. Press "Select" to enter the “Gages Data” display. When “Gage Data” is selected the PowerView will communicate with the analog gages at a fixed rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.

GaGe Data remoVe all GaGeS

Software VerSioN fault coNVerSioN

PV-02124N page 14 of 17


35

SectioN 2


5

. Use the “Arrow buttons” to scroll through the items or press “Menu” to return to the “Utilities” menu.

6

1 of x eNGiNe oil PreSSure aDDreSS: 20

Software reViSioN #: errorS: NoNe

. Press “Menu Button” to return to the “Utilities” menu.

11

. Using the “Arrow” buttons scroll to highlight the version to be selected. Press the“Select” button to select the version. Note that an asterisks appears to the right of the selection.

NOTE: There are four (4) different methods for converting fault codes.

The PowerView always looks for J1939 Version 4 and can be set to use one of the three (3) other J1939 versions. Most engine ECU’s use

Version 4, therefore in most cases adjustment of this menu option will not be required.

Upon receiving an unrecognizable fault, change to a different J1939

Version. If the fault SPN does not change when the version is changed, the

ECU generating the fault is using Fault Conversion method 4. If the SPN number does change but is still unrecognizable, try changing to another

J1939 Version not yet used and continue to check the SPN number.

1 of x eNGiNe oil PreSSure aDDreSS: 20

Software reViSioN #: errorS: NoNe

J1939 VerSioN 1

J1939 VerSioN 2

J1939 VerSioN 3

*

7

. Use the “Arrows” to highlight “Remove All Gages”. Press “Select” to clear gage data from memory. It takes a moment to clear all gages.

cleariNG GaGeS

PleaSe wait

12

. Press the “Menu” button to return to “Utilities” menu. Press the

“Menu” button again to to return to the “Main” menu.





8

. When the gage data has cleared, the display automatically returns to the “Utilities” menu. Scroll to “Software Version”. Press “Select” to view the software version currently in the PowerView.

Software

VerSioN murPHY: x.xx

9

. Press “Menu” to return to “Utilities”. Highlight “Fault Convertion” using the “Arrows”. Press “Select” to enter the Fault convertion menu.

GaGe Data remoVe all GeS

Software VerSioN fault coNVertioN

36

PV-02124N page 15 of 17


2.9 wiriNG DiaGram

DeScriPtioN


37

SectioN 2

2.10 electrical SYStem, fuNctioNal DeScriPtioN

The electrical system consists of the basic electrical elements required to operate the compressor and also has a system feature that automatically shuts down the compressor when a malfunction occurs. The system’s components include: an engine starter, battery, alternator/ voltage regulator, and a fuel solenoid. It also has a compressor discharge temperature switch that will shut the compressor down if the compressor temperature exceeds

250° F (121° C). It has an engine water temperature switch set to shut down the compressor when the coolant temperature reaches 234° F (112° C) and an oil pressure switch that will shut down the compressor if the engine oil pressure goes too low. An underspeed sensor shuts down the compressor if the engine speed falls below 1500 rpm and a low fuel level switch shuts down the engine when fuel level is low to prevent running the engine dry (out of fuel). The engine is also equipped with an ECM (electronic control module).

2.11 comPreSSor SHutDowN

& warNiNG SYStem, fuNctioNal DeScriPtioN

•

•

•

•

The Shutdown System and Annunciator Module (SSAM) continuously monitors the status of the compressor. In the event of a shutdown condition, the SSAM will shut down the compressor and display (flashing) the appropriate code on the instrument panel annunciator light. The display will continue flashing until the ignition switch is turned OFF. The shutdown codes are:

• One flash: high compressor discharge temperature

Two flashes: high engine coolant temperature

Three flashes: low engine oil pressure

Four flashes: low engine speed

Five flashes: low fuel level

The SSAM also provides startup logic for the compressor.

When the ignition switch is in the ON position, the annunciator light will illuminate for 30 seconds. During this

30 second period, pressing the ignition switch will engage the engine starter. The low engine speed switch is inactive during this startup time interval. By the end of these 30 seconds, the annunciator light goes out and the engine

START cycle is disabled. At this time the system runs all safety checks including low fuel level.

The engine is equipped with an electronic speed control and has a shutdown protection/diagnostic capability. A variety of sensors and a speed control module interface with the ECM. These sensors include the following: oil pressure, coolant temperature, intake manifold, fuel temperature, timing cranking; and a remote shutdown switch. The engine speed control module consists of the module and a pressure transducer. The pressure transducer senses the compressor control pressure and as the control pressure increases, the speed control module decreases the engine speed by lowering the output voltage to the ECM.

38


DeScriPtioN

2.12 aftercooleD aND filtereD air SYStem, fuNctioNal

DeScriPtioN

Refer to Figure 2-3. The purpose of the aftercooled system is to operate the air compressor in conditions when compressed air temperature is required to be within 20° to

25°F (13° to 17°C) of the ambient temperature.

A selector valve is provided on all aftercooled compressors. Choosing the aftercooled air completely forces the airflow from the receiver tank to the aftercooler.

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 condensation is removed from the cooler air 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 air enters the (optional) first stage filter. Particles and additional water are removed from the first stage filter. the condensate should be

drained and stored in a suitable container. From the first stage filter, the air enters the (optional) second stage filter. This filter removes smaller particles and any additional water. the condensate should be drained

and stored in a suitable container. Upon compressor shutdown, the filters will drain to clear the condensate from the system. This will prevent freezing in cold conditions.

Note

the aftercooler system should not be operated when the ambient temperature is below 32°f (0°c). to operate in the non-aftercooled mode close the aftercooler selector valve completely.


39

SectioN 2

2.13 liStiNG of DiaGNoStic coDeS

Note

in some cases there are differences between J1939SPN and cDl codes

(those normally viewed on the service tool).

Trouble Codes

type ciD/eiD J1939SPN fmi

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Event

Event

Event

Event

Event

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Event

Event

Diagnostic

91

91

774

91

774

91

774

91

774

100

100

100

360

360

360

539

539

172

172

1785

1785

1785

361

361

110

91

91

91

91

91

91

91

91

91

100

100

100

100

100

100

105

105

105

105

106

106

106

110

100

100

15

16

3

17

18

1

15

3

4

10

2

3

3

12

12

4

4

8

8

16

3

4

3

4

10

lamp flash code

(future)

154

154

155

154

155

154

155

154

155

157

157

157 n/a n/a n/a n/a n/a

133

133

135

135

135 n/a n/a

169

component Description

Throttle Position Sensor


Secondary Throttle Position

Sensor



Sensor


Data Erratic, Intermittent, or Incorrect

Voltage Above Normal or Shorted High


Voltage Below Normal or Shorted Low



Sensor



Sensor

Engine Oil Pressure Sensor






Inlet Manifold Air Temp

Sensor

Abnormal Frequency, Pulse Width, or

Period

Abnormal Frequency, Pulse Width, or

Period

Bad Device or Component

Bad Device or Component



Engine Oil Pressure Sensor 5V

Supply Connection Circuit Open

Low Oil Pressure - WARNING

Low Oil Pressure - DERATE

Low Oil Pressure - SHUTDOWN

High Intake Manifold Pressure -

WARNING


Sensor


Sensor


Sensor

Inlet Manifold Pressure

Sensor

High Intake Manifold Pressure -

DERATE





Sensor


Sensor


Inlet Manifold Pressure Sensor 5V

Connection Circuit Open

Engine Coolant Temp Sensor High Coolant Temp - WARNING

Engine Coolant Temp Sensor High Coolant Temp - DERATE

Engine Coolant Temp Sensor Voltage Above Normal or Shorted High

40


DeScriPtioN type

Event

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Event

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

ciD/eiD J1939SPN fmi

361

110

1797

268

6

6

5

5

6

4

5

4

4

41

3

3

2

3

2

2

1

1

253

247

526

526

526

1

1797

1834

168

168

168

190

362

91

774

110

110

157

630

655

655

656

656

656

654

654

654

655

678

652

653

653

653

651

651

652

652

631

639

646

646

646

651

157

158

168

168

168

190

190

588

558

5

6

6

7

7

7

5

5

6

3

6

7

7

5

5

6

6

7

5

6

2

9

7

5

2

8

15

0

1

4

2

2

2

0

4

3

2 n/a

439

422

422

422

141 n/a

154

155 n/a n/a n/a n/a n/a n/a n/a n/a n/a

517 n/a n/a n/a n/a n/a n/a n/a n/a

415

514

177

177

177 n/a

lamp flash code

(future)

n/a

169 n/a

527

component Description

Engine Coolant Temp Sensor High Coolant Temp - SHUTDOWN

Engine Coolant Temp Sensor Voltage Below Normal or Shorted Low

Fuel Rail Pressure Sensor

Fuel Rail Pressure Sensor

Keyswitch

ECM Battery Power

ECM Battery Power

ECM Battery Power

Speed/Timing Sensor

Engine Speed

Voltage Above Normal or Shorted

Low


Data Erratic, Intermittent, or Incorrect

Excessive Battery Power

Low Battery Power

Intermittent

Abnormal Signal Frequency

Engine Overspeed - WARNING

Throttle Position Switch


Switch

Customer or System

Parameters

Engine Software

SAE J1939 Data Link

Turbo Wastegate

Turbo Wastegate

Turbo Wastegate

Cylinder #1 Injector


















8V DC Supply

Idle Validation Switch

Data Erratic, Intermittent, or

Abnormal

Data Incorrect

Data Incorrect

Abnormal Update

Solenoid Current Low

Solenoid Current High

Turbo Wastegate Not Responding

Injector Current Low

Injector Current High

Injector Not Responding
















ECM 8V DC Supply - Voltage Above

Normal or Shorted High


41

SectioN 2 type ciD/eiD J1939SPN fmi

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

Diagnostic

41

342

262

262

261

1779

1779

1779

2246

2246

678

723

1079

1079

637

1347

1347

1347

676

676

4

8

7

5

5

6

6

3

4

11

lamp flash code

(future)

517

component

8V DC Supply

142

516

516

143

162

162

162

199

199

Secondary Engine Speed

Sensor

5V DC Supply Sensor

5V DC Supply Sensor

Primary to Secondary Speed

Sig.

Fuel Rail Pump

Fuel Rail Pump

Fuel Rail Pump

Glow Plug Start Aid Relay

Glow Plug Start Aid Relay

Description

ECM 8V DC Supply - Voltage Below

Normal or Shorted Low

Abnormal Signal Frequency



Calibration Fault

Output Current Low

Output Current High

Not Responding

Current Low

Current High

42


DeScriPtioN

2.14 oPeratioN of tHe iNDicator lamPS

warning lamp

(alert lamp)

On

Stop lamp

(action lamp)

On

lamp State Description of the indication

Off

On

On

Flashing

Flashing

On

Off

Off

Flashing

Off

Flashing

On

engine State

Lamp Check

No Faults

Active Diagnostic

Derate (A derate is caused by certain active codes.)

Warning

(Warning only)

Derate

(Warning and Derate)

Engine Shutdown

When the engine switch is moved to the ON position, the lamps come on for a period of 2 seconds and the lamp will then go off.

With the engine in operation, there are no active warnings, diagnostic codes or event codes

If the warning lamp comes on during engine operation, this indicates that an active diagnostic code (an electrical fault) is present.

If the warning lamp comes on and the stop lamp flashes during engine operation, this indicates that an active diagnostic code (an electrical fault) is present. The diagnostic is sufficiently serious in order to cause an engine derate.

When the warning lamp flashes during operation of the engine, the lamp indicates that one or more of the warning values for the engine protection strategy has been exceeded. However, the value has not been exceeded to a level that will cause a derate or a shutdown.

If both the warning lamp and stop lamp flash during operation of the engine, the lamps indicate that one or more of the values for the engine protection strategy have been exceeded beyond the level that will cause an engine derate.

If both the warning lamp and the stop lamp come on during engine operation, this indicates one of the following conditions.

1.

2.

One or more of the shutdown values for the engine protection strategy has been exceeded.

A serious active diagnostic code has been detected.

After a short period of time, the engine will shut down.

The engine switch is in the ON position but the engine has not yet been cranked.

The engine is operating with no detected faults.

The engine is operating normally but there is one or more faults with the electronic management system for the engine.

The engine is operating but there is one or more active diagnostic codes that have initiated an engine derate.

The engine is operating normally. However, there is one or more of the monitored engine parameters that are outside of the range that is acceptable.

The engine is operating.

However, one or more of the monitored engine parameters is outside of the acceptable range.

The acceptable range has been exceeded to a level which requires a warning and an engine derate.

The engine is either shutdown or an engine shutdown is imminent.

One or more monitored engine parameters have exceeded the limit for an engine shutdown.

This pattern of lamps can be caused by the detection of a serious active diagnostic code.


43

SectioN 2

2.15 flaSH coDeS

The “Flash Code” feature is used to flash the code of all active diagnostic codes and logged diagnostic codes. The sequence for the flash code is started by moving the engine switch to “Off” and then move the engine switch to

“On” twice within a period of three seconds. After a delay of 2 seconds, the “Stop” lamp will flash once for a period of half a second. This sequence indicates the start of the active fault codes. After a further delay of 2 seconds, the

“Warning” lamp will flash repeatedly in order to indicate the active diagnostic codes. Each flash will be on for half a second and off for 300 milliseconds. The “Warning” lamp will remain off for 2 seconds between each digit of a code.

If there is more than one active diagnostic code, the “Stop” lamp will go off for 2 seconds. The lamp will then come on for a period of half a second. The “Warning” lamp will go off for a period of 2 seconds before starting the next code.

If there are no active diagnostic codes, the “Warning” lamp will flash the code “551”. Refer to Troubleshooting Guide,

“No Diagnostic Code Detected”. As an example, an active diagnostic code of “21” is indicated by the “Warning” lamp coming on for 500ms, then off for 300 ms, the on for 500 ms, then off for 2000 ms, then on for 500 ms and then off.

After all the active diagnostic codes have been displayed, the “Stop” lamp will go off for 2 seconds. The “Stop” lamp will flash twice in order to indicate the start of the sequence that will display the logged diagnostic codes.

The process for flashing logged diagnostic codes is identical to the process for flashing active diagnostic codes.

After all of the codes have been displayed, the “Stop” lamp will flash 3 times in order to indicate that there are no further codes. Cycling the engine switch twice within a period of 3 seconds will start the process again. All codes will be displayed in ascending numerical order.

Refer to the listing of “Diagnostic Codes” for the diagnostic code that relates to the flash code.

Note

flash codes are always sent in ascending numerical order.

Note

if there are no logged codes then the

“551” code should be flashed again.

44

Engine Shutdown Lamp ON

Engine Shutdown Lamp OFF

Active Codes

0.5

“Warning” Lamp ON

“Warning” Lamp OFF

Flash code 21

0.5

0.3

0.5

2.0

0.5

Note: Times shown in seconds

Inactive Codes

0.5

0.5


Section 3

SPecificatioNS

3.1

SPecificatioNS – 300HH aND 375 caterPillar

model Series in length (i) mm

300HH, and 375

2-Wheel

156.2

3967.5

300HH, and 375

Less Running Gear

98.8

(l) Length over drawbar for 2 – wheel version

*add 115 lbs (52 kg) for aftercooled Version

2509.5

DimeNSioNS width in mm

77.2

59.3

1960.9

1506.2

in

74.0

63.6

Height mm

1879.6

1615.4

comPreSSor

Type

300HH

Rotary Screw

Maximum Operating Pressure 200 psig (13.8 bar)

Pressure Delivery 300 Free CFM

(142 L/S)

Rated Pressure 200 psig (13.8 bar)

Rotary Screw

375

125 psig (8.6 bar)

375 Free CFM

(177 L/S)

100 psig (6.9 bar)

Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid

Lubricating Compressor Fluid See Table 1 See Table 1

Sump Capacity 7 US gallons

(26.5 liters)

7 US gallons

(26.5 liters)

Track Width

Tire Size (Load Range)

67.5"

(1714.5 mm)

H78 x 15ST (D)

67.5"

(1714.5 mm)

H78 x 15ST (D)

Tire Pressure

Wheel Size

Lug Nut Torque

Operating Tilt (maximum)

Electrical System

Compressor Discharge

Temperature

Service Valves

Maximum Towing Speed

Axle Rating

Sound Level

65 psig (4.4 bar)

15 x 6JJ

60 ft-lbs (81 Nm)

15°

12 volt

Shutdown 250°F (121°C)

(2) ¾"

55 mph (88 kmph)

5000 lbs

(2268 kg)

76 dBA at 7 m

65 psig (4.4 bar)

15 x 6JJ

60 ft-lbs (81 Nm)

15°

12 volt


(2) ¾"

55 mph (88 kmph)

5000 lbs

(2268 kg)

76 dBA at 7 m

weight (wet) lb kg

4420* 2004.9*

4175* 1893.8*


45

SectioN 3 eNGiNe:

Type

Make

Model

Displacement

Cylinders

Bore x Stroke

Rated Speed

Rated Power

Type of Motor Oil

Fuel Tank Capacity

Radiator Capacity

Engine Water Temperature

Minimum Idle Speed

Alternator Rating

300HH

Diesel

Caterpillar

C4.4

268 cu/in (4.4L)

4

375

Diesel

Caterpillar

C4.4

268 cu/in (4.4L)

4

4.13 x 5.00

(105 mm x 127 mm)

2200 rpm

130HP/97kW

4.13 x 5.00

(105 mm x 127 mm)

2200 rpm

117HP/87kW

See engine operator manual See engine operator manual

56 gallons

(212 liters)

56 gallons

(212 liters)

4 gallons (15 liters)


1600 rpm (ii)

65 amp



1600 rpm (ii)

65 amp

(ii) Do 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 shutdown the compressor if engine speed falls below 1500 rpm.

3.2

SPecificatioNS – 375H aND 425 caterPillar

model Series in length (i) mm

375H and 425

2-Wheel

156.2

3967.5

375H and 425

Less Running Gear

98.8

(l) Length over drawbar for 2 – wheel version

*add 115 lbs (52 kg) for aftercooled Version

2509.5

DimeNSioNS width in mm

77.2

59.3

1960.9

1506.2

in

74.0

63.6

Height mm

1879.6

1615.4

comPreSSor

Type

375H

Rotary Screw

Maximum Operating Pressure 150 psig (10 bar)

Rotary Screw

425

125 psig (8.6 bar)

Delivery

Rated Pressure

Cooling

Track Width

375 Free CFM

(177 L/S)

150 psig (10.3 bar)

Lubricating Compressor Fluid See Table 1

Sump Capacity 7 US gallons

(26.5 liters)

425 Free CFM

(201 L/S)

100 psig (6.9 bar)

Pressurized Compressor Fluid Pressurized Compressor Fluid

See Table 1

7 US gallons

(26.5 liters)

Tire Size (Load Range)

Tire Pressure

67.5"

(1714.5 mm)

H78 x 15ST (D)

65 psig (4.4 bar)

67.5"

(1714.5 mm)

H78 x 15ST (D)

65 psig (4.4 bar)

Wheel Size

Lug Nut Torque

Operating Tilt (maximum)

15 x 6JJ

60 ft-lbs (81 Nm)

15°

15 x 6JJ

60 ft-lbs (81 Nm)

15°

weight (wet) lb kg

4420* 2004.9*

4175* 1893.8*

46


Electrical System 12 volt

Compressor Discharge Temp Shutdown 250°F (121°C)

Service Valves (2) ¾"

Maximum Towing Speed

Axle Rating

Sound Level

55 mph (88 kmph)

5000 lbs

(2268 kg)

76 dBA at 7 m

eNGiNe:

Type

Make

Model

Displacement

Cylinders

Bore x Stroke

Rated Speed

Rated Power

Type of Motor Oil

Fuel Tank Capacity

Radiator Capacity

Engine Water Temperature

Minimum Idle Speed

Alternator Rating

Diesel

Caterpillar

375H

C4.4

268 cu/in (4.4L)

12 volt


(2) ¾"

55 mph (88 kmph)

5000 lbs

(2268 kg)

76 dBA at 7 m

425

Diesel

Caterpillar

C4.4

268 cu/in (4.4L)

4

4.13 x 5.00

(105 mm x 127 mm)

2200 rpm

4

4.13 x 5.00

(105 mm x 127 mm)

2200 rpm

130HP/97kW 130HP/97kW

See engine operator manual See engine operator manual

56 gallons

(212 liters)

56 gallons

(212 liters)



1600 rpm (ii)

65 amp



1600 rpm (ii)

65 amp

(ii) Do 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 shutdown the compressor if engine speed falls below 1500 rpm.

SPecificatioNS


47

SectioN 3

3.3 lubricatioN GuiDe – comPreSSor

fluiD tYPe cHaNGe PerioD/HourS

Sullair AWF (I)

SAE 10W SE, SF, SG, CD

MIL-L-2104E 10W

1500

250

250

ambieNt temPerature raNGe °f (°c)

-20 to 120 (-29 to 49)

0 to 100 (-18 to 38)

0 to 100 (-18 to 38)

(i) Sullair part numbers for Sullair AWF are 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon drum/208 liters).

3.4 aPPlicatioN GuiDe

Sullair air compressors are supplied with Sullair AWF which is a heavy duty multi-viscosity, all weather fluid which provides an extended change interval when compared to other fluids. Detergent motor oils (SAE 10W

Class SE, SF, SG, or CD) can also be used. Any of these oils are suitable under conditions where severe oil oxidation can occur.

Water must be drained from the receiver tank periodically.

In high ambient temperature and humidity conditions, condensed moisture can emulsify with the oil forming a

“milky” color. SAE 10W is especially prone to this condition. The fluid should be changed if this condition develops. DO NOT mix different fluids. Combinations of different fluids can lead to operational problems such as foaming, plugged filters, blocked orifices or lines.

When ambient conditions exceed the recommended ranges, or if other conditions warrant the use of other extended life lubricants, contact your local Sullair representative for recommendations.

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.

Sullair Corporation offers a fluid analysis for Sullair AWF.

Contact Sullair for details.

D-A Lubricant® Company Inc. offers an analysis for users of Sullair AWF. Contact your Sullair representative for details.

3.5 lubricatioN GuiDe – eNGiNe

Refer to the engine operator’s manual for oil specifications.

1.

2.

3.

Fluid Fill Port

Sight Glass

Sump Tank

Figure 3-1

SU_0000699

Note

Proper compressor fluid level

Visible halfway in fluid sight glass when checked on a level surface with the compressor not running.

48


Section 4

GeNeral

4.1

GeNeral

While Sullair has built into this compressor a complete set of controls and indicators that allow the operator to control and monitor the compressor’s operation and performance.

Operators should learn to recognize indications which identify a service requirement or conditions that could lead to (or show) a (current) malfunction. Before starting the compressor, read this section thoroughly to gain familiarity with the controls and indicators – their function and location.

4.2

PurPoSe of coNtrolS

Control or Indicator Purpose

Engine Switch

Press this switch to the ON (ignition) position to energize the electrical system of the compressor. Press the switch to the START position to momentarily engage the starter and start the compressor. Press the switch to the OFF position to shut the compressor down. This switch is located on the instrument panel.

Emergency Stop Switch

Press in case of emergency when immediate shutdown is required.

Pressure Transducer

Monitors the system control pressure.

Speed Module

Monitors the pressure transducer output and determines the appropriate speed signal for the engine.

Air Pressure Gauge

Continuously monitors the pressure inside the receiver sump at various load and unload conditions.

Fluid Sight Level Glass

Indicates the fluid level in the sump. Proper level is marked halfway up the sight glass. Check the level when the compressor is shutdown and on level ground.

Compressor Discharge Temperature Switch

Opens the electrical circuit to shut down the compressor when the discharge temperature reaches a specific value

(See Specifications on page 53 and on page 55).

Thermal Valve

Functions as a temperature regulator by directing the compressor fluid either to the cooler or to the compressor unit.

Minimum Pressure Device

Maintains the minimum of 80 psig (5.6 bar) in the compressor sump.


Vents sump pressure to the atmosphere if pressure inside the sump exceeds 250 psig (17.3 bar).

Air Inlet Valve

Regulates the amount of air allowed to enter the air compressor inlet. Regulation is determined by a signal from the pressure regulator(s).

Pressure Regulator(s)

Allows the pressure signal to reach the engine speed transducer and the air inlet valve to control air delivery according to demand.

Discharge Air Filter Differential Pressure Gauge

(Optional Aftercooled and Filtered Models Only)

Monitors the air filter (first and second stage) condition. A reading over 10 psig (0.7 bar) in the red zone indicates the air filters require servicing.

Shutdown System/Annunciator Module (SSAM)


49

SectioN 4

Monitors the compressor safety system for conditions requiring shutdown. The annunciator on the instrument control will flash the applicable shutdown code.

Blowdown Valve

Vents sump pressure to the atmosphere at shutdown.

Idle Warm-Up Control

Keeps the compressor inlet valve closed for reduced compressor load at start-up. When the compressor is warmed-up, the handle is turned from the START to the

RUN position for full operation.

Pressure Selector Switch (H and HH Models)

Sets compressor operation in the LOW range from 80 to

110 psig (5.6 to 7.6 bar), or in the HIGH range from 80 to

165 psig (5.6 to 11.4 bar) on H models, and from 80 to 220 psig (5.6 to 15.2 bar) on HH models.

4.3 iNitial StartuP/SHutDowN

ProceDure

Startup

Perform the following actions when starting the compressor for the first time:

1. Ensure that the compressor is on a level surface. (If the compressor is on an uneven surface, the fluid

4.

5.

6.

2.

3.

7.

8.

Check the oil and fluid levels in the engine and compressor: add oil and/or fluid if necessary.

Fill the fuel tank and drain any water from the fuel/ water separator.

Crack open one service line.

Place the WARM-UP control in the START position.

Place the PRESSURE SELECTOR switch to the LOW position (H and HH models).

Press the ENGINE SWITCH to the ON position.

When glow plugs are required, when the engine start switch is pressed on the ON position, the amber “Wait to Start” warning lamp will light. Leave the engine switch in the ON position until the warning light for the glow plugs is extinguished.

9.

START position to engage the starter: release the switch when the engine starts.

10.

30 seconds) Turn the IDLE WARM-UP SWITCH from

START to RUN to put the compressor in full operation.

11. Close all doors to maintain proper noise level.

(i) The radiator is filled with a 50/50 mixture of ethylene glycol and water. All engines receive Supplemental Coolant Additive

operator’s manual for specific requirements.

Shutdown

1.

2.

3.

Close the service valves and run the compressor for approximately five minutes to allow the compressor to cool down.

Place the pressure selector switch in the low position

(H and HH models).

Press the ENGINE SWITCH to the OFF position after five minutes. When an emergency shutdown is required, IMMEDIATELY press the EMERGENCY

SHUTDOWN BUTTON.

4.4 reStart ProceDure

After running and shutting down the compressor for the first time, perform the following actions when restarting the compressor:

3.

4.

5.

6.

1.

2.

7.

8.

9.

Check engine oil, engine coolant, and fuel levels.

Check the compressor fluid level (sight glass) and drain any water from the fuel/water separator.

Check the dust collectors and clean if necessary.

Crack open the service valve.

Place the WARM-UP control in the START position.

Place the PRESSURE SELECTOR switch to the LOW position (H and HH models).

Press the ENGINE SWITCH to the ON position.

When glow plugs are required, when the engine start switch is pressed on the ON position, the amber “Wait to Start” warning lamp will light. Leave the engine switch in the ON position until the warning light for the glow plugs is extinguished.

Momentarily press the ENGINE SWITCH to the

START position to engage the starter: release the switch when the engine starts.

10.

11.

12.

After 30 seconds (the annunciator light will go off after

30 seconds) Turn the IDLE WARM-UP SWITCH from

START to RUN to put the compressor in full operation.

Close all doors to maintain proper noise level.

To shut down the compressor, see

Shutdown on page 58.

warNiNG

Do Not use aerosol types of starting aids such as ether.

Such use could result in an explosion and personal injury.

if the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again.

50


Section 5

maiNteNaNce

warNiNG

Do Not remove caps. Plugs and/or other components when the compressor is running or pressurized. Shutdown the compressor before removing any components.

5.1

GeNeral

Consistent and correctly performed maintenance will ensure the compressor’s performance and extend its operational life. See Part Replacement and Adjustment

Procedures on page 61

for a detailed description of specific compressor components. Before performing maintenance actions, read the CIMA Safety Manual, if applicable. For engine maintenance requirements and procedures, refer to the engine operator’s manual.

5.2

DailY maiNteNaNce

See Initial Startup Shutdown/Procedure on page 58 for general operation.

Note the radiator and engine cooling system must be drained and flushed every 1500 hours. replace the solution coolant with a 50% ethylene glycol and 50% water solution or as required for local climatic conditions.

Do Not use a leak-sealing type antifreeze. all engines must have

Supplemental coolant additive (Sca) added to the engine coolant system. refer to the engine operator’s

Manual for specific requirements.

If fluid must be added too frequently at startup, a problem might have developed causing an excessive fluid loss. See Trouble Shooting on page

68

(excessive fluid consumption) for a probable cause and remedy. after the compressor has warmedup, make a general inspection of its components and instrument panel to ensure that the compressor is running properly.

Note

Dispose of fluids in accordance with applicable federal, state and local regulations.


51

SectioN 5

5.3 maiNteNaNce after iNitial 50

HourS of oPeratioN

1.

2.

3.

After the initial 50 hours of operation, the following maintenance actions are required to eliminate contaminants from the system:

4.

5.

Clean the return line orifice and change the strainer.

Change the compressor fluid filter.

Check the engine operator’s manual for service requirements.

Check the fuel filter for water.

Confirm that the sump cover bolts are tightened to 160 lb-ft (215N•m).

5.4

1.

2.

5.5 maiNteNaNce eVerY 50

HourS

Inspect air filter elements and replace if necessary.

Check the fuel filter for water.

maiNteNaNce eVerY 100

HourS

After 100 hours of operation:

1.

2.

Clean the radiator and cooler exterior surfaces.


5.6 maiNteNaNce eVerY 250

HourS

After 250 hours of operation:

1.

2.

3.

4.

Check fan belt tension.

Clean the radiator and cooler exterior surfaces.

(Where dust and other atmospheric contaminants are present, it might be necessary to clean these parts more frequently.)


Change the engine oil and filter.

Note

The fluid change period varies by fluid brand, Refer to the Lubrication

Guide – Compressor on page 56.

5. Change the compressor fluid if it is not Sullair AWF:

a. e.

Fill the sump with fluid in accordance with the specifications in Specifications on page 53 and on

page 54.

6.

7.

8.

9.

10.

Clean or replace the return line strainer.

Change the air filter primary elements.

Change the compressor fluid filter.

Clean the return line orifice.

Change the fuel filter. (If the filter tends to clog more often than what is expected, change the filter more frequently.)

11.

12.

Change the engine fuel/water separator.

Check the engine rpm idle speed. The idle speed should be at the specified minimum idle speed listed in

Specifications on page 53 and on page 55.

5.7

1.

2.

3.

b. c.

Shut the compressor down and relieve all internal pressure

Drain the fluid sump by removing the plug, or opening the valve at the bottom of the sump tank

d.

warNiNG

operating the compressor at below its minimum specified idle speed will damage the compressor. operating the compressor in this condition will cause coupling and/or compressor failure.

maiNteNaNce eVerY 1500

HourS

If the compressor fluid is Sullair AWF, change the fluid and replace the fluid filter element. (See Compressor

Fluid Filter Element Replacement on page 61).

Service the engine cooling system.

Lubricate axle bearings on wheel-mounted units.

52


maiNteNaNce

5.8

Part rePlacemeNt aND aDJuStmeNt ProceDureS

Compressor Fluid Change Procedure

1.

2.

3.

4.

5.

Run the compressor five to ten minutes to warm the fluid.

Shut the compressor down and relieve all internal pressure.

Drain the fluid sump by removing the plug, or opening the valve at the bottom of the sump tank.

Change the compressor fluid and replace the fluid filter element (For element replacement see the filter servicing procedure in this Section.)

Fill the sump with fluid in accordance with the specifications in Specifications on page 53 and on

page 54.

Air Filter Maintenance

Refer to Figure 5-2.

Air filter maintenance should be performed as often as conditions require. If the filters are equipped with optional maintenance indicators, change the filters every time the indicators show a change is necessary.

Compressor Fluid Filter Element

Replacement

Refer to Figure 5-1.

1.

2.

3.

4.

5.

6.

Remove the old element with a strap wrench.

Clean the gasket seating surface.

Apply a light coating of fluid to the new gasket.

Hand tighten the new element (P/N 250025-525) until the new gasket is seated.

Continue tightening the element by hand an additional

1⁄2 to 3⁄4 turn.

Restart the compressor and check for leaks.

2

1

SU_0000678

1.

2.

3.

4.

Filter Body

Filter Cover

Safety (Secondary) Element**

Primary Element*

*Replacement Primary Element

P/N 02250164-532

**Replacement Safety (Secondary) Element

P/N 02250164-533

Figure 5-2

4.

5.

6.

7.

1.

2.

3.

Air Filter Replacement

Loosen and remove the air filter and cover.

Remove the primary and secondary elements.

Clean the body, inside and out, with a damp cloth.

Reinstall (if clean) or replace the secondary element.

Replace the new primary filter element.

Reposition the cover and lock it into the position.

Reset the filter restriction indicator (if equipped).

SU_0000669

1.

2.

Filter Head

Fluid Filter

Figure 5-1


53

SectioN 5

Element Inspection

1.

2.

3.

4.

Insert a bright light source into the element and look for any light leaks which indicate the presence of damage (holes, cracks, etc.)

Inspect all gaskets and gasket contact surfaces of the housing and replace any damaged ones.

Store clean elements for later use in a clean container.

After installing the element, inspect and tighten all air inlet connections before operating the compressor.

Separator Element Replacement

Refer to Figure 5-3. When compressor fluid carryover is evident, after replacing or inspecting the fluid return line strainer and orifice, and the blowdown valve; and all are in satisfactory condition, the separator element must be replaced with Kit number 250034-087 (element for air/fluid separator).

1

3

2

3.

4.

5.

6.

7.

8.

9.

Remove the eight (8) cover bolts and washers and lift the cover off the sump.

Remove the separator element.

Scrape the old gasket material from the cover and the flange on the sump. Do not allow the scrapings to fall into the tank.

Install the new element.

Replace the sump cover and bolts. Lightly tighten all the bolts and then gradually tighten them alternating between bolts which are diagonally opposite each other. Torque the bolts to 160 ft-lbs (215 N•m).

Reconnect all piping. The fluid return line tube should extend to the bottom of the separator element which will ensure proper return line flow.

Clean the fluid return line strainer and clear the orifice before starting the compressor.

10. After 24 hours of operation, tighten the sump cover bolts to the value given in step 7.

Procedure For Setting Speed And Pressure

Controls On Portable Compressors

Equipped With Poppet Valves

Refer to Figure 5-4 and Figure 5-5. Before adjusting the compressor’s control system, the rated full-load pressure and the high/low rpm settings must be determined. This information is provided in Specifications on page 54 and

on page 55

or can be obtained by contacting a Sullair representative.

4

5

1.

2.

3.

4.

5.

SU_0000670

Capscrew

Washer

Cover

Separator Element with Gaskets

Receiver Tank

Figure 5-3: Air/Fluid Separator

1.

2.

Disconnect all sump cover piping connections to permit removal (return line, service line, etc.).

Remove the fluid return line from the fitting on the cover.

54


maiNteNaNce

5.

6.

7.

1.

2.

3.

4.

Compressor Unit

Air Pressure Gauge

Warm-Up Control Valve

Receiver/Sump Tank

fig_5-4a-hi-press-t3-r01

Pressure Regulator/Blowdown Manifold

Oil Return Line

Blowdown Line (To Fitting At Filter Hose)

Figure 5-4: Control System Adjustment –

Standard Pressure

The following procedure applies to a compressor with full- load pressure rating of 100 psig (6.9 bar).

1.

2.

3.

Remove the speed control module (mounted on lifting bail) mounting screws and lift the module away from the mounting surface. Turn the module over to expose the engine speed adjustment buttons.

Start the compressor and allow the engine to warm- up to its normal operating temperature with the service valve closed.

With service valve closed, set the engine low speed

(idle) to it’s specified setting with the LO (+) or LO (-) buttons on the speed control module. Holding the LO

(+) button will increase the idle speed: holding the LO

(-) butting decreases the idle speed setting.

warNiNG

operating the compressor at below its minimum specified idle speed will damage the compressor. operating the compressor in this condition will cause coupling and/or compressor failure.

4.

5.

6.

7.

Adjust the pressure regulator setting to maintain 115 psig (8 bar) receiver tank pressure.

Gradually open the service valve to atmosphere until the engine speed increases and the receiver tank pressure stabilizes at 100 psig (6.9 bar). Adjust the engine high idle speed to its specified setting with the

HI (+) or HI (-) buttons on the speed control module.

Holding the HI (+) button will increase the high idle speed: holding the HI (-) butting decreases the high idle speed setting.

Open the service valve to 100 psig (6.9) (rated full- load pressure) and recheck maximum engine speed and control response. Close the service valve and allow the compressor to cycle and recheck the low engine idle speed.

To reset the speed control module to the default values, press the LO (+) and LO (-) buttons at the same time.

5.

6.

7.

8.

1.

2.

3.

4. fig_5-4std-press-t3-r01

Compressor Unit

Air Pressure Gauge

Warm-Up Control Valve

High/Low Pressure Valve

Receiver/Sump Tank

Pressure Regulator/Blowdown Manifold

Oil Return Line

Blowdown Line (To Fitting At Filter Hose)

Figure 5-5: Control System Adjustment –

Dual Pressure


55

SectioN 5

The following steps apply to “H” and “HH” compressors equipped with dual pressure controls.

1.

2.

3.

4.

5.

Start the compressor and allow the engine to warm up to its normal operating temperature with the service valve closed and the pressure selector valve set to the

LOW position.

Follow the procedure for setting the controls to 100 psig (6.9 bar) rated full load pressure as describe in preceding steps 2 through 6.

Turn the pressure selector valve to the HIGH position with the service valve closed.

Adjust the high pressure regulator so that the compressor maintains a receiver tank pressure of 165 psig (11.4 bar) on “H” models or 220 psig (15.2 bar) on

“HH” models.

Gradually open the service valve to atmosphere until the engine speed increases and the receiver tank pressure stabilizes at 150 psig (10.3 bar) on “H” models or 200 psig on “HH” models. At this point the engine should be operating at its rated speed. If necessary use the HI (+) or HI (-) buttons on the speed control module to set the specified idle speed.

Bearing Lubrication

Refer to Figure 5-6. Proper lubrication of the portable compressor’s bearing axle is critical to its proper function and reduction of wear on this part. Wheel bearings should be lubricated at least every 12 months, or more, to ensure proper performance and minimize wear. Use a wheel bearing grease that conforms to MILSPEC MIL-G-10924 or a high temperature one such as lithium complex NLGI consistency #2.

Axles with the E-Z Lube feature can be periodically lubricated without removing the hubs from the axle. This feature consists of axle spindles that have been fitted with a grease zerk in their ends. When grease is pumped into the zerk, it is channeled to the inner bearing and then flows back to the outer bearing, and then back out of the grease cap hold (see Figure 5-6).

1.

2.

3.

4.

Remove the rubber cap from the grease cap’s end.

Using a full charged grease gun, place the gun onto the grease zerk located on the end of the spindle.

Make sure the nozzle is fully engaged on the fitting.

Pump grease into the zerk. The old grease will be displaced and flow out of the cap around the grease gun nozzle.

When the new grease starts flowing out of the cap, disengage the gun and wipe off any excess off the cap; and replace the rubber plug.

6

1

2

3

1.

2.

3.

4.

Rubber Plug

Outer Bearing

Grease Flow

Grease Fitting

4

5

7

5.

6.

7.

SU_0000671

Metal End Cap

Inner Bearing

Spring Loaded Double Lip Seal

Figure 5-6: Typical E-Z Lube Axle

56


maiNteNaNce

First and Second Stage Discharge Air Filter

Maintenance – Aftercooled & Filtered Models

General

Refer to Figure 5-7. Familiarity with the filtration process and the unit’s monitoring system (consisting of a compete set of gauges) will enable the operator to locate and analyze malfunctions.

The first and second stage filter element should be changed when the pressure drop reaches the red band on the pressure differential gauge.

Daily Operation

Check the automatic drain trap daily to ensure it is operating properly.

First and Second Stage Element Replacement

1.

2.

3.

4.

5.

6.

Depressurize the filter and remove the filter housing.

Remove the element.

Clean the inside of the filter housing, if necessary.

Install a new element and gaskets

(P/N 02250153-294 FIRST STAGE)

(P/N 02250153-305 SECOND STAGE)

Reassemble the unit and check for air leaks.

Record the initial pressure drop when the compressor is started.

Safety

Toxic And Irritating Substances

warNiNG

Death or serious injuries can result from inhaling compressed air without using proper safety equipment. (See applicable oSHa Standards)

DO NOT use air from this filter as a source for respiration

(breathing air) except when in compliance with OSHA

STANDARDS 29 CFR 1910, and all other applicable

Federal, state, or local codes or regulations.

1

2

3

1

SU_0000680

1.

2.

3.

O-Ring

Filter Element

Filter Housing

Figure 5-7: First and Second Stage Discharge Air

Filter (Optional)

These filters will not remove water vapor, oil vapor, carbon monoxide, or other toxic gases.

The first stage filter efficiently removes contaminants such as ash, dust, water aerosols, lubricant mist, carbon particles, rust and other contaminants (0.3 microns and larger).

The second stage filter removes particulates and all lubricant aerosols of 0.01 micron size and larger.

Design Ratings

Design ratings are 150°F (66°C) maximum air inlet temperature. All welded filter housings are ASME code stamped for 250 psig (17.3 bar) maximum working pressure.


57

SectioN 5

5.9 trouble SHootiNG

The following Trouble Shooting chart is based upon data obtained from factory tests and information from the field.

It lists symptoms, probable causes and remedies. This chart does not cover all possible malfunctions or cases of abnormal operation. Before undertaking repairs or replacement actions, analyze all of the available data.

Performing a detailed visual inspection in all cases can prevent additional damage or abnormal operation.

Always:

1.

2.

Check for loose wiring or connections.

Check for damaged piping.

3. Check for heat damage to parts (electrical short circuits can cause heat damage) which can appear as discolorations or the presence of a burnt odor.

If the troubleshooting remedy does not work, or the malfunction is not covered in this Trouble Shooting chart, contact your nearest Sullair representative or Sullair for technical assistance.

SYmPtom

NO SSAM FLASH CODE

eNGiNe DoeS Not craNk or craNkS but DoeS Not Start

SSAM FLASH CODE: ONE FLASH

SSAM FLASH CODE: TWO FLASHES

Probable cauSe

Low voltage or battery disconnected

remeDY

Check battery cables and tighten if loose

Check ground wire for proper attachment to frame. Tighten if required.

Blown fuse in wiring harness

Instrument panel connectors loose or disconnected.

Faulty SSAM module

Recharge or replace battery if required.

Remove and inspect fuse. Replace if necessary.

Check instrument panel connectors and reattach if required

Check instrument panel wires for broken connections or corrosion. Clean and/or replace if damaged.

Replace the module

Compressor temperature switch is open Check wiring connection to the switch and tighten if loose

Engine coolant temperature switch is open

Check switch continuity to ground and replace if necessary

If the compressor feels hot see

COMPRESSOR OVERHEATING trouble shooting procedure

Check wiring connection to the switch and tighten if necessary

Cooling air flow is insufficient

Loose or broken fan belt

Engine problems might be present

No engine coolant

SSAM FLASH CODE:THREE FLASHES Engine oil pressure switch is open

Check switch continuity to ground and replace if necessary

Clean cooler and check for proper ventilation

Check fan belt and tighten or replace if necessary

Refer to the engine operator’s manual

Fill with proper water/glycol mixture as required

Check wiring conne ction to switch and tighten if necessary

Install gauge in parallel with the switch.

Replace the switch if the pressure exceeds 15 psig and stays open. If the pressure is less than 15 psig, refer to the

engine operator’s manual.

58


maiNteNaNce eNGiNe DoeS Not craNk or craNkS but DoeS Not Start

SYmPtom

SSAM FLASH CODE:FOUR FLASHES

SSAM FLASH CODE: FIVE FLASHES

Probable cauSe

Did not start compressor within the 30 seconds from turning the ignition switch to the ON position

Low battery voltage

No fuel

Water or dirt in the fuel and/or filter

Plugged air filter

Plugged fuel filter

Engine problems

Starter solenoid relay does not engage

No input frequency from alternator

No fuel

Defective fuel switch

remeDY

After turning the ignition switch to the ON position, press the switch to the START position within 30 seconds

Check the battery cables and tighten if necessary

Recharge or replace battery if necessary

Refuel

Drain water from the fuel/water separators on the fuel filters. Siphon water from the fuel tank and clean the tank if necessary

Clean and replace if necessary

Replace the fuel filter

Turn the compressor OFF. Use the

PowerView menu to determine the engine fault. Ignore the SSAM Flash Code. See the Engine Warning/Shutdown Table for probable causes

Check wiring and tighten all connectors

Replace relay

Check alternator “W” terminal (7.5 ± 2.50

VAC greater than 300 HZ)

Check fuel level and fill tank if empty

Replace switch

SYmPtom

NO FLASH CODE:

SSAM FLASH CODE: ONE FLASH

comPreSSor SHutS DowN

Probable cauSe

Blown fuse in wiring harness

Instrument panel connectors loose or disconnected

remeDY

Remove/inspect fuse and replace if necessary

Check instrument panel connectors and reattach if required

Check instrument panel wires for broken connections or corrosion. Clean and/or replace if required

Replace the SSAM module Faulty SSAM module

Compressor temperature switch is open Check wiring connection to switch and tighten as required

Check switch continuity when cool and replace if necessary

Cooling air flow is insufficient Clean the cooler and check for proper ventilation

Low compressor receiver tank fluid level Add fluid as required

Clogged compressor fluid filter

Faulty thermostat


Plugged fluid cooler tube (internal)

Change the filter element

Change the thermostat element

Check the fan belt and tighten or replace if necessary

Replace the cooler


59

SectioN 5

SYmPtom

COMPRESSOR DOES NOT ACHIEVE

FULL DISCHARGE PRESSURE

IMPROPER UNLOADING WITH AN

ExCESSIVE PRESSURE BUILD-UP

CAUSING THE PRESSURE RELIEF

VALVE TO OPEN

INSUFFICIENT AIR DELIVERY

ExCESSIVE COMPRESSOR FLUID

CONSUMPTION

comPreSSor SHutS DowN

Probable cauSe

Run/start switch not in run position

Air demand is excessive

Dirty air filter

Clogged return line

Lubrication system leak

Separator element damaged or malfunctioning

remeDY

For compressors with idle warm-up controls, switch toggle to RUN for full operation

Check service lines for leaks or open valves

Check the filter and change the element if required

Defective pressure regulator

Defective idle warm-up control

Engine Warning/Shutdown lamp flashing—engine is derating

Turn the compressor OFF. Use

PowerView menu and arrow keys to determine engine fault. Ignore the SSAM

Flash Code. See the Engine Warning/

Shutdown table for probable cause

Pressure regulating valve is set too high Readjust

Control system leak causing loss of pressure signal

Check the diaphragm and replace with Kit if necessary

Replace control

Check control lines

Defective pressure regulating valve.

Repair valve (kit available)

Inlet valve jammed

Restriction in the control system

Defective pressure relief valve opens when pressure is too low


Free or replace valve

Check all control lines and components— ice and/or other contaminants could be the cause

Replace the pressure relief valve

Run/start switch not in run position

Plugged air filter

Defective idle warm-up control

Plugged air/fluid separator

Check the diaphragm and replace with Kit if necessary

For compressors with idle warm-up controls, switch toggle to RUN for full operation

Replace

Replace control

Replace separator element and also change compressor fluid and fluid filter


Engine speed too low

Engine Warning/Shutdown lamp flashing—engine is derating

Adjust or repair

Readjust engine speed

Turn the compressor OFF. Use

PowerView menu and arrow keys to determine engine fault. Ignore the SSAM

Flash Code. See the Engine Warning/

Shutdown table for probable cause

Clear orifice and return line strainer

Check all pipes, connections and components

Change separator element

60


SYmPtom

COMPRESSOR OVERHEATING

ENGINE OVERHEATING

maiNteNaNce comPreSSor SHutS DowN

Probable cauSe

Low receiver tank fluid level


Dirty fluid cooler core

Plugged compressor fluid filter

Faulty thermostat

Plugged fluid cooler tube (internal)


Dirty radiator core

Low fluid level

Faulty water pump

Plugged radiator

Defective engine thermostat

remeDY

Fill receiver tank

Tighten or replace belt

Clean core thoroughly

Change element

Change thermostat element

Replace cooler

Tighten or replace belt

Clean thoroughly

Refill

Change pump

Clean and flush thoroughly

Replace


61

SectioN 5


62


Section 6

NoiSe coNtrol

6.1

NoiSe emiSSioNS warraNtY

Sullair Corporation 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.

6.2 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 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: a. Engine exhaust system or parts thereof b. c.

Compressor air intake system or part thereof

Enclosure of part thereof

2.

3.

Removal of any of the following: a. Vibration isolators b. c.

Control silencer

Floor panel d. e.

Fan shroud

Acoustical materials including fiberglass foam or foam tape

Operation with canopy doors open for any purpose other than starting, stopping, adjustment, repair, replacement of parts or maintenance.


63

SectioN 6

6.3

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.

Noise Emission Maintenance and Maintenance Record Log

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 defetive exhaust system. Remove and replace any defective parts by ordering with part numbers indicated in the Parts List.

Maintenance Performed

By

Location

Date


By

Location

Date

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.


By

Location

Date


By

Location

Date

64


NoiSe coNtrol

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.


By

Location

Date


By

Location

Date

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.


By

Location

Date


By

Location

Date

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.


By

Location

Date


By

Location

Date


65

SectioN 6

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.


By

Location

Date


By

Location

Date

66


Section 7

PartS liSt

7.1

ProceDure for orDeriNG

PartS

Parts should be ordered from the nearest Sullair representative or the representative from whom the compressor was purchased. If parts cannot be obtained from these sources, contact the factory directly at the addresses, fax or phone numbers listed on following page.

When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the compressor’s bill of lading or the Serial Number Plate on the front of the compressor (see Figure 7-1).

Figure 7-1: Serial Number Plate Location


SU_0000675

67

SectioN 7

68


7.2 recommeNDeD SPare PartS liSt

key Description

1 element for air filter assy (primary)

2 element for air filter assy (secondary)

3 element for main compressor fluid filter 250025-521

4 element for air/fluid separator

5 element for 1st stage discharge filter (aftercooled)

6 element for 2nd stage discharge filter (aftercooled)

7 element for engine oil filter

8 element for engine primary fuel filter

9 element for final fuel filter

10 repair kit for thermal valve 02250113–796

11 repair kit for flange SAE O-ring

12 repair kit for pressure regulator valve 250017-280

13 repair kit for inlet valve 250026-779

14 repair kit for return line strainer 241771

15 repair kit for minimum pressure/check valve 02250094-294

16 repair kit for shaft seal

17 repair coupling assemblies (375)

18 repair coupling assemblies (300HH, 375H, & 425 )

19 Sullair AWF (5 gallons/18.9 liters)

20 Sullair AWF (55 gallon drum/208 liters)

21 manual, CIMA safety

22 manual, Portable Component Service

23 repair kit for regulator/blowdown valve manifold

Note

when ordering parts, indicate the serial number of the compressor. illuStratioNS aND PartS liSt

Part Number

02250164-532

02250164-533

250025-525

250034-087

02250153-293

02250153-304

02250083-017

02250168-191

02250168-192

044583

02250099-416

250019-453

250029-249

241772

250019-444

602541-002

250031-586

250024-470

250030-757

250030-758

250023-146

02250056-343

02250147-737

Note Quantity

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

1


69

SectioN 7

7.3 eNGiNe, comPreSSor aND PartS

0225D166-332R02

70


illuStratioNS aND PartS liSt

7.3

eNGiNe, comPreSSor aND PartS (CONTINuED)

key Description Part Number

20

21

22

23

24

16

17

18

19

28

29

30

31

25

26

27

32

33

34

39

40

41

42

35

36

37

38

4

5

6

7

8

1

2

3

9

10

11

12

13

14

15 bushing, taperlock 2012 valve, drain eng oil 19mm x 1.50 key, shaft step 375h elbow, check valve 1/4t x 1/8p elbow, 90 3/8" tube x 1/4”npt m cable, ground 4-gauge strap - fan, blower 25” 300h-425 cat washer, snubbing vibration mount mount, vibration isolator 375 support, engine front rh cat support, engine front lh cat washer, snubbing 375 vibration mount clamp, t-bolt ss band 3.50" id switch, engine oil pressure n.o. clamp, t-bolt ss band 2 1/4”id elbow, silicone cac reducing 2 x 3 hose, rad upper cat 375 tier ii hose, rad lower cat 375 tier ii pipe, cac hot/upper cat t2 switch, engine hi-temp 225f nc 1/2 npt clamp, 2" id high temp elbow, silicone cac 2" id x 45 deg coupling, assembly ringfedder ac-t4.1 tube, cac hot sd 375 cat t3 strap, cac pipe supt 375 ca t3 sub assembly, control orifice 375h jd t3 clamp, hose 1 5/16" to 2 1/4" adj. clamp, hose 1 13/16" x 2 3/4" adj. clamp, hose 13/16” to 1-1/2” gasket, 1/32 x 5 1/4 od x 4 1/8 id connector,1/4t x 1/4 npt str adapter, eng-compr 375 jd spacer, coupling 375 jd & cat key, shaft 375 valve, air inlet 4” 375 dpq coupling assy 375 jd & cat bushing, taper-loc 2517 1.93id nut, hex f pltd 1/4-20 nut, hex locking 5/8-11 capscrew, hex 8.8 m8 x 100mm capscrew, hex 8.8 m10 x 35mm capscrew, hex 8.8 m12 x 25mm

02250137-802

02250138-190

02250138-191

02250138-194

02250138-450

02250140-362

02250145-483

02250146-634

02250164-546

02250166-753

02250168-182

040014

040083

040513

040708

250018-428

250022-732

250023-218

250023-340

02250049-415

02250051-231

02250053-263

02250058-275

02250099-626

02250101-258

02250115-570

02250125-471

02250125-473

02250125-479

02250125-480

02250125-604

02250129-227

02250130-668

02250137-795

250026-779

250031-586

407848

825304-236

825510-329

828008-100

828010-035

828012-025

Quantity

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

2

4

12

4

1

1

1

1

1

1

4

1

1

1

1

1

2

1

4

1

1

1

3

Note

(I)


71

SectioN 7

7.3


0225D166-332R02

72



7.3



43 capscrew, hex gr5 3/8-16 x 1

44 capscrew, hex gr5 3/8-16 x 1 1/4





49 screw, hex ser washer 1/4-20 x 3/4

50 washer, spr lock reg pltd 3/8


52 washer, pl-b reg pltd 5/8

53 washer, spr lock-metric pltd m8

54 washer, spr lock-metric pltd m10

55 hose, heater 1/2" (ft)

56 washer, metric-iso7089- 10

57 plug, pipe 1/2” 3000# stl plt

58 bushing, red pltd 1/4 x 1/8

59 washer, nord-lock pl 1/2”

60 unit,16 series 375

61 engine, cat 4.4 130hp t

829106-100

829106-125

829108-100

829108-150

829108-400

829110-350

829704-075

837806-094

837808-125

838210-112

838808-200

838810-220

842115-050

865410-210

866900-020

867100-005

878608-077 consult factory consult factory

(I) See page 92.

Quantity

1

8

6

2

2

2

4

10

4

8

8

4

1

1

1

1

12

1

12

Note


73

SectioN 7

7.4 raDiator & comPreSSor fluiD cooliNG SYStem

A1

A2

A3

02250166-333R02-CAT

74



7.4

raDiator & comPreSSor fluiD cooliNG SYStem (CONTINuED)

key Description Part Number Note Quantity

1 bucket, radiator fluid recovery

2 hose, mp 1" x 48" lg

3 elb, 90 sae x orfs 1.25" x 1.00"

4 filter, fluid 1 5/8 sae str thrd co

5 housing, thermo vlv leak free 375

6 support, oil filter thrmo-vlv 375

7 plate, access 375 after clr

10 support, cooler assy 375 dpq

12 hose, mp orfs f-swvl 1"

13 support, cooler center brace

14 clamp, t-bolt ss band 2 1/4"id

15 cooler, oil 375 jd/cat tier ii

16 radiator, 300h-425q jd/cat tier ii

17 cooler, cac 375 jd/cat tier ii

18 adapter, cac pipe 2"id x 6"lg

19 baffle, clrs. r.h. 375-425 t3

20 baffle, clrs. lh 375-425 t3

21 baffle, clrs bottom 375-425 t3

22 baffle, clrs top 375-425 t3

23 shroud, fan 26" 375-425 jd t3

25 plug, finishing 2.5" steel

26 guard, fan 28" 375-600t3

27 drainlock, 1/4"

28 grommet, rubber 1" hole

29 element, thrm vlv (155 deg f)

30 clamp, hose 3/8"

31 grommet, rubber 1-3/4" hole

32 weatherstrip, 1" thick x 1" wide (ft) -

33 nut, hex f pltd 1/4-20


35 capscrew, hex gr5 5/16-18 x 3/4





40 screw, hex ser washer 5/16-18 x 1



43 hose, fuel line 5/16 (ft)

02250083-466

02250088-283

02250093-804

02250096-783

02250113-796

02250114-008

02250116-321

02250119-030

02250135-593

02250137-235

02250137-795

02250137-798

02250137-799

02250137-800

02250138-196

02250164-454

02250164-455

02250164-456

02250164-457

02250164-458

02250164-475

02250164-542

040061

040162

044583

047235

250020-358

250041-174

825304-236

825305-283

829105-075

829105-100

829704-050

829704-075

829705-075

829705-100

837805-078

838205-071

842315-031

1

1

1

1

1

1

2

1

1

7

1

2

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

4

8

19

4

3

26

2

10

20

7

45

3


75

SectioN 7

7.4


A1

A2

A3

02250166-333R02-CAT

76



7.4


key Description

44 nut, retainer 5/16-18 .092

45 reducer, str thrd viton 1 1/4 x 1

46 connector, straight x jic 1 5/16 x 1 5/16

47 connector, 45 deg str x jic 1 5/16 x 1 5/16

48 connector, 90d str x jic 1 5/16 x 1 5/16

49 union, straight thrd 1 5/16-12

50 tee, run 37fl str thd 1 5/16-12

A1 Overflow to bottom of frame.

A2 To unit fluid supply.

A3 Air fluid separator tank assembly (reference).

Part Number

861405-092

870020-016

870116-016

870516-016

870616-016

871316-131

871916-131

Note Quantity

1

1

1

1

5

2

2

NOTE: For connection “D” to “D” use clear plastic tubing and clamps supplied with overflow bottle.


77

SectioN 7

7.5 air iNlet SYStem & exHauSt SYStem

02250166-339R00

78



7.5

air iNlet SYStem & exHauSt SYStem (CONTINuED)


4

5

6

7

1

2

3 elbow, 90m 5/16”tube x 1/8”npt - gasket, exht ca3054na 185q tube,exhaust 375-425 cat muffler, exhaust 300h-425 ft mtg hose, air inlet eng (part 1) tube, aluminum 3.5”od x 4”lg 16ga clamp, t-bolt ss band 4.00”id

8

9 clamp, t-bolt ss band 5.00”id clamp, t-bolt ss band 2.75”id

10 tube,exhst ext 375-600q t3

11 elbow,air inl compr 375-600 t3

12 filter, air inl 375-600 cfm

13 support, air fltrs 375 t3

14 hose,eng inl 375 t3

15 clamp, t-bolt ss band 5.50”id

16 clamp. exhaust 3”

17 cap, rain exhaust 3”

18 nut,hex f pltd 5/16-18

19 capscrew,hex gr5 3/8-16 x 1

20 screw, hex ser washer 5/16-18 x 1

21 screw, hex ser washer 5/16-18 x 1 1/4



24 bulkhead, pipe 1/8” npt

25 plug, pipe 1/8” 3000# stl plt

02250109-423

02250110-425

02250115-010

02250115-201

02250140-336

02250140-363

02250140-869

02250140-870

02250152-375

02250164-526

02250164-530

02250164-531

02250164-534

02250164-547

042324

043713

047208

825305-283

829106-100

829705-100

829705-125

837806-094

838206-071

841500-002

866900-005

Note Quantity

1

1

1

2

1

2

1

1

2

1

1

1

1

1

2

1

1

3

3

2

1

3

4

7

3


79

SectioN 7

7.6 coNtrol PartS & DiScHarGe PartS - 375 aND 425

A4

A3

A1

A2

80


02250166-335R03


7.6

coNtrol PartS & DiScHarGe PartS - 375 aND 425 (CONTINuED)

key Description

1 valve, relief 1" npt x 1 1/4" fnpt 200 psig

2 insert, nylon tubing 1/4" od

3 tube, nyl .25 od x 040w wht (ft)

4 tube, nyl .25 od x .040w blk (ft)

5 tube, 5/16 od x .040 wall

6 plug, sight glass 1-7/8" sae

7 insert, nyl tubing 3/8" od

8 flange, kit sae splt 2.5" - viton

9 elbow, 90 3/8" tube x 1/4" npt m

10 sub assembly, service valves std 375-425

11 connector, tube oil return 5/16 x 1/4

12 hose, air service std 375

13 valve, 1 1/2" npt min press chk

14 valve, ball 2-way 1/8" npt 90 deg

15 switch, temp n.c. 250°F, single pole

16 tubing, nylon 3/8" od red

17 tubing, nylon 3/8" od yellow

18 tubing, nylon 3/8" od blue

19 tubing, nylon 3/8" od orange

20 hose, discharge 375-600 dpq

21 panel, frm frt 375-600 t3

22 support, reg/bd assy 375-600 t3

23 sub assembly, reg/bd assy 375 t3

24 tank, air-oil sep 300HH-600

25 plug, o-ring boss sae 1 1/4

26 strainer, v-type 300 psi x 1/4

27 tube, steel 5/16" od oil siphon

28 connector, 1/4t x 1/4 npt str

29 elbow, 90 1/4" tube x 1/8" npt

30 element, oil sep 8.81 x 11.18

31 washer, .625 hardened

32 tee, m run 1/4t plsx 1/8 npt

33 plug, str thd 3/4-16 sae vit

34 connector, tube-male 5/16 x 1/4




38 washer, pl-b reg unfin 1/2

39 washer, spr lock 1/2


41 elbow, 37fl 90m 1 1/2 x 1 1/2

42 nipple, pipe-xs plt 1 x cl

43 nipple, pipe-xs plt 1 1/2 x cl

Note

(III)

(IV)

(I)

(II)

Part Number

02250047-679

02250052-841

02250054-860

02250054-861

02250081-220

02250097-611

02250099-052

02250099-416

02250099-626

02250118-603

02250118-809

02250119-080

02250121-558

02250130-629

02250159-777

02250139-950

02250139-951

02250139-953

02250139-954

02250164-548

02250164-704

02250166-243

02250166-244

02250170-513

040029

241771

250009-253

250018-428

250018-429

250034-087

250040-100

250041-088

250042-623

812205-025

828208-175

829110-175

829706-050

837208-112

837508-125

838206-071

860224-150

866416-000

866424-000

Quantity

3

1

4

2

1

1

1

1

1

1

1

2

1

1

8

1

1

4

3

1

4

3

1

1

1

1

3

1

1

4

2

1

8

2

1

4

4

1

8

1

1

1

1


81

SectioN 7

7.6


A4

A3

A1

A2

82


02250166-335R03


7.6


key Description

44 nipple, pipe-xs plt 1 1/2 x 6

45 bushing, red pltd 1 1/2 x 1

46 elbow, pipe 45 deg 300# plt 1 1/2"

47 conn, 90d str x jic 1 5/16 x 1 5/16

A Shown 3/8" OD tubing blue

B To start run valve (end tee) 3/8 OD tubing red

C To unit oil return port 1/4" OD tubing white

D To start run valve (side) port 3/8" OD tubing orange

E To inlet valve 3/8" OD tubing yellow

G To inlet valve hose 5/16" OD white

H To unit (below inlet valve) 1/4" black

A1 START/RUN warm-up valve at instrument panel

A2 To pressure gauge

A3 To unit

A4 Line up “Z” and rotate CCW 90 degrees

(I) Replacement 0-ring part number 826502-232.

(II) See page 94.

(III) For color variations consult factory.

(IV) See page 88.

Part Number

866424-060

867106-040

869430-060

870616-016

Note Quantity

1

1

1

1


83

SectioN 7

7.7 coNtrol PartS & DiScHarGe PartS - 300HH aND 375H

A5

A6

A1

A2

A4

A3

84


02250166-336R03


7.7

coNtrol PartS & DiScHarGe PartS - 300HH aND 375H (CONTINuED)

key Description

2 insert, nylon tubing 1/4"od

3 tube, nyl .25 od x 040w wht(ft)


5 tube, 5/16 od x .040 wall

6 plug, sight glass 1-7/8" sae

7 insert, nyl tubing 3/8"od

8 flange, kit sae splt 2.5" - viton


10 valve, relief 1x1/4 250 psig

11 sub assembly, service valves std 375-425

12 connector, tube oil return 5/16x1/4

13 hose, air service std 375

14 valve, 1 1/2" npt min press chk

15 valve, ball 2-way 1/8" npt 90 deg

16 switch, temp n.c. 250°f, single pole

17 tubing, nylon 3/8" od red

18 tubing, nylon 3/8" od yellow

19 tubing, nylon 3/8" od green

20 tubing, nylon 3/8" od blue

21 hose, discharge 375-600 dpq


23 support, reg/bd assy 375-600 t3

24 sub assembly, reg/bd assy 375 t3

25 sub assembly, control orifice

26 tank, air-oil sep 300hh-600

27 plug, o-ring boss sae 1 1/4

28 strainer, v-type 300 psix1/4

29 tube, steel 5/16"od oil siphon

30 connector, 1/4t x 1/4 npt str

31 elbow, 90 1/4" tube x 1/8" npt

32 element, oil sep 8.81 x 11.18

33 washer, .625 hardened

34 tee, m run 1/4t plsx 1/8 npt

35 plug, str thd

36 connector, tube-male 5/16 x 1/4




40 washer, pl-b reg unfin 1/2

41 washer, spr lock 1/2


43 elbow, 37fl 90m 1 1/2 x 1 1/2

44 nipple, pipe-xs plt 1 x cl



Note

(V)

(III)

(IV)

(I)

(II)

Part Number

250009-253

250018-428

250018-429

250034-087

250040-100

250041-088

250042-623

812205-025

828208-175

829110-175

829706-050

837208-112

837508-125

838206-071

860224-150

866416-000

866424-000

02250052-841

02250054-860

02250054-861

02250081-220

02250097-611

02250099-052

02250099-416

02250099-626

02250111-740

02250118-603

02250118-809

02250119-080

02250121-558

02250130-629

02250159-777

02250139-950

02250139-951

02250139-952

02250139-953

02250164-548

02250164-704

02250166-243

02250166-245

02250168-182

02250170-513

040029

241771

Quantity

1

1

1

1

8

1

4

8

1

1

2

2

1

4

4

1

1

2

1

4

2

1

1

1

1

1

1

1

1

1

8

2

1

1

3

3

4

4

1

1

1

1

1

3

85

SectioN 7

7.7


A5

A6

A1

A2

A4

A3

86


02250166-336R03


7.7


key Description


47 bushing, red pltd 1 x 3/4

48 bushing, red pltd 1 1/2 x 1


50 connector, 90d str x jic 1 5/16 x 1 5/16

A Shown regulators to tank 3/8" OD tubing blue

B Shown start run valve (end tee) to reg block 3/8 OD tubing red

C To unit oil return port 1/4" OD tubing white

D Shown start vlv side port to hi-low vlv end port tee 3/8" OD orange

E Shown inlet control orifice to reg. assy 3/8" OD tubing yellow

G To inlet valve hose 5/16" OD white

H To unit (below inlet valve) 1/4 black

J Shown hi-low vlv (end port tee) to reg sa 3/8" OD tubing green

K Shown hi-low vlv (side port) to reg sa 3/8" OD tubing yellow

A1 START/RUN warm-up valve at instrument panel

A2 To pressure gauge

A3 HI-LOW pressure gauge at instrument panel

A4 To unit

A5 Line up “Z” and rotate CCW 90 degrees

A6 To inlet valve control

(I) Replacement 0-ring part number 826502-232.

(II) See page 94.

(III) See page 90.

(IV) See page 92.

(V) For color variations consult factory.

Part Number

866424-060

867104-030

867106-040

869430-060

870616-016

Note Quantity

1

1

1

1

1


87

SectioN 7

7.8 reGulator/blowDowN ValVe - 375 aND 425

02250166-246-r03

88



7.8

reGulator/blowDowN ValVe - 375 aND 425 (CONTINuED)

key Description Part Number Note

1 connector, 5/16" tube x 1/4"npt

2 tee, m run 3/8" tube x 1/4"npt

3 connector, 3/8tube x 1/2npt

4 transducer, pressure 0-100psi 5volt n4

5 manifold, regulator blowdown 185

6 connector, 3/8 tube x 1/4npt

7 elbow, 1/4" tube x 1/4" npt

8 tee, pipe 150# plt 1/4


10 nipple, pipe-hx pltd 1/4 x 1/4

02250081-219

02250099-615

02250129-957

02250140-194

02250146-046

02250148-188

250018-430

866815-010

867100-005

868504-025

(I)

(I) For maintenance on regulator blowdown manifold, order repair kit no. 02250147-737.

NOTE: Reference – sub-assembly number 02250166-244.

Quantity

1

1

1

1

1

1

1

1

1

1


89

SectioN 7

7.9 reGulator/blowDowN ValVe - 300HH aND 375H

02250166-247R02

90



7.9

reGulator/blowDowN ValVe - 300HH aND 375H (CONTINuED)

key Description

1 connector, 5/16" tube x 1/4" npt

2 tee, m run 3/8" tube x 1/4" npt


4 transducer, pressure 0-100psi 5volt n4


6 manifold, press reg/bd 150psi 185h

7 valve, pressure regulator

8 elbow, 1/4" tube x 1/4" npt





(I) For maintenance on regulator blowdown manifold, order repair kit no. 02250147-737.

(II) For maintenance on pressure regulator valve, order repair kit no. 250019-453.

NOTE: Reference – sub-assembly number 02250166-245.

Part Number

02250081-219

02250099-615

02250099-626

02250140-194

02250148-188

02250151-201

250017-280

250018-430

866815-010

867100-005

867102-010

868504-025

Note

(I)

(II)

Quantity

1

1

1

1

2

1

1

1

1

3

2

1


91

SectioN 7

7.10 coNtrol PartS orifice - 300HH aND 375H

02250168-183R00

92



7.10

coNtrol PartS orifice - 300HH aND 375H (CONTINuED)

key Description

1 orifice, ctl .078 1/8 fnpt x 1/8 mnpt


3 silencer, air ejection 1/8" npt-male thread




Part Number

02250069-264

02250148-188

248755

866815-010

867100-005

868504-025

Note Quantity

1

1

1

1

1

1


93

SectioN 7

7.11

SerVice ValVeS

1

2

02250118-602R02

94


7.11

SerVice ValVeS (CONTINuED)

key Description

1 valve, double ball 3/4" x 1"

2 coupling, 3/4" female npt


Part Number

250019-916

040383

Note Quantity

1

2


95

SectioN 7

7.12 oPtioNal aftercooler/filter aND PartS

A1

A4

A3

A2

02250166-353R02

96



7.12

oPtioNal aftercooler/filter aND PartS (CONTINuED)


1 valve, blowdown 1/4 npt hi prs

2 hose, medium pressure 250psi 1.5" x 38" fjic


4 tube, nylon .375" od x .050w black (ft)

5 valve, ball 3-wat 1-1/2 fnpt

6 hose, aftr clr to sep 375 48"

7 hose, air 3-way to manifold 375

8 support, after cooler filters

9 cooler, air to air 300h-375

10 hose, mpress 1-1/2 x 25"


12 filter, scf-465n 1 1/4" npt w/auto drains

13 filter, sch-465n 1 1/4" npt w/auto drains

14 kit, auto drain sc filters

15 kit, sc head clmp 340-700

16 kit, sc mounting bracket 340-700

17 separator, water scws-740n 1 1/2" l/ad

18 support, manf ac drains 375 t3

19 manifold, tubing push-in 1/4 & 3/8

20 plug, 1/4" push-in plastic



23 conn, 1/4" tube x 1/8" npt

24 elbow, 90 1/4" tube x 1/8" npt

25 elbow, 90 1/4t pls x 1/4 npt m

26 connector, straight 1/4t plsx 1/4npt f

27 clamp, hose 1 3/8" i.d.


29 nut, hex locking #10-24







36 elbow, 37fl 45m 1 1/2 x 1 1/2

37 connector, 37 fl/mpt pltd 1 1/2 x 1 1/2

38 elbow, 37fl 90m 1 1/2 x 1 1/2

39 nipple, pipe-xs plt 1/4 x cl


41 nipple, pipe-xs plt 1 1/2 x 3 1/2



02250049-634

02250051-446

02250054-861

02250099-630

02250118-872

02250119-082

02250119-083

02250142-733

02250142-958

02250119-083

02250148-188

02250153-038

02250153-062

02250153-280

02250153-286

02250154-587

02250166-741

02250167-724

02250167-725

02250167-726

025690

250014-060

250018-427

250018-429

250018-430

250041-084

408300-008

825305-283

825502-083

829105-075

829105-100

829704-075

829705-075

837805-078

838205-071

860024-150

860124-150

860224-150

866404-000

866424-000

866424-035

866424-080

867030-060

Quantity

2

1

1

1

2

1

5

1

1

2

2

1

1

1

1

4

2

1

1

1

1

2

1

1

1

1

39

6

2

1

2

1

4

1

3

2

1

8

2

1

3

2

1


97

SectioN 7

7.12


A1

A4

A3

A2

02250166-353R02

98



7.12




45 bushing, red pltd 1 1/2 x 1/4

46 coupling, pipe 1/4 300# plt

47 tee, pipe pltd 1 1/2


49 screw, rnd phillips 10-24 x 1 1/4"

A1 To min. pressure valve

A2 Mounted on frame near receiver

A3 Used with aftercooler less filters option

A4 From tee fitting below inlet valve

867100-005

867106-010

867430-010

868430-060

869430-060

876002-125

Quantity

1

2

1

1

1

2


99

SectioN 7

7.13 electrical PartS

A1

02250166-341R02-CAT

100


7.13

electrical PartS (CONTINuED)

key Description

1 channel, extruded rubber “u” .25" w (ft)

2 washer, external serrated m10

3 cable, ground 4-gauge strap

5 battery, grp 31 hi cap taper post

6 lamp, license plate std

7 harness, 6-wire lites 375

8 bracket, license plate lamp

9 module, electronic speed control

11 relay, 12-volt 40-amp 1no/1nc

12 gasket, e.s.c. jd tier ii

13 relay, 12-volt 50-amp 1no/1nc

15 switch, battery disconnect 6-36v; 175 amps cont

16 switch, e-stop hd push-pull red

17 plate, cover large portable e-stop

18 frame, assy 375-600 q t3

19 bail, lifting 375 t3

20 channel, batt hold dwn 375-600t3

21 panel, batt cvr/baff 375-600t3

22 panel, frm rear 375-600 t3

23 lock, batt disconnect switch

25 grommet, rubber 1" hole

26 nut, plastic square license plate

27 cable, battery 1/o x 50"

28 lamp, tail/turn/stop (shock mtg)

29 cable, battery 18" lg black

30 clamp, hose 9/16" id

31 clamp, hose 7/8" i.d.






39 screw, mach-rd hd #10-24 x 3/4

40 wrap, tie nylon tf4-8


Note

(I)

Part Number

02250164-693

02250164-958

02250165-472

040162

250006-076

250018-235

250028-415

250029-839

408300-001

408300-004

825304-236

825305-283

825502-083

829704-075

829705-075

831602-075

843200-025

02250086-448

02250092-169

02250101-258

02250114-276

02250119-658

02250119-673

02250119-678

02250138-678

02250141-092

02250141-766

02250144-353

02250160-837

02250163-818

02250163-821

02250164-386

02250164-550

02250164-692

Quantity

2

3

1

5

12

5

3

9

2

4

1

1

1

1

4

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1


101

SectioN 7

7.13


A1

02250166-341R02-CAT

102


7.13


key Description

41 rod, threaded 5/16 x 10" lg

42 screw, rnd phillips 10-24 x 1/2"


A1 Relays and speed control supplied with panel harness

(I) For color variations consult factory.


Part Number

843505-100

876002-050

876002-075

Note Quantity

2

1

2


103

SectioN 7

7.14 iNStrumeNt PaNel & PartS

104


02250166-348R00


7.14

iNStrumeNt PaNel & PartS (CONTINuED)

key Description

1 hinge, instrument panel door 185q-8f

2 screw, phil pan hd #6-32 x 3/8

3 latch, locking instrument panel

4 door, instrument panel 185 60hp

5 panel, canopy frt lh 375 t3

6 panel, instr 375-425 cat t3 std

7 weatherstrip, 3/16 x 3/8 ft

8 screw, mach phill #10-24 x 1/2

9 bumper, rubber 1/2 dia



12 nut, acorn pltd #8-32

13 washer, pl-b reg pltd #6

14 screw, flt phillips 8-32 x 3/4"


Part Number

02250103-623

02250112-009

02250125-511

02250138-181

02250164-807

02250165-421*

250022–436

250025-692

250035-095

825500-102

825501-070

825615-002

838200-045

875901-075

876001-038

Note

(I)

* P/N 02250165-422 for 300HH and 375H


1

2

4

1

2

1

3

8

2

4

Quantity

1

1

1

4

1


105

SectioN 7

7.14


0225D165-422R02

106



7.14


key Description

1 gauge, pressure air 0-300 2”

2 hour-meter, 12-24vdc 10000hr 2”

3 lamp, warning indicator - amber

4 tee, m run 3/8” tube x 1/4” npt

5 elbow, 90 3/8” tube x 1/4” npt m

6 tube, nylon .375” od x .050w black (ft)

7 lense, cliplite led

8 panel, instrument plastic ssam

9 decal, dual pressure 185-375 ssam

10 decal, starting aid 185-375 cat

11 decal, group std panel (ssam)

12 switch, engine ignition 12-volt

13 decal, ssam low fuel option

14 valve, ball 2-way 1/4” npt

15 elbow, 90 f 3/8” tube x 1/4” npt

16 cover, access ssam molded abs

17 cont, ssam 185-60 hp

18 harness, eng & compr 375 cat t3

19 decal, warn lites 375 t3 pnls

20 switch, starter push-buttons

21 lamp, warning indicator - red

22 screw, tc-f rd hd #6-32 x 1/2

23 washer, pl-b reg pltd #6


A1 Pressure selector

A2 Warm-up control

A3 Part of P/N 02250044-361

A4 Part of P/N 02250050-361

A5 Reference wiring diagram P/N 02250165–163

A6 Part of P/N 02250136–999

A7 Part of P/N 040038

Part Number

02250044-361

02250050-517

02250054-392

02250099-615

02250099-626

02250099-630

02250129-189

02250129-190

02250130-630

02250130-631

02250131-485

02250132-883

02250133-620

02250136-999

02250137-033

02250137-265

02250139-296

02250165-172

02250165-425

040038

250003-117

835700-050

838200-045

867100-005

Quantity

1

1

1

1

1

2

1

1

1

1

2

2

1

1

1

2

2

1

1

1

1

1

2

2

Note

(II)

(I)

(I) 300HH and 375H models only

(II) Use P/N 02250141-092 for replacement of starter and shutdown relays. Use P/N 02250144-353 for replacement of glow plug relay.

REFERENCE WIRING DIAGRAM P/N 02250165-163


107

SectioN 7

7.15 fuel taNk & coNNectioNS

A1

A2

A4

A5

A3

02250166-343R02-CAT

108



7.15

fuel taNk & coNNectioNS (CONTINuED)

key Description

1 tube, fuel return 1/4" jd 185q

2 connector, tube oil return 1/4 x 1/4

3 connector, tube oil return 5/16x1/4

4 tube, fuel pick-up 185dpq 60hp

5 adapter, fuel pickup 185 60hp

6 ventilator, fuel tank

7 cap, fuel fill buttress thread

8 tank, fuel plstc 56 gal 375

9 strap, fuel tank mtg 375-600 t3

10 switch, float fuel sht dwn 22.25 lg

11 connector, quick dis 5/8 id hose

12 fitting, hose barb 3/8 npt x 5/8 hose id

13 fitting, hose barb 3/8 npt x 5/16 hose id

14 clamp, hose 13/16" to 1-1/2"

15 connector, hose 5/16" hose x 1/4" npt

16 clamp, hose 3/8"

17 gasket, fuel gauge neoprene


19 nut, hex locking 5/16-18

20 screw, hex ser washer 5/16-8 x 1 1/4

21 washer, spr lock reg pltd #10





26 screw, rnd phillips 10-24 x 3/4”

A1 From engine fuel return fitting.

A2 To engine fuel inlet fitting (3" long for CAT).

A3 Cut to 5" length and secure to fuel return hose with cable tie.

A4 To engine fuel inlet fitting.

A5 Caterpillar supplied filter mounted at end of air inlet filter bracket.

Part Number

02250102-573

02250108-700

02250118-809

02250139-885

02250152-163

02250162-229

02250162-230

02250164-384

02250165-197

02250167-999

02250169-488

02250169-493

02250171-164

040513

043258

047235

250004-752

825305-283

825505-166

829705-125

837802-047

838205-071

842315-025

842315-031

842315-062

876002-075

Note Quantity

2

2

1

5

4

2

10

4

6

4

7

10

1

3

1

2

1

1

4

1

1

1

1

1

1

1


109

SectioN 7

7.16 frame, axle & PartS aND axle aSSemblY

110


02250166-334R02


7.16

frame, axle & PartS aND axle aSSemblY (CONTINuED)


1 reflector, red 3" truck-lite

2 reflector, yellow 3" truck-lite

3 nut, shackle (dexter 6-7)

4 bolt, shackle (dexter 7-17)

5 washer, flat hardened 1/2"

6 tire, assembly h78-15 st d

7 plug, 4" round black plastic

8 axle, assembly 300h-425 dpq std

9 jack, hd w/pad 185-425 std

10 panel, acoustic toolbox 375dpq

11 drawbar, std pivot 185dpq

12 support, shipping 185 pivot drbar

13 support, dr-bar swivel 185q

14 fender, 15" wheel 185h-260dpq

15 striker, latch frt-bk-sides 185h-260

16 frame, assy 375-600 q t3

17 bail, lifting 375 t3

18 panel, frm rh 375-600 t3

19 panel, frm lh 375-600 t3

20 panel, frm rear 375-600 t3

21 panel, bumper 375-600 t3


23 panel, acoustic frm frt 375 t3

24 panel, acoustic frm r&l rear 375 t3

25 panel, acoustic frm rear 375 t3

26 panel, toolbox 375-600 t3

27 bolt, keeper (dexter 07-007-00)

28 nut, keeper (dexter 06-011-00)

29 hanger, front mount 375dpq

30 hanger, rear slipper dexter #030-028-03

31 eye, 3" lunette demountable -

32 chain, 3/8" x 71" w/2 hks pltd












02250052-701

02250052-702

02250058-263

02250058-267

02250064-266

02250100-518

02250106-068

02250116-323

02250116-794

02250132-877

02250133-864

02250133-984

02250141-183

02250146-111

02250149-684

02250164-386

02250164-550

02250164-695

02250164-698

02250164-701

02250164-707

02250164-704

02250165-531

02250165-532

02250165-533

02250165-538

040116

040117

045194

045195

250002-221

250018-492

825305-283

825501-070

825502-083

825508-262

825510-329

829108-125

829108-150

829110-475

829705-075

837808-125

838205-071

(I)

(I)

(I)

(I)

(I)

Quantity

1

2

2

2

2

2

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

8

2

2

2

3

4

6

1

1

18

3

14

3

50

25

36


111

SectioN 7

7.16


112


02250166-334R02


7.16


key Description



46 nut, retainer 5/16-18 .092

47 capscrew, hex gr5 1/2-13 x 1 1/4 plt

48 screw, flt phillips 8-32 x 3/4"


Part Number

838208-112

838210-112

861405-092

875608-125

875901-075

876002-075

Note Quantity

17

6

15

8

4

6



113

SectioN 7

7.17 axle aSSemblY

02250116-323R01

114


7.17

axle aSSemblY (CONTINuED)

key Description

1 spring, leaf 2500# 375dpq

2 plate, tie dexter# 12-2

3 u-bolt, axle spring mtg. 3"

4 nut, hex 1/2-20 plated

5 hub, 6 on 5-1/2" bolt center

6 cap, grease axle assy dexter#21-042

7 plug, rubber axle assy ez-lube

8 fitting, grease-str 1/4" npt

9 nut, wheel 1/2-20 plated

10 stud, wheel hub axle assy

11 washer, spindle dexter#5-023

12 bearing, inner dexter#31-30

13 nut, spindle dexter#6-001

14 bearing, outer dexter#31-32

15 seal, oil axle assy dexter# 10-10

16 beam, axle 49.92sc 67.5hf

17 washer, tang axle assembly


Part Number

250010-112

045197

242486

047881

250025-527

250040-788

–

861000-025

250023-470

250023-468

047874

040118

047875

040119

250040-787

–

250040-784

Note Quantity

2

2

2

8

2

2

2

4

12

12

2

2

2

2

2

1

1


115

SectioN 7

7.18 caNoPY, acouStical PaNelS & PartS

116


02250166-351R01


7.18

caNoPY, acouStical PaNelS & PartS (CONTINuED)

key Description

1 catch, pivot slam pad lck blk -

2 insulation, clr baff fill 185h

3 panel, can frt rh 375 t3

4 panel, can frt lh 375 t3

5 panel, can rear rh 375t3

6 panel, can rr lh 375 t3

7 panel, door can frt 375 t3

8 panel, canopy rear 375 t3

9 panel, roof 375-600 t3

10 hinge, canopy door frt 375 t3

11 hinge, can door sides 375 t3

12 grille, canopy roof inl 375 t3

13 baffle, can roof 375 t3

14 louver, air exhaust 375-600 t3

15 panel, acoustic can rr rh 375 t3

16 panel, acoustic can rr lh 375 t3

17 panel, acoustic can rr side rh 375 t3

18 panel, acoustic can rr side lh 375 t3

19 panel, acoustic rear acc 375 t3

20 panel, acoustic can door frt 375 t3

21 panel, acoustic can frt 375 t3

22 panel, acoustic roof baff 375 t3

23 panel, acoustic roof rear 375 t3

24 panel, acoustic roof frt rh 375 t3

25 panel, acoustic roof frt lh 375 t3

26 tabulation, door canopy l&r 375-425 t3

27 panel, acoustic can dr r&l 375-425 t3

28 screw, mach phill #10-24 x 1/2

29 hook, door latch male ss

30 catch, door latch female ss

31 insert, 1/4-20 blind








39 nut, retainer 5/16-18 .092

Part Number

02250107-837

02250147-126

02250164-802

02250164-807

02250164-812

02250164-817

02250164-836

02250164-859

02250164-864

02250164-878

02250164-879

02250164-880

02250164-881

02250164-882

02250165-522

02250165-523

02250165-524

02250165-525

02250165-526

02250165-529

02250165-530

02250165-534

02250165-535

02250165-536

02250165-537

02250167-515

02250167-545

250025-692

250033-828

250033-829

250034-538

825305-283

825502-083

825504-145

829104-050

829104-075

829705-075

838204-071

861405-092

Note

(I)

(I)

(I)

(I)

(I)

(I)

(I)

Quantity

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

3

2

1

3

24

6

36

15

33

6

1

2

1

1

2

36

3

31

54

19



117

SectioN 7

7.19

DecalS

3

1

2

4

02250140-925

118


SU_0000681


7.19

DecalS (CONTINuED)


1 decal, operator procedure start stop

2 decal, “need an air tool” sml

3 decal, drwbr instl 185q pe std

4 decal, diesel fuel

02250165-938

02250140-925

02250142-050

040248

(I) OSHA guidelines are superseded by any Federal, State or Local regulations whenever applicable.

(I)

Quantity

1

1

1

1


119

SectioN 7

7.19


7

8

9

10

120


SU_0000682


7.19



7 decal, warning tongue heavy 100-375

8 decal, warning side door T-latch

9 decal, lead warning proposition 65

10 sign, warning hot surfaces

02250077-929

02250136-670

02250118-638

407408

(I) OSHA guidelines are superseded by any Federal, State or Local regulations whenever applicable.

(I)

Quantity

1

3

1

3


121

SectioN 7

7.19


122


SU_0000683

7.19


key Description

14 decal, caution do not overfill

15 decal, noise emission control

18 decal, 5 year warranty

19 decal, rated 2200 idle 1600 rpm

22 reflector, red

23 reflector, amber


Part Number

02250142-530

049463

02250097-455

02250146-383

040103

250034-319

Note Quantity

1

1

2

1

1

2


123

SectioN 7

7.19


124


SU_0000684

7.19


key Description

24 decal, “300HH Sullair” frnt blk

25 decal, “375 Sullair” frnt blk

27 decal, “375H Sullair” frnt blk

28 decal, “425 Sullair” frnt blk

30 decal, “300HH” 3" tall blk

31 decal, “375” 3" tall blk

33 decal, “375H” 3" tall blk


36 decal, Sullair 3 x 24 blk

37 decal, ISO 9001


Part Number

02250139-154

02250117-349

02250117-352

02250118-606

02250165-929

02250165-927

02250165-928

02250165-930

02250059-056

02250057-624

Note Quantity

1

1

1

1

1

1

1

1

1

1


125

SectioN 7

7.19


126


7.19


key Description

39 decal, maint 300HH-425 cat t3


Part Number

02250165-935

Note Quantity

1


127

SectioN 7

7.19


128

02250119-385-r01


02250075-505-r00

7.19


key Description

40 decal, wd e & c 375-425 cat t3

41 decal, aftercooled/filtered air

42 decal, aftercooler by-pass valve


Part Number

02250165-171

02250075-506

02250119-385

Note Quantity

1

1

1


129

SectioN 7

7.20

Decal locatioNS

130


7.20

Decal locatioNS (CONTINuED)

key Description

1 decal, iso 9001 blk 3.44x5.75

2 decal, “Sullair” 3.0 x 24.0

3 decal, warning tongue heavy 100-375

4 decal, 5 year warranty

5 nameplate, Sullair serial no. 185q-8f

6 decal, “375 Sullair” frt blk

7 decal, “375H Sullair” frt blk

8 decal, “425 Sullair” frt

9 decal, lead warning proposition 65

11 decal, warning side door t-latch

12 decal, “300HH Sullair” frt blk

13 decal, “need an air tool?” sml

14 decal, drwbr instl 185q pe std

15 decal, caution- do not overfill

17 decal, rated 2200 idle 1600

19 decal, wiring diagram 375-425 cat t3


21 decal, “375H” 3" tall blk

22 decal, “300HH” 3" tall


24 decal, maintenance 375-425 cat t3

26 decal, operator procedure start stop 375 cat t3

28 decal, “375HH” 3" tall blk

33 reflector, red 1.68 x 4.25

34 decal diesel fuel

35 decal, noise emission control

36 reflector, amber 1.68 x 4.25

37 sign, warning-hot surfaces

38 rivet, pop 1/8 x 3/8


Note

(I)

(I)

Part Number

02250057-624

02250059-056

02250077-929

02250097-455

02250108-078

02250117-349

02250117-352

02250118-606

02250118-638

02250136-670

02250139-154

02250140-925

02250142-050

02250142-530

02250146-383

02250165-171

02250165-927

02250165-928

02250165-929

02250165-930

02250165-935

02250165-938

02250168-422

040103

040248

049463

250034-319

407408

843102-038

Quantity

1

2

3

1

4

1

1

2

2

2

1

1

2

2

1

3

1

1

1

1

1

1

1

1

1

3

1

1

1


131

SectioN 7

7.20

Decal locatioNS

132



7.20

Decal locatioNS (CONTINuED)

key Description

A decal, water drain

B decal, warning cluster breath

C sign, warning compr oil fill cap

D decal, sullair awf instruction

E sign, warning sever fan port

F sign, warning sever belt drive

G sign, caution towing 55 mph

H sign, warning hot surfaces

I sign, warning crush/sever

J decal, caution doors closed

K axle lube instructions

L decal, warning pressurized clg sys location

A one on engine near drain, one on rear baffle near radiator drain

B shown -over service valves

C on receiver near fluid fill cap

D on receiver near fluid fill cap

E one on each side of fan shroud

F on alternator

G shown -on top of drawbar

H one on each side of lifting bail

I shown -on top of drawbar

J shown -one on back of each door latch

K shown-one at upper rear of fenders

L shown-on baffle over radiator fill

(I) This decal not used on less running gear machines.

Part Number

040345

250028-258

049685

250032-902

049965

049964

250005-578

407408

408919

250038-030

250042-543

02250051-826

Note

(I)

(I)

(I)

Quantity

2

1

1

1

1

2

2

1

1

4

2

1


133

SectioN 7


134


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 repoductive 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.

02250118-633 illuStratioNS aND PartS liSt


135

W

orldWide

S

aleS and

S

ervice

Printed in the u.S.a

Specifications subject to change

No results