SULLAIR 750XHH 900XH (A), 900XHH 1150XH (A), 1150XHH 1350XH (A) air compressor Operator’s Manual and Parts List
The Sullair 750XHH 900XH (A), 900XHH 1150XH (A), and 1150XHH 1350XH (A) air compressors are powerful and reliable machines that are perfect for a variety of applications. These compressors are powered by Caterpillar engines and are available in both aftercooled and non-aftercooled models. Featuring a durable open frame design, these compressors are built to last and can handle even the most demanding jobs.
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SULLAIR
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O
PEN
F
RAME
A
IR
C
OMPRESSOR
750XHH / 900XH (A)
900XHH / 1150XH (A)
1150XHH / 1350XH (A)
XHH = 500 PSIG, XH = 350 PSIG
(A) = Aftercooled Models
Caterpillar 475-630 HP
PART NUMBER:
02250167-328 Rev03
KEEP FOR
FUTURE
REFERENCE
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SULLAIR CORPORATION
The information in this document is correct at the time of printing for portable compressor serial number
20070920 000
and all subsequent serial numbers.
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SULLAIR
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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
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TABLE OF CONTENTS
Preparing To Tow...............................................................................1
Parking Or Locating Compressor .........................................................3
Hot Surfaces, Sharp Edges And Sharp Corners...........................................6
Toxic And Irritating Substances..................................................................7
Implementation of Lockout/Tagout.............................................................9
California Proposition 65.........................................................................10
Symbols and References........................................................................11
Description of Components.....................................................................15
Sullair Compressor Unit, Functional Description.........................................17
Compressor Cooling and Lubrication System, Functional
Compressor Discharge System, Functional Description..............................19
Capacity Control System, Functional Description.......................................21
Start Mode - 0 to 200 PSIG (0 to 13.8 BAR)..........................................21
Low Pressure Mode - 200 to 350 PSIG (13.8 to 24.1 BAR) .....................21
High Pressure Mode - 200 to 500 PSIG (13.8 to 34.5 BAR) .....................21
Shutdown........................................................................................21
Air Inlet System, Functional Description....................................................22
Instrument Panel Group, Functional Description.........................................22
Engine Control Module, Functional Description..........................................22
Electrical System, Functional Description..................................................25
Aftercooler Air System, Functional Description...........................................32
Lubrication Guide – Compressor..............................................................34
Lubrication Guide, Engine.......................................................................35
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TABLE OF CONTENTS
Compressor Start-up Procedure...............................................................41
Shutdown Procedure..............................................................................42
Maintenance After Initial 50 Hours of Operation..........................................44
Maintenance Every 300 Hours.................................................................44
Parts Replacement and Adjustment Procedures........................................44
Compressor Fluid Change Procedure.................................................44
Main Fluid Filter Servicing..................................................................44
Air Filter Maintenance.......................................................................45
Primary Element Removal.................................................................45
Secondary Element Removal.............................................................45
Element Replacement.......................................................................46
Control System Adjustment...............................................................46
Separator Element Replacement........................................................48
Troubleshooting Guide............................................................................49
Procedure For Ordering Parts..................................................................53
Recommended Spare Parts List...............................................................56
Compressor System 750 - 1350 XHH/XH..................................................58
Engine System 750 XHH - 1350 XH..........................................................60
Frame Assembly....................................................................................64
Compressor, Frame And Drive.................................................................66
Engine Exhaust System..........................................................................70
Air Inlet Valve Sub-assembly....................................................................74
Receiver Tank Assembly.........................................................................76
Receiver Tank Sub-Assembly..................................................................78
Cooling System Assembly.......................................................................84
High Pressure Electrical and Pneumatic Control System.............................92
Discharge System, Non-AfterCooled........................................................98
Control Lines, High Pressure..................................................................100
Open Frame Assembly Components......................................................102
Fuel System, Optional - Export Only........................................................104
Discharge System, Aftercooled Only, Optional ........................................108
Water Separator, Aftercooled Only, Optional...........................................110
Shutters Assembly, Optional..................................................................112
Air Start Tank, Optional.........................................................................114
Open Frame Components with Air Start, Optional.....................................116
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Section 1
SAFETY
NOTE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
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.
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.
1.2 TOWING (I)
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.
(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-
MOUNTED PORTABLE AIR COMPRESSORS AS WELL.
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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. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor.
C. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar 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. Make sure the coupling device is fully engaged, closed and locked.
E. If chains are provided, pass each chain through its point of attachment on the towing vehicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under 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.
F. Make sure that the coupling device and adjacent structures on the towing vehicle (and also, if utilized, chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain.
G. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render them inoperative.
WARNING
This equipment may be tongue heavy.
DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.
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. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack, and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full upright position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to towing.
I. Make sure tires are in good condition and are the size
(load range) specified and are inflated to the specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques.
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J. If provided, make sure all dual stop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional.
K. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided.
L. Make sure all access doors and tool box covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors.
M. Make sure parking brakes in towing vehicle are set, or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided.
N. Make sure the compressor wheels are not chocked or blocked, and that all tie-downs, if any, are free.
O. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail.
P. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor.
Q. DO NOT load this equipment with accessories or tools such that it is unbalanced from side to side or front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result.
Towing
A. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed).
B. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions:
1. Two axle four-wheel or three axle six-wheel steerable models: 15 MPH (24 km/h).
2. All other models: 55 MPH (88 km/h).
C. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle.
Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, Uturns 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.
D. Avoid grades in excess of 15Ëš (27%).
E. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain.
SAFETY
F. 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.
G. DO NOT permit personnel to ride in or on the compressor.
H. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction.
I. 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 grade so the compressor does not tend to roll downhill.
DO NOT park or locate compressor on grades exceeding 15Ëš (27%).
B. Make sure compressor is parked or located on a firm surface that can support its weight.
C. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to excessive dust from the work site.
D. On steerable models, park compressor with front wheels in straight-ahead position.
E. Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake connections, if provided.
F. Block or chock both sides of all wheels.
G. If provided, unhook chains and remove them from the points of chain attachment on the towing vehicle, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting.
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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
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.
CAUTION
Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar.
Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.
On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.
I. If a caster wheel is provided on the screw jack, it is part of the screw jack and cannot be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar and reinsert the pin. Make sure the jack is secured in place prior to towing.
J. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the drawbar or if hinged, to raise it to the upright position by hand, if the weight is more than you can safely handle. Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others.
K. 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.
L. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is parked on or adjacent to public roads. Park so as not to interfere with traffic.
NOTE
While not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted portable air compressors as well.
1.3 PRESSURE RELEASE
A. Open the pressure relief valve at least weekly to make sure it is not blocked, closed, obstructed or otherwise disabled.
B. Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throttle) valve, when an air hose exceeding
1/2" (13 mm) inside diameter is to be connected to the shutoff (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302
(b) (7) or any applicable Federal, State and Local codes, standards and regulations.
C. 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.
D. Provide an appropriate flow-limiting valve for each additional 75 feet (23 m) of hose in runs of air hose exceeding 1/2" (13 mm) inside diameter to reduce pressure in case of hose failure.
E. Flow-limiting valves are listed by pipe size and rated
CFM. Select appropriate valve accordingly.
F. DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO
NOT exceed manufacturer's rated safe operating pressures for these items.
G. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled.
H. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap.
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I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound.
J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes, standards and regulations.
L. DO NOT engage in horseplay with air hoses as death or serious injury may result.
M. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure.
N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure.
O. 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 and make sure coolant is not boiling before removing cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand.
P. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty.
Q. If a manual blowdown valve is provided on the receiver, open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air/fluid system.
1.4 FIRE AND EXPLOSION
WARNING
Do not attempt to operate the compressor in any classification of hazardous environment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty.
A. Refuel at a service station or from a fuel tank designed for its intended purpose. If this is not possible, ground the compressor to the dispenser prior to refueling.
SAFETY
B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills occur.
C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and
DO NOT permit smoking in the vicinity when adding fuel, or when checking or adding electrolyte to batteries, or when checking or adding fluid, or when checking diesel engine ether starting aid systems or replacing cylinders, or when refilling air line anti-icer systems antifreeze compound.
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 acoustical material, or on any external or internal 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 liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes.
E. Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the battery connections so others will not unexpectedly reconnect it.
F. 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.
G. Turn off battery charger before making or breaking connections to the battery.
H. 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.
I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system.
Tag the compressor and render it inoperative until repair can be made.
J. Remove any acoustical material or other material that may be damaged by heat or that may support combustion 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.
K. Keep a suitable, fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor.
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L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine.
N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas.
O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in wellventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160ËšF (71ËšC).
Remove ether cylinder from the compressor when operating in ambient temperatures above 60ËšF (16ËšC).
P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result.
Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result.
R. Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use systems and refill with compound only in well-ventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150ËšF (66ËšC).
Vapors from the antifreeze compound are heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas. DO
NOT store containers of antifreeze compound in direct sunlight.
S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended.
Check readiness of fire suppression systems and detectors if so equipped.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body and also clothing away from belts, pulleys and other moving parts.
B. DO NOT attempt to operate the compressor with the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts inside the enclosure.
D. Keep access doors closed except when making repairs or adjustments, performing service or when starting or stopping the compressor.
E. Make sure all personnel are out of and clear of the compressor prior to attempting to start or operate it.
F. Shut off engine before adding fuel, fluid, coolant lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders.
G. Disconnect the grounded negative battery connection 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. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibility of slips and falls.
1.6 HOT SURFACES, SHARP EDGES
AND SHARP CORNERS
A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.
C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection.
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SAFETY
1.7 TOXIC AND IRRITATING
SUBSTANCES
A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other Federal,
State or Local codes or regulations.
DANGER
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.
B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas.
C. Operate the compressor only in open or well- ventilated areas.
D. If the compressor is operated indoors, discharge engine exhaust fumes outdoors.
E. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor.
F. 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 induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact.
G. Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, immediately flush with large quantities of water.
H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting, but call a physician immediately.
I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze compound to air line anti-icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourself and other personnel.
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J. If ethyl ether or air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for 15 minutes. A physician, preferably any eye specialist, should be contacted immediately.
K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operator's cabs or in other similar confined areas.
L. The antifreeze compound used in air line 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 of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10 feet (3 m) from power lines and buried cables.
B. 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. Attempt repairs only in clean, dry and well-lighted and ventilated areas.
D. Stay clear of the compressor during electrical storms!
It can attract lightning.
1.9 LIFTING
A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with
OSHA Standards 29 CFR 1910 subpart N or any other
Local, State, Military and Federal regulations that may apply.
B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight of snow, ice, mud or stored tools and equipment. If your are unsure of the weight, then weigh compressor before lifting.
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D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail.
E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance whenever compressor is suspended.
J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional
10% allowance for the weight of snow, ice, mud or stored tools and equipment.
K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disengaging the lifting hook.
1.10 ENTRAPMENT
A. Make sure all personnel are out of compressor before closing and latching enclosure doors.
B. 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. Observe all safety precautions mentioned elsewhere in this manual.
B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away.
C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid-resistant apron and face shield when attempting to jump start the compressor.
D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells.
E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance-free batteries).
F. DO NOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60ËšF (16ËšC) before attempting to jump start or it may explode.
G. Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start.
H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result.
I. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle.
J. Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels.
K. Place the starting vehicle in neutral or park, turn off all non-essential accessory electrical loads and start its engine.
L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current.
M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition.
N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign.
O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the positive (POS) (+) terminal of the ungrounded battery.
P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor, or when jump starting 24V compressor, to the positive (POS) (+) terminal of the ungrounded battery in the compressor.
Q. Connect one end of the other jumper cable to the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the negative (NEG) (-) terminal of the grounded battery.
R. Check your connections. DO NOT attempt to start a
24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V to one 12V battery in the compressor.
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S. Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening and the battery.
T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking.
U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two
(2) 12V batteries connected in series.
V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps.
1.12 IMPLEMENTATION OF
LOCKOUT/TAGOUT
The energy control procedure defines actions necessary to lock out 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 of any machine shall be locked out by each employee doing the work except when motion is necessary during set up, adjustment or troubleshooting.
SAFETY
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. Alert operator and supervisor of which machine is to be worked on, and that power and utilities will be turned off.
3. Check to make certain no one is operating the machine before turning off the power.
4. Turn off the equipment using normal shutdown procedure.
5. Disconnect the energy sources: a. Air and hydraulic lines should be bled, drained and cleaned out. There should be no pressure in these lines or in the reservoir tanks. Lock out or tag lines or valves.
b. Any mechanism under tension or pressure, such as springs, should be released and locked out or tagged.
c. Block any load or machine part prior to working under it.
d. Electrical circuits should be checked with calibrated electrical testing equipment, and stored energy and electrical capacitors should be safely discharged.
6. Lock out and/or tag out 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. Tagout devices shall be used only when power 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 tag along with date tag was placed on power source.
8. Release stored energy and bring the equipment to a “zero mechanical state.”
9. Verify Isolation: Before work is started, test equipment to ensure power is disconnected.
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SECTION 1
B. General Security
1. The lock shall be removed by the “Authorized” person who put the lock on the energy-isolating device. No one other than the person/persons placing padlock and lockout hasp on power shall remove padlock and lock out hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it his/her Supervisor may remove padlock/padlocks and lock out hasps and restore power only if it is first: a. verified that no person will be exposed to danger.
b. verified that the “Authorized” person who applied the device is not in the facility.
c. noted that all reasonable efforts to contact the
“Authorized” person have been made to inform him or her that the lockout or tagout device has been removed.
d. ensured that the “Authorized” person is notified of lock removal before returning to work.
2. Tagout System - Tags are warning devices affixed at points of power disconnect and are not to be removed by anyone other than the person placing tag on power lockout. Tags shall never be bypassed, ignored or otherwise defeated.
1.13 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 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.
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1.14 SYMBOLS AND REFERENCES
The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols.
SAFETY
SU_0000701
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SU_0000702
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SAFETY
SU_0000703
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SECTION 1
THIS PAGE INTENTIONALLY LEFT BLANK
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Section 2
DESCRIPTION
2.1 INTRODUCTION
The Sullair Portable Open Frame Air Compressor models offer superior performance and reliability while requiring only minimal maintenance.
The compressor is equipped with a Sullair rotary screw compressor unit. Compared to other compressors, the
Sullair is unique in mechanical reliability and compressor durability. No inspection is required of the working parts within the compressor unit.
As you continue reading this manual and come to learn how the compressor operates and is cared for, you will see how surprisingly easy it is to keep a Sullair compressor in top operating condition.
Read “Maintenance” on page 43 to keep your
compressor in top operating condition. Should any problem or question arise which cannot be answered in this text, contact your nearest Sullair representative or the
Sullair Corporation Service Department.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure 2-1. The components and assemblies of
the Sullair Portable Open Frame Air Compressor models are clearly shown. The package includes a compressor, diesel engine, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical system. The Sullair compressor unit is driven by an industrial engine designed to provide enough horsepower for more than adequate reserve at rated conditions. Refer to Engine Operator's Manual for a more detailed description of the engine.
The engine cooling system is comprised of a radiator, high capacity fan and thermostats. The high capacity fan draws air through the radiator, keeping the engine at the proper operating temperature.
The same fan also cools the fluid in the compressor cooling and lubrication system. While passing through the radiator, the fan air also passes through the compressor fluid cooler (which is mounted adjacent to the radiator). As air passes through the cooler, the heat of compression is removed from the fluid.
The same fan also cools the engine intake air supply.
While passing through the radiator and oil cooler, the fan air passes through an air to air aftercooler. As air passes through the air to air aftercooler heat is removed which was introduced by the engine's turbo charger.
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SECTION 2
15
14
7
11
8
10
4
9
6
16
1
13
5
3
16
2
12
17
1. Blowdown Valve (attached to inlet valve)
2. Moisture Separator (if equipped)
3. Thermal Valve
4. Regulator Valves
5. Fluid Stop Valve
6. Discharge Check Valve
7. Engine Coolant Fill
8. Fluid Cooler
9. After Cooler (if equipped)
10. Engine Charge Air Cooler
11. Engine Radiator
12. Compressor Fluid Filter
13. Receiver Tank
14. E-Stop
15. Engine Muffler
16. Manual Enclosure
17. Battery Disconnect Switch
Figure 2-1: Main Component Locations
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2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
Sullair XH/XHH compressors feature the Sullair compressor unit, a two-stage, positive displacement, flood lubricated-type compressor. This unit provides continuous compression to meet your needs.
NOTE
With a Sullair compressor, there is no maintenance or inspection of the internal parts of the compressor unit permitted in accordance with the terms of the warranty.
Sullair compressors are factory-filled with Sullair AWF lubricant. For more information on fluid fill, refer to
Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three basic functions:
1. As coolant, it controls the rise of air temperature normally associated with the heat of compression.
2. Seals the clearance paths between the rotors and the stator and also between the rotors themselves.
3. Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler.
After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows through an aftercooler and separator then to your service line while the fluid is being cooled in preparation for reinjection.
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
DESCRIPTION
temperature of the compressor. In addition to the cooler and fan, the system consists of a main filter, fluid stop valve and thermal valve.
Fluid is used in the system as a coolant and a lubricant.
The fluid is housed in the receiver tank. Upon start-up, the temperature of the fluid is cool and routing to the fluid cooler is not necessary. The fluid, taking the path of least resistance, flows to the thermal valve.
As previously stated, upon start-up, the fluid temperature is cool, and routing to the cooler is not required. The fluid first enters the thermal valve and then flows to the compressor unit, bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and the thermal valve element begins to shift. This forces a portion of the fluid to the fluid cooler. The cooler is a radiator-type that works in conjunction with the engine fan.
The fan draws air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve. Before the temperature of the fluid reaches the valve set point, cooled fluid is mixed with warmer fluid. When the temperature of the fluid reaches 230°F (110°C), the thermal element shifts completely causing all fluid to flow to the cooler. The thermal valve incorporates a pressure relief valve, which allows fluid to bypass the cooler, if the cooler becomes plugged or frozen. This helps assure that fluid will continue to be provided to the compressor for lubrication. After the fluid passes through the thermal valve it is then directed through the main fluid filter. There, the fluid is filtered in preparation for injection into the compression chamber and bearings of the compressor unit. The filter has a replaceable element and a built-in bypass valve which allows the fluid to flow even when the filter element becomes plugged and requires changing or when the viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it then flows on to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and gears.
The fluid stop valve functions on shutdown when it shuts off the fluid supply to the compressor unit. The fluid stop valve is held open by a pressure signal from the compressor discharge. At shutdown, the pressure signal is lost and the fluid stop valve closes, isolating the compressor unit from the cooling system.
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SECTION 2
5
2
3
1
4
1. Compressor Fluid Filter
2. Thermal Valve
3. Stop Valve
4. Cooler
5. Separator Tank
Figure 2-2: Cooling and Lubrication System
NOTE
Arrows indicate direction of fluid flow within the Cooling and Lubrication
System.
SU_0000037
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2.5 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3. The Sullair compressor unit
discharges compressed air/fluid mixture into the receiver tank.
The receiver tank has three functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid storage sump.
3. Houses the final fluid separator.
The compressor unit discharges compressed air/fluid mixture through a discharge check valve into the receiver tank. The discharge check valve is located on the inlet port of the receiver tank. The discharge check valve prevents discharged air from returning to the compression chamber after shutdown.
The compressed air/fluid mixture enters the receiver tank and is directed against the tank side wall. By change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the receiver tank. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid collects on the element's surface, the fluid descends to the bottom of the separator. A return line
(or scavenge tube) leads from the bottom of the separator element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator element is
DESCRIPTION
returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet. An orifice (protected by a strainer) is included in this return line to help assure proper flow.
The receiver tank is code rated. A minimum pressure/ check valve, located downstream from the separator, helps assure a minimum receiver pressure of 200 psig
(13.8 bar) during all conditions. This pressure is necessary for proper air/fluid separation and proper fluid circulation.
The minimum pressure/check valve is also used to prevent compressed air in the service line from bleeding back into the receiver on shutdown when the compressor is being run in parallel with other compressors tied to a large air system.
A pressure relief valve (located on the wet side of the separator) is set to open if the receiver tank pressure exceeds 600 psig ( 41.4 bar). A temperature switch will shut down the compressor if the discharge temperature reaches 300°F (149°C) or 280°F (138°C) at the interstage.
Fluid is added to the receiver tank via a capped fluid filler.
A fluid level sight glass enables the operator to visually monitor the receiver tank fluid level.
WARNING
DO NOT remove caps, plugs, and/or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
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SECTION 2
3
16
1
2
15
14
12
8
4
5
9
6
7
13
10
11
20
1. Unit Air Filter
2. Engine Air Filter
3. Engine
4. Compressor Fluid Cooler
5. Thermal Valve
6. Compressor Fluid Filter
7. Receiver Tank
8. Unit
SU_0000038
9. Relief Valve
10. Fluid Fill/Upper Sight Glass
11. Lower Sight Glass
12. Fluid Return/Sight Glass Assembly
13. Minimum Pressure Check Valve
14. Inlet Valve
15. Strainer
16. Control Manifold Block
Figure 2-3: Discharge System
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2.6 CAPACITY CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Compressor System 750 - 1350 XHH/XH on page
58 and Engine System 750 XHH - 1350 XH on page
60. The purpose of the control system is to regulate the
amount of air intake in accordance with the amount of compressed air demand. The control system consist of an inlet valve, the high and low pressure regulators, the pressure reducing regulator, the blowdown/running blowdown valve, the Compass Controller, a START/RUN selector switch, and the HIGH/LOW selector switch.
Start Mode - 0 to 200 PSIG (0 to 13.8 BAR)
Push OFF/ON/START switch to "ON" position to initialize the Compass Controller. Once the Compass Controller says “READY” on LCD, press OFF/ON/START switch to the "START" position. In the "START" position, the inlet valve is held closed by the springs in the inlet valve. The valve is cracked open by vacuum in the compressor and is allowed to build up to 200 psig (13.8 bar). The reason for keeping the valve closed during start is to allow the engine to warm up without being loaded by the compressor. Air pressure is contained in the receiver tank by the minimum pressure valve which has a set point of
200 psig (13.8 bar), At this point the valve opens allowing the air to pass to the service valve. After engine has warmed up the machine automatically transfers to “RUN” mode.
Low Pressure Mode - 200 to 350
PSIG (13.8 to 24.1 BAR)
With the HIGH/LOW switch in the "LOW" position, and the controller in "RUN" mode, the service valve can now be opened. Pressure from the 60 psig (4.1 bar) reducing
DESCRIPTION
regulator opens up the inlet valve and the Compass
Controller increases the engine speed to full load (1800 rpm). As the demand for air decreases, the Compass
Controller commands the engine to reduce speed to idle
(1400 rpm) and the inlet valve closes, where it stabilizes until the air demand is required again.
High Pressure Mode - 200 to 500
PSIG (13.8 to 34.5 BAR)
When the HIGH/LOW switch is switched to the "HIGH" position, the low pressure regulator is blocked off allowing the high pressure regulator to take over control of the machine. The 60 psi (4.1 bar) reducing regulator fully opens the inlet valve and the Compass Controller commands maximum speed (1800 rpm) from the engine.
As the pressure reaches the set point of the system the high pressure regulator cracks open and closes the inlet valve and the Compass Controller returns the engine back to idle, until a demand for air is seen.
Shutdown
The blowdown valve is normally closed. When the compressor is shutdown, system pressure backs up to the inlet valve causing the check spring in the inlet valve to close the air inlet valve. This sends a pressure signal to the blowdown valve causing it to open and vent the pressure in the system. After the pressure is vented, the blowdown valve spring returns the blowdown valve to the closed position.
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SECTION 2
2.7 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
The inlet system consists of two air filters, a compressor air inlet valve and interconnecting piping to the engine and compressor. Also, nylon tubing and air filter restriction indicator gauges are provided.
The air filters are a 2-stage unit with a safety element dry element-type filter. This filter is capable of cleaning extremely dirty air. However, in such cases, frequent checks of the air filter will be required. Referring to the instrument panel, the engine air filter restriction gauge or the compressor air filter restriction gauge will indicate when restriction of the air passing through the filter becomes too high.
At this time, change the air filter element. Refer to Air Filter
Maintenance on page 45. These indicators should be
checked daily, after start-up under normal conditions.
The compressor air inlet valve controls the amount of air intake of the compressor in response to the air demand.
2.8 INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION
Refer to Compass Controller Manual, Sullair Part No.
02250167-454
2.9 ENGINE CONTROL MODULE,
FUNCTIONAL DESCRIPTION
Diagnostic fault codes are provided to indicate a problem has been detected by the ECM (Engine Control Module).
In some cases, the engine performance can be affected when the condition causing the code exists. More frequently, however, the operator cannot detect any difference in the engine performance.
The Compass Controller indicates a performance problem has occurred whenever the engine warning lamp is flashing. The diagnostic code may indicate the cause of the problem, and should be corrected.
If the Compass Controller does not indicate a problem with the engine performance but a diagnostic code is logged by the ECM, the ECM detected an abnormal condition that did not affect performance.
If this is the case, unless there are several occurrences of the code in a very short period of time, or, the ECM is indicating an Active Code at the present time, there is most likely nothing wrong with the system.
The diagnostic FLASH CODE may be retrieved using this lamp.
The lamp is not required for engine operation, however, it can be useful to determine Active diagnostic codes. The lamp will illuminate (ON) at initial ECM power-up to test the lamp operation (self test).
Count the first sequence of flashes to determine the first digit. After a two-second pause, count the second sequence of flashes to determine the second digit. Any additional flash code diagnostics will follow
(after a pause) and will be displayed in the same manner.
In addition to the flash codes described above, the
Compass Controller should display a brief verbal message in the LCD of the master gauge. This message helps to pinpoint the source of the problem and aid in troubleshooting the compressor.
NOTE
Only Active diagnostic codes can be read in this manner. Logged diagnostic codes must be retrieved with an Electronic Service Tool.
Refer to Table 2-1 on page 23 for possible performance
of active diagnostic codes.
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DESCRIPTION
TABLE 2-1 POSSIBLE PERFORMANCE OF ACTIVE DIAGNOSTIC CODES
Flash
Code
Description Of Code CID-FMI
Code
SPN-FMI
Code
678-03
678-04
100-03
100-04
102-00
102-03
102-04
108-03
108-04
110-03
Engine
Misfires
x
Low
Power
x x x x
Reduced
Engine
Speed
12
13
21
24
25
26
27
Incorrect crank-without-inject inputs
Fuel temperature open/short to +batt
Fuel temperature short to ground
5-Volt sensor DC power supply short to
+batt
5-Volt sensor DC power supply short to ground
Digital sensor supply short to +batt
Digital sensor supply short to ground
Engine oil pressure open/short to +batt
Engine oil pressure open/short to ground
Turbo outlet pressure above normal
Turbo outlet pressure open/short to +batt
Turbo outlet pressure short to ground
266-02
174-03
174-04
262-03
262-04
Atmospheric pressure open/short to +batt
Atmospheric pressure short to ground
274-03
274-04
Engine coolant temperature open/short to
+batt
110-03
Engine coolant temperature short to ground 110-04
262-03
263-04
100-03
100-04
273-00
273-03
273-04
266-02
174-03
174-04
620-03
620-04
28
32
34
35
37
38
42
46
Throttle position calibration required
Throttle position signal abnormal
Speed/timing sensor loss of signal
Speed/timing sensor mechanical failure
Loss of secondary engine speed signal
Secondary engine speed sensor mechanical failure
Engine overspeed shutdown
Engine overspeed warning
Fuel pressure open/short to +batt
Fuel pressure short to ground
Engine oil temperature open/short to +batt
91-13
91-08
320-02
320-11
342-02
342-11
004
190
94-03
94-04
175-03
Engine oil temperature short to ground 175-04
Intake manifold air temp open/short to +batt 172-03
Intake manifold air temp short to ground
Engine timing calibration required
172-04
261-13
Low engine oil pressure warning
Low engine oil pressure derate
100
039
110-04
91-03
91-08
190-02
190-11
723-02
723-11
0190-16
0190-00
94-03
94-04
175-03
175-04
172-03
172-04
228-13
0100-17
0100-18 x x x x x x x x x x x x x x
51
53
56
Low engine oil pressure shutdown
System voltage intermittent/erratic
Electronic Control Module error
040
168-02
254-12
0100-01
168-02
No code x x x (I) x x x (I) x
Personality Module mismatch
Check programmable parameters
253-02
268-02
234-02
111-02 x x
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier x x x x x x x x (I) x (I) x (I) x (I) x x (I) x x x (II)
Engine
Shutdown
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SECTION 2
Flash
Code
Description Of Code CID-FMI
Code
SPN-FMI
Code
Engine
Misfires
Low
Power
58
61
62
64
65
72
73
J1939 Data Link communications
High engine coolant temperature derate
High engine coolant temperature shutdown
High engine coolant warning
Fuel filter restriction derate
Fuel filter restriction shutdown
Fuel filter restriction warning
High fuel pressure
High inlet temperature derate
High inlet temperature warning
High fuel temperature derate
High fuel temperature shutdown
High fuel temperature warning
Injector cylinder #1 fault
Injector cylinder #2 fault
Injector cylinder #3 fault
Injector cylinder #4 fault
247-09
015
016
017
005
006
095
096
025
027
054
055
056
1-11
2-11
3-11
4-11
639-09
0110-16
0110-00
0110-15
0094-15
0094-16
0094-00
0094-00
0172-16
0172-15
0174-16
0174-00
0174-15
651-11
652-11
653-11
654-11 x x x x x x x x
74 Injector cylinder #5 fault
Injector cylinder #6 fault
Either start relay open/short to +batt
5-11
6-11
545-05
655-11
656-11
545-05 x x x x
00
Either start relay short to ground 545-06 545-06
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier
Reduced
Engine
Speed
Engine
Shutdown
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DESCRIPTION
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
Refer to Figure 2-4. The electrical system is comprised of
not only the necessary equipment required to operate the compressor, but also a system to shut it down in the event of a malfunction. The components of the electrical system are an engine starter (with an integral solenoid), battery, an alternator with a built-in voltage regulator, a compressor discharge temperature switch (which will shut down the compressor should the compressor temperature exceed
300°F [149°C]), a low coolant shutdown switch and low fuel shutdown protection. The engine coolant level detector is located in the overflow tank near the top of engine radiator. It will shut the compressor down or prevent it from being started if the engine coolant level drops too low. In addition, there is a starter protection relay which prevents accidental starter engagement after the engine is running or whenever there is pressure in the receiver tank.
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SECTION 2
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION (CONTINUED)
D2
D
25
D1 D7
D
26
D
24
D
21
D
23
D
20
D
22
D
19
26
02250159-195R09-1
Key Description
D1 Alternator
D2 60A Fuse
D3 2A Fuse
D4 Ether Start Solenoid
D5 Filter Minder Engine
D6 Filter Minder Compressor
D7 Battery Disconnect Switch
D8 12V Battery
D9 Starter Relay
D10 Starter Solenoid
Note
Figure 2-4: Wiring Diagram, part one
Key Description
D11 Starter
D12 E-Stop
D13 Compass Controller
D14 Louver Solenoid
D15 Remote Start Input
D16 Spring Valve Solenoid
D17 Ambient Temperature
Sensor
D18 Fuel Sender
Note
See Compass Controller
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DESCRIPTION
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION (CONTINUED)
D3
D4
D5
D6
D8
D9
D
10
D
11
D
12
D
13
D
15
A1
D
14
D
17
D
16
D
18
D
27
D
28
D
29
D
30
D
31
02250159-195R09-2
Key Description
D19 Manifold Block
D20 Recirculation
D21 Start/Run
D22 Relay HI/LO
D23 P2
D24 Engine Coolant Level
D25 Air Stop
D26 Engine ECM
D27 Compressor Discharge
Temperature
Note
See Engine ECM
Figure 2-4: Wiring Diagram, part two
Key Description
D28 Interstage Temperature
(H.P. Only)
D29 Receiver Tank
Temperature
D30 Receiver Tank Pressure
(Dry)
D31 Receiver Tank Pressure
(Wet)
A1 Required for XXH/XH Only
Note
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SECTION 2
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION (CONTINUED)
PIN Description
10 Ether Start Sol.
54 Air Stop Switch
11 Air Stop Module
Engine ECM
67 Air Stop Common
61 Batt. -
63 Batt. -
65 Batt. -
4 Dig. Sensor +8V
49 Coolant LVL SW.
5 Dig. Sensor Ret.
2 Analog SNSR +5V
70 Switch Batt. +
8
9
Data Link +
Data Link -
28 Diagnostic Lamp
29 Warning Lamp
34 J1939 -
50 J1939 +
42 J1939 Shield
48 Unswitch Batt. +
52 Unswitch Batt. +
53 Unswitch Batt. +
55 Unswitch Batt. +
Compass Controller
PIN Description
21 Fltr Restrict Eng.
22 Fltr Rstr. Compr.
1 E-Stop (+24V)
10 + Batt E-Stop
2 - Ground
7 Starter Relay
11 - Louver
29 Remote Start
25 Amb Temp Sensor
12 Fuel Sender
5 HI/LO Switch
28 - Recirc. Sol.
6 Start/Run Swtch
14 P2 Control Press.
16 CDT Sensor
19 RTT Sensor
13 P1 Dryside Press.
15 P3 Wetside Press.
17 + 5 Volt DC
4 + Batt. Switch
23 + Cat Data Link
24 - Cat Data Link
20 Diagnostic LP. Eng.
18 Warning Lamp Eng.
9 - Can (J1939)
8 + Can (J1939)
3 + Batt. Unsw.
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DESCRIPTION
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SECTION 2
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION (CONTINUED)
17
16
15
14
A4
A6
A3
30
13
12
11
A5
10
02250172-331R00-1
Key Description
1 Relay Switch Power
2
3
Relay Engine Crank
Relay HI LO
4
5
Relay Start/Run
AMP 770024-1, 2-Pos Mate-N-Lock
(PIN #'s not crucial) uses AMP 770008-3
8
9
6
7
Auto Reset Breaker 3
Auto Reset Breaker 2
Auto Reset Breaker 1
Connector #2
10 Connector #1
Figure 2-5: Wiring Diagram, part two
Key Description
11 HI/LO
12 Reset
13 Start/On/Off
14 AMP 770579-1, 8-POS Mini Mate-N-Lock, AMP Term
171637-1
15 Tyco 1411001-1, 8-Pos Sealed Housing, uses Tyco
1393366-1
16 Tyco 1411001-1, 8-Pos Sealed Housing, Label
“Master”, uses Tyco 1393366-1
17 Tyco 1438031-1, 16-Pos Sealed Housing, uses Tyco
1393366–1
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DESCRIPTION
2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION (CONTINUED)
A1
1
2
3
4
5
6
8 7
A2
9
02250172-331R00-2
Figure 2-6: Wiring Diagram, part two
Key Description
A1 Tyco 4-1419106-0, Bracket Mountable Relay Socket,
4 places, Interlock sockets together in this order, uses
Packard 1201-5865
A2 Bussman 124B15-B2M-01-KA, 15A 24V Circuit
Breaker, 3 places, uses AMP 2-34146-1 or equiv #10
Ring Term
A3 Connector #2, Deutsch, HDP24-24-29PE, 29-Pin
Receptacle, Deutsch PINS
PINS 1-4: 0460-204-12141, PINS 5-17, 19, 21, 22, 25
& 28: 0480-202-16141, PINS 18, 20, 23, 24, & 28:
0460-202-20141
Seals Pos. 26 with Deutsch 114017, Seal Pos. 27 with
Deutsch 0413-204-2005
Key Description
A4 Connector #1, Deutsch HDP24-18-14PN, 14-Pin
Receptacle, uses PINS 0460-202-16141, Seal unused positions with Deutsch 114017
A5 Carling 'VCH' Switch Block w/AMP Fastin-Faston 250 series terminals
A6 Deutsch HD 10-9-96P-B009, 9-Pin Receptacle, uses
PINS 1060-16-01222, Seal unused Pos. with Deutsch
114017
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SECTION 2
2.11 AFTERCOOLER AIR SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-7. The purpose of the aftercooler air
system is to operate the air compressor in conditions when compressed air temperatures are required to be 10 to 25ËšF
(5 to 13ËšC) over ambient temperature. Two discharge valves are provided on all aftercooled compressor models. One valve is labeled standard air and one valve is labeled aftercooled air. Closing the standard air (nonaftercooled) valve completely forces the air flow 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 and discharged. This condensation does carry some oil and it should be disposed of properly in accordance with local regulations.
From the moisture separator the compressed air goes to the compressor service valve.
NOTE
Aftercooler system should not be operated in ambient conditions below
32ËšF (0ËšC). If it is necessary to operate in these conditions, Sullair can supply optional equipment to accommodate this requirement.
To operate in the non-aftercooled mode, close the aftercooler service valve completely and open nonaftercooler valve.
4
5
9
1
3
8
7
2
10
6
SU_0000040
32
1. Minimum Pressure/Check Valve
2. Air Aftercooler
3. Air/Water Separator
4. Receiver Tank
5. Discharge Check Valve
6. Air Valve (Std To AC Air)
7. Standard Air
8. Aftercooled Air
9. Water Drain
10. From Unit Discharge
Figure 2-7: Aftercooler Air System
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Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS
Model Series
OPEN FRAME (ALL)
(I) Aftercooled add 500 lbs / 227 kg
TABLE 3-1 OVERALL SPECIFICATIONS
Length in (mm)
181.6 (4613)
Width in (mm)
86.0 (2184)
Height in (mm)
Weight (wet) lbs (kg) (I)
89.7 (2278) 13000 (5897)
TABLE 3-2 COMPRESSOR SPECIFICATIONS
COMPRESSOR
Type
750XHH / 900XH
Rotary Screw
Maximum Operating Pressure 500 psig (34.5 bar)
Receiver Tank Capacity
Electrical System
Battery (2)
35 U.S. Gallons (170 liters)
Engine – 24 Volt
Instrument System – 24 Volt
1550 CCA @ 32°F (0°C)
900XHH / 1150XH
Rotary Screw
500 psig (34.5 bar)
1150XHH / 1350XH
Rotary Screw
500 psig (34.5 bar)
Rated Pressure 500 / 350 psig (34.5 / 24.1 bar) 500 / 350 psig (34.5 / 24.1 bar) 500 / 350 psig (34.5 / 24.1 bar)
Delivery at 500 psig (34.5 bar) 750 / 900 Free CFM 900 / 1150 Free CFM 1150 / 1350 Free CFM
Cooling
Lubricating Compressor
Pressurized Compressor Fluid Pressurized Compressor Fluid Pressurized Compressor Fluid
Consult Lubrication Guide Consult Lubrication Guide Consult Lubrication Guide
35 U.S. Gallons (170 liters)
Engine – 24 Volt
Instrument System – 24 Volt
1550 CCA @ 32°F (0°C)
35 U.S. Gallons (170 liters)
Engine – 24 Volt
Instrument System – 24 Volt
1550 CCA @ 32°F (0°C)
Alternator
Service Valves
(8D) 1125 CCA @ 0°F (-18°C) (8D) 1125 CCA @ 0°F (-18°C) (8D) 1125 CCA @ 0°F (-18°C)
60 amp 60 amp 60 amp
3” npt 3” npt 3” npt
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SECTION 3
ENGINE
Make
Type
Rated Speed
Horsepower, SAE
Cylinders
Cycles
Bore x Stroke
Displacement
Lubricating System
Type of Motor Oil
TABLE 3-3 ENGINE SPECIFICATIONS
750XHH / 900XH
Caterpillar
Cat C15 ATAAC TIER III (I)
1800 RPM
475 HP (354 kw)
6
4-cycle
5.4 x 6.7 in
(137 x 170 mm)
923 cubic inches (15.1 liters)
Full Pressure Fluid
See Engine Operator's
Manual
12.6 U.S. gallons (48 liters)
900XHH / 1150XH
Caterpillar
Cat C15 ATAAC TIER III (I)
1800 RPM
540 HP (403 kw)
6
4-cycle
5.4 x 6.7 in
(137 x 170 mm)
923 cubic inches (15.1 liters)
Full Pressure Fluid
See Engine Operator's
Manual
12.6 U.S. gallons (48 liters)
1150XHH / 1350XH
Caterpillar
Cat C18 ATAAC TIER III (I)
1800 RPM
630 HP (470 kw)
6
4-cycle
5.7 x 7.2 in
(145 x 183 mm)
1106 cubic inches (18.1 liters)
Full Pressure Fluid
See Engine Operator's
Manual
12.6 U.S. gallons (48 liters) Engine Cooling System
Capacity
Idle Speed
(I) Air to air aftercooled
1400 RPM 1400 RPM 1400 RPM
3.2 LUBRICATION GUIDE – COMPRESSOR
Fluid Type
Sullair AWF (I)
Mobil Rarus SHC 1026600
Mobil Rarus SHC 1024
300
600
800
Change Period, Hours Ambient Temperature Range °F (°C)
–20 to 120 (–29 to 49)
50 to 125 (10 to 52)
–20 to 100 (–29 to 38)
(I) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5 gallons/18.9 liters), 250030-758 (55 gallons/208 liter drum)
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SPECIFICATIONS
3.3 APPLICATION GUIDE
Refer to Figure 3-1 Sullair Air Compressors are supplied
with Sullair AWF which is heavy duty multi-viscosity, allweather fluid. Sullair AWF also allows an extended change interval.
The fluids in the Lubrication Guide – Compressor can be
used. Any of these oils are suitable under conditions where severe oil oxidations can occur.
Water must be drained from the receiver periodically. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a
"milky" color. The fluid should be changed if this condition develops.
CAUTION
DO NOT mix types of fluids.
Combinations of different fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging.
When ambient conditions exceed those noted or if conditions warrant use of other extended life lubricants, contact Sullair for recommendations.
Sullair encourages the user to participate in a fluid analysis program. This could result in a fluid change interval differing from that stated in the manual. Sullair Corporation offers a fluid analysis program for Sullair AWF. Contact your local Sullair representative for details.
D-A Lubricant
®
Company Inc. offers an analysis program for users of D-A products and Sullair AWF. Contact your
D-A Lubricant ® supplier or Sullair representative for details.
1
3
2
SU_0000042
1. Lower Sight Glass (I)
2. Upper Sight Glass (II)
3. Fluid Fill Port
Figure 3-1: Fluid Fill Location
(I) If fluid level is seen in the lower sight glass when the machine is not running, add Sullair AWF until level is seen in upper sight glass.
(II) If fluid is seen in the upper sight glass when the machine is
NOT running, no fluid is needed.
3.4 LUBRICATION GUIDE, ENGINE
For engine oil specifications, refer to the Engine
Operator's Manual.
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SECTION 3
8
1 2
3
4
5
7
18
6
9
10
11
14
36
13
12
Figure 3-2: Functional Description, part one
1. Engine Radiator Fill
2. Oil Filter Manifold Block
3. Lifting Bail Eye
4. 3" NPT After-Cooled Air Discharge (Optional)
5. 3" NPT Standard Air Discharge
6. 6" Engine Exhaust
7. Engine Air Intake
8. H.P. Unit Air Intake
9. E-Stop
10. Instrument Panel Door
11. Air Controls Door
12. Remote Fuel Connections
13. Fork Lift Pockets (4 Places)
14. Cooling Air Inlet
18. Approx. Center of Gravity
02250159-171R00-1
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SPECIFICATIONS
15. Pulling Eye (2 Places)
16. 2.5” Drain Plug (5 Places)
17
02250159-171r00
SU_0000043-2
Figure 3-2: Functional Description, part two
17. ½" NPT Drains (4 Places)
16
15
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Section 4
OPERATION
4.1 GENERAL
While Sullair has built into this compressor a comprehensive array of controls and indicators to assure you that it is operating properly, you will want to recognize
4.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR
OFF/ON/START Switch (Start Up)
OFF/ON/START Switch (Shut Down)
LCD Display
Air Pressure Gauge
Engine Water Temperature Gauge
Compressor Discharge Temperature Gauge
Fluid Level Sight Glass and interpret the readings which will call for service or indicate the beginning of a malfunction. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators - their purpose, location and use.
PURPOSE
The engine switch is used to both energize the compressor's electrical system and engage the engine/starter. It also has a builtin anti-restart device that protects the starter from engaging while the engine is running. The switch must be turned back to the "OFF" position before the engine can be re-started.
NOTE
When re-starting the compressor, the
Compass Controller will not allow restart until system pressure falls below 10 psig
(0.7 bar) or less. More than 10 psig (0.7 bar) can put extra load on the starter.
Allows the engine to run at unload speed (lower pressure) until properly cooled down. Controls start up, run and shutdown procedures. Refer to Compass Controller Manual, Sullair Part
No. 02250167-454 for further details.
Refer to Compass Controller Manual, Sullair Part No.
02250167-454 for further detail.
Continually monitors the pressure inside the receiver tank at various load and unload conditions.
Monitors the temperature of the engine water. The normal operating temperature should read approximately 160°F to 210°F
(71°C to 99°C).
Monitors the temperature of the air/fluid mixture leaving the compressor unit. The normal reading should be approximately
210°F to 250°F (99°C to 121°C).
Monitors the fluid level in the receiver tank. Proper level is always visible in the sight glass. Check the level when the compressor is shutdown.
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SECTION 4
CONTROL OR INDICATOR
Reducing Regulator Valve
Control Regulating Valve
Minimum Pressure/Check Valve
HI/LO Selector Switch
Pressure Relief Valve
Air Inlet Valve
Blowdown Valve
Thermal Valve
Recirculation Valve
PURPOSE
Provides regulated air pressure to the inlet valve and engine speed control to open the inlet valve and move engine governor to full speed with warm-up valve in the "RUN" position.
Provides an air signal to the inlet valve and engine speed controller to close the inlet valve and reduce engine speed to control air delivery according to demand.
Maintains a minimum of 200 psig (13.8 bar) in the compressor receiver tank. This valve restricts receiver air discharge from receiver/receiver tank when pressure falls to 200 psig (13.8 bar).
Also prevents back flow into the receiver tank during unload conditions and after shutdown.
Select high pressure 500 psig (34.5 bar) or low pressure 350 psig
(24.1 bar) at instrument panel to correspond to operator's needs.
Opens receiver tank pressure to the atmosphere should pressure inside the receiver tank exceed 600 psig (41.4 bar).
Regulates the amount of air allowed to enter the air inlet valve. This regulation is determined by the amount of air being used at the service line.
Vents receiver tank pressure to the atmosphere at shutdown.
Vents surplus receiver tank pressure to the atmosphere during operation.
Regulates flow of fluid to and around the fluid cooler. Designed to maintain a minimum operating temperature; used for fast warm-up at start-up and to eliminate condensation during operation.
Provides limited air supply back to inlet valve during unload/no load conditions to prevent cavitation in the unit.
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4.3 COMPRESSOR START-UP
PROCEDURE
For more detailed instruction and useful information regarding machine operation and the Compass Control
System, refer to the Sullair Compass Controller User's
Manual (Sullair P/N: 02250167-454).
1. Turn the ON/OFF/START switch, located on the
Compass Controller, to the "ON" position. The controller will power up and a self-diagnostic program will be initiated. During the initiation process, the gauges will wag (the needles on each gauge will sweep through its full scale) to verify all relevant sensors are operational. Also, a communication link will be established with the engine ECU. During this time, several messages will be displayed on the panel.
Some of these messages may not be noticed by the operator because the controller steps through the initialization phase rather quickly. However, the operator should see the following messages during this step:
OPERATION
2. Turn the OFF/ON/START switch to the "START" position. You do not have to hold the switch in the
“START” position. The LCD panel will show the following message:
WARNING
SU_0000046
If machine does not start successfully when starter disengages, the starter will automatically engage up to four more times after brief pauses to try and start the machine.
Once the compressor has started, the unit will enter a warm-up phase. At this point, the unit is not producing usable compressed air and the service valve should still be closed. The following message will be displayed on the LCD panel:
&
SU_0000044
When the system has successfully initialized, the following message will be displayed in the upper left corner on the LCD Graphic Display:
SU_0000047
Once the proper operating conditions are met, the machine will automatically switch into run mode and provide pressurized service air.
NOTE
Below 40°F (4°C) use starting aid (per instructions printed on starting aid device).
SU_0000045
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SECTION 4
4.4 SHUTDOWN PROCEDURE
1. Close the service valve.
2. Turn the OFF/ON/START switch to the “OFF” position.
The following message will be displayed in the LCD
Graphic Display:
SU_0000048
3. The unit will continue to run, though it will not produce usable air. At the end of the cool down, the engine will be shut down. The controller will stay powered up, and a new message will be displayed:
42
SU_0000049
The controller will continue to monitor the system pressures and will not power down until all pressures drop below 10 PSI (0.7 bar). This final process may take 2 to 5 minutes. Operator interaction is not necessary during this time as the controller will automatically disconnect power to all systems so that the battery is not inadvertently drained after shutdown.
WARNING
The E-Stop (emergency stop switch) should be used only in the event of an emergency. Refrain from using the
E-Stop to shut the machine down during normal operations. All usage of the E-Stop is logged in permanent memory for use by service technicians when troubleshooting a machine. Non-emergency use of
E-Stop is considered equipment abuse and could void the manufacturer's warranty.
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Section 5
MAINTENANCE
5.1 GENERAL
A good maintenance program is the key to long compressor life. Below is a program that when adhered to, should keep the compressor in top operating condition.
For engine maintenance requirements, refer to the Engine
Operator's Manual for a detailed description of service
instructions. Refer to Parts Replacement and Adjustment
Procedures for a detailed description of specific
compressor system components. Prior to performing maintenance, read the CIMA Safety Manual, if applicable.
CAUTION
DO NOT remove caps, plugs and/or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
5.2 DAILY OPERATION
Prior to starting the compressor, it is necessary to perform a daily inspection. Perform the following maintenance operations to prevent unnecessary problems.
1. Check the fluid level in the compressor receiver tank.
Should the level be low, simply add the necessary amount. If the addition of fluid becomes too frequent, a simple problem has developed which is causing this
excessive loss. Refer to Troubleshooting
Guide on page 49 under Excessive Compressor
Fluid Consumption for a probable cause and remedy.
2. Drain water from the fuel/water separator.
3. Check the fuel level in the fuel tank.
4. Check the engine oil level.
5. Check the engine coolant level.
CAUTION
The radiator and engine cooling system must be drained and flushed periodically. The required change interval is determined by the following table. Refer to the OEM Engine Manual for more information. Replace the coolant with a solution of 50% ethylene glycol and 50% water or as required for your geographic location.
DO NOT use a leak sealing type of antifreeze. Should a 100% water solution be used, a non-chromate rust inhibitor must be added.
NOTE
Dispose of fluids in accordance with applicable federal, state and local regulations.
Coolant Type
Caterpillar ELC
Caterpillar DEAC
Coolant Service Life
Service Life
Six Years / 12,000 Hours
Three Years / 3,000 Hours
Two Years / 3,000 Hours Commercial Heavy-Duty
Coolant/Antifreeze that meets
"ASTM D5345"
Commercial Heavy-Duty
Coolant/Antifreeze that meets
"ASTM D4985"
One Year / 3,000 Hours
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SECTION 5
NOTE
Caterpillar DEAC DOES NOT require a treatment with an SCA at the initial fill.
Commercial heavy-duty coolant/ antifreeze that meets "ASTM D4985" or "ASTM D5345" specifications MAY require a treatment with an SCA at the initial fill. Read the label or the instructions that are provided by the
OEM of the product.
After a routine start has been made, it is necessary to perform an inspection to ensure all operations are performing correctly. Perform the following inspections to prevent unnecessary problems. .
1. Observe the instrument panel gauges and be sure they monitor the correct readings for their particular phase of operation.
2. After the compressor has warmed up, it is recommended that a general check on the overall compressor and instrument panel be made to assure that the compressor is running properly.
3. Check the air filter restriction gauges. Should they indicate restriction, replace the elements immediately.
Refer to Air Filter Maintenance on page 45.
5.3 MAINTENANCE AFTER INITIAL
50 HOURS OF OPERATION
After the initial 50 hours of operation, a few simple maintenance routines can rid the system of any possible foreign materials, if any. Perform the following maintenance operations to prevent unnecessary problems.
1. Clean the return line orifice and strainer
2. Change compressor fluid filter.
3. Check Engine Operator's Manual for required service.
5.4 MAINTENANCE EVERY 300
HOURS
When using Sullair AWF, change the compressor fluid and
replace the fluid filter element. Refer to Main Fluid Filter
Perform the following after every 300 hours of operation:
1. Clean the return line orifice and strainer.
2. Inspect and check fan belt tension. If necessary, adjust the tension to 160 lbs while cold.
3. Clean the radiator, oil cooler and aftercooler exterior.
Depending on how contaminated the atmosphere may be, more frequent cooler and radiator cleaning may be necessary in dusty conditions.
4. Check the battery level and fill with water if necessary.
5. Check Engine Operator's Manual for required service.
5.5 PARTS REPLACEMENT AND
ADJUSTMENT PROCEDURES
Compressor Fluid Change Procedure
Warm-up the compressor for 5 to 10 minutes to warm the fluid. Shut the compressor off and relieve all internal pressure before proceeding. Drain the fluid by opening the valve that is bulkhead mounted to the frame (see
Figure 3-2 on page 37 for location of drain port). Change
the compressor fluid and replace the fluid filter element.
For element replacement see procedure for servicing the fluid filter in this section. Fill the receiver tank with fluid
according to SPECIFICATIONS on page 33.
Main Fluid Filter Servicing
Refer to Figure 5-1. The main fluid filter is located
schematically in the coolant line between the receiver tank and the compressor unit. The main filter element is replaceable. For installation of the filter element, follow the procedure explained below.
1. The compressor MUST be shut off and system pressure MUST be relieved.
2. Drain by removing drain plug at bottom of bowl and catching drainage in a container.
3. Rotate bowl counterclockwise and remove.
4. Remove element and O-ring from housing and discard. This element is NOT cleanable.
5. Make sure mounting surface of filter head is clean.
6. Apply a light film of AWF to O-ring and place it in its proper position.
7. Place new, clean element in bowl, over centerperforated tub.
8. Inspect bowl seal and replace if necessary.
9. Replace bowl. Rotate clockwise and hand-tighten.
10. Replace drain plug.
Torque to 15 to 20 ft-lbs. (20 to 27 N·m).
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2
3
4
6
MAINTENANCE
3. Remove the primary filter from the housing.
4. Clean the interior of the housing by using a damp cloth.
DO NOT blow out dirt with compressed air as this may introduce dust downstream of the filter.
Secondary Element Removal
The secondary element serves as a safety element. The secondary element must be replaced after every third primary element change.
1. Gently pull the element off the outlet tube and out of the housing.
2. Carefully wipe the inside of the outlet tube with a clean cloth.
5
5
SU_0000050
1. Fluid Filter Bypass
2. Filter Head*
3. Bowl Seal (O-ring)
4. Element**
5. Bowl
6. Fluid Stop Valve
Figure 5-1: Main Fluid Filter Assembly
* Repair kit for thermostat element, P/N 02250167-366;
Service kit for fluid stop valve, 02250167-369
** Replacement filter element, P/N 02250139-996
Air Filter Maintenance
Refer to Figure 5-2. Maintenance should be performed
when indicated on the instrument panel located by the engine air filter restriction gauges. Both air filters are twostage with a primary element and secondary element each.
Primary Element Removal
1. Clean the exterior of the air filter housing.
2. Unlatch and remove the service cover. Make certain the latches are folded back.
4
3
1
2
SU_0000051
1. Access Cover
2. Vacuator ™ Valve
3. Primary Filter Element*
4. Secondary Element**
5. Air Cleaner Housing
Figure 5-2: Air Filter Assembly
* Primary replacement element, P/N 02250155-691
(qty 2)
** Secondary replacement element, P/N 02250155-692
(qty 2)
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SECTION 5
Element Replacement
1. Insert the secondary element carefully over the outer tube. Seat the new element by hand while making certain it is completely on.
2. Insert the primary filter element over the secondary element by hand. Push on the outside edge until it is completely into the housing.
3. Install the cover with the vacuator installed at the bottom. If the cover hits the element before it is fully in place, remove the cover and push the filter into the housing and try again.
NOTE
Never use the latches on the cover to force the element into the housing.
Using the latches to push the element in could cause damage to the housing and will void the warranty.
Control System Adjustment
Refer to Figure 5-3. Prior to adjusting the control system,
it is necessary to determine the desired operating pressure range as well as the maximum pressure at which the machine is to operate. This pressure must not exceed the maximum operating pressure which is stamped on the machine serial number plate. The following explanation applies to a typical machine with a desired operating range of 350 to 500 psig (24.1 to 34.5 bar). This information will apply to a machine with any other operating range except for the stated operating pressure. For high-pressure machines, adjustment pressures are shown in parenthesis.
1. Start the machine and let it warm-up and enter full
“RUN” mode.
2. Open service valve slightly until engine tries to speed up. Slowly close the service valve. With service valve closed, check and adjust the pressure at the reducing regulator to a minimum of 60 psig (4.1 bar) and not to exceed 75 psig (5.2 bar). With service valve still closed, and the "HI/LO" switch in the "LO" position, adjust the low-pressure back-pressure regulator so the service pressure is between 360 to 375 psig (24.8 to 25.9 bar) with the engine at 1400 rpm. Open the service valve to load the compressor to maintain 350 psig (24.1 bar) discharge pressure. Operating speed should be 1800 RPM on the instrument panel. If not, repeat step, but adjust the unload service pressure up or down as needed until 350 psig (24.1 bar) is maintained when engine speed is 1800 rpm.
3. For 500 psig (34.5 bar), turn the “HI/LO” switch to "HI" position. Close the service valve and set the “HI” pressure control regulator to maintain 520 to 535 psig
(35.8 to 36.9 bar) discharge pressure. Open the service valve to maintain 500 psig (34.5 bar) and check for 1800 RPM full-load speed. If lower speed is observed, raise the setting of the low pressure control regulator until rated speed is achieved.
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MAINTENANCE
2
1
3
5
4
10
11
12
16
15
1.
Unit
2.
Air Inlet Valve
3.
Running Blowdown Valve
4.
Enclosure
5.
Minimum Pressure Check Valve
6.
High Pressure Regulator
7.
Low Pressure Regulator
8.
Reducing Pressure Regulator
9.
Control Pressure Gauge
10. HI/LOW Switch
11. Reset Switch
NOTE
For a breakdown of part kits reorder
Manifold on page 96 in this manual.
6
7
Figure 5-3: Control System Assembly
12. START/ON/OFF Switch
13. Main Pressure Gauge
14. Temp/Tach/Fuel Gauge
15. Diagnostic Service Port
16. Instrument Warning Bank
A1. Green Line
A2. Orange Line
A3. Red Line
A4. Yellow Line
A5. White Line
A6. Blue Line
9
8
13
14
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SU_0000052
47
SECTION 5
Separator Element Replacement
Refer to Figure 5-4. When the need for a separator element
replacement is indicated by the Compass Controller, use the following procedure for separator replacement.
1. Remove the air receiver tank lid by removing the hex head capscrews and washers.
CAUTION
To assist with the removal of the tank lid, Sullair has provided a jack bolt at the bottom of the lid pivot shaft.
Simply jack the lid up until it will clear the dowel pin located on the top tank flange underneath the lid. Rotate out of the way.
2. Remove the elements from the separator chamber by gently rocking back and forth and pulling upward and discarding.
3. Before installing the new separator elements, make sure to lubricate the sealing O-ring on each element with a lubricating compound (i.e. Silglyde). Then install the new separator elements by firmly pressing downward until the element is fully seated on the baffle plate inside the tank.
4. Next, inspect the tank flange O-ring and replace if necessary. Before installing lid, relubricate the O-ring
(i.e. Silglyde). Reinstall the tank lid. Install the capscrews and washers finger tight, then gradually tighten in a crisscross pattern in 4 to 5 steps. Always tighten the capscrews alternately at opposite sides of the cover. Torque lubricated capscrews to 322 ft-lbs.
(440 N·m).
5. Clean or replace fluid return line strainer.
6. Clean the fluid return line orifice installed in the side of the compressor unit air end.
5
6
1
3
4
8
2
6
SU_0000053
1. Grounding Plate
2. Davit Assembly Support
3. Separator Elements (3)*
4. Receiver Tank
5. Hex Nut
6. Capscrew
7. Spring Lock Washer
8. Washer
9. Lockwasher
10. O-ring
Figure 5-4: Separator Element Assembly
* Replacement kit p/n 02250167–378 (contains three elements)
7
6
8
9
10
6
3
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MAINTENANCE
5.6 TROUBLESHOOTING GUIDE
The following Troubleshooting Chart is based on both the data obtained from actual tests conducted at our factory and real applied situations. It contains symptoms and usual causes for the described problems. However, DO
NOT assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures.
• Check for loose wiring.
• Check for damaged piping.
• Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation.
SYMPTOM
Instrument panel will not power up
Compressor will not start
Compressor shuts down with air demand present
Compressor will not build up full discharge pressure
PROBABLE CAUSE
Battery voltage low
REMEDY
Check battery voltage, check electrolyte levels. Top off batteries with distilled water and recharge as needed.
Battery disconnect switch in "OFF" position Turn switch to "ON" position
No fuel / plugged fuel filter
Battery
Check fuel level and add fuel if necessary.
Replace the fuel filter element.
Check electrolyte level and add distilled water and recharge if necessary.
Loose battery cables; tighten cables.
Plugged air filter
Engine problems may have developed
Instrument panel problems may have developed
No fuel
Compressor discharge temperature switch is open
Dirty battery cables; clean thoroughly.
Replace the air filter element.
Refer to Engine Operator's Manual.
Refer to Compass Controller Manual,
Sullair Part No. 02250167-454.
Check fuel gauge and add fuel if necessary.
Cooling air flow is insufficient; clean cooler and check for proper ventilation.
Low fluid sump level; add fluid.
Dirty compressor fluid filter; change element.
Thermostatic element is not functioning properly; change the thermostatic element.
Defective discharge temperature switch; check for a short or open circuit to the engine fuel solenoid. Should this checkout normal, it could be possible that the temperature switch itself is defective.
Instrument panel problems may have developed
Air demand is too great
Dirty air filter
Pressure regulator out of adjustment
Defective pressure regulator
Refer to Compass Controller Manual,
Sullair Part No. 02250167-454.
Check service lines for leaks or open valves.
Check the filter gauges near filters or for fault messages at controller and change element if required.
Adjust regulator according to control adjustment instructions in the
MAINTENANCE section.
Check diaphragm and replace if necessary
(kit available).
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SECTION 5
SYMPTOM
Improper unloading with an excessive pressure build-up causing pressure relief valve to open
PROBABLE CAUSE
Fluid charge lost from spring chamber on inlet valve pressure regulating valve is set too high
REMEDY
Add fluid to inlet valve spring chamber by removing plugs in the top of the spring chamber and filling with compressor fluid.
Some fluid may leak from the control regulator at first but will stop leaking when fluid level in the spring chamber equalizes.
Readjust.
Running blowdown valve pressure regulating valve set too high
Leak in control system causing loss of pressure signal. Inlet valve jammed
Check control lines.
Worn seals in inlet valve. Replace seals
(kit available).
Defective pressure regulating valves; repair valves (kits available).
Free or replace valve.
Insufficient air delivery
Restriction in the control system
Defective pressure relief valve
Plugged air filter
Plugged air/fluid separator
Check all control lines and components. Ice and other contaminants could cause restrictions.
Replace pressure relief valve.
Replace.
Defective pressure regulator
Engine speed too low
Replace separator element and also change compressor fluid and fluid filter at this time.
Adjust or repair.
Check control pressure settings and adjust if necessary.
Clear orifice and mesh screen.
Excessive compressor fluid consumption Clogged return line
Leak in the lubrication system
Separator element damaged or not functioning properly
Check all pipes, connections and components.
Change separator element.
Defective minimum pressure/check valve Repair or replace.
Compressor overheating
Engine overheating
Shutdown panel lights
Check engine light
Fluid receiver tank overfilled
Loose or broken fan belt
Dirty fluid cooler core
Dirty aftercooler
Faulty thermostat element
Plugged fluid cooler tube (internal)
Low receiver tank fluid level
Plugged compressor fluid filter
Loose or broken fan belt
Dirty radiator core
Low water level
Dirty aftercooler
Low fluid level
Faulty water pump
Plugged radiator (internal)
Defective engine thermostat
Faulty switch indicated by light
Engine safety switch (low coolant) fault
Drain to proper level.
Tighten or change belt.
Clean core thoroughly.
Clean core thoroughly.
Change thermostat element.
Clean tube thoroughly.
Refill.
Change element.
Tighten or change belt.
Clean thoroughly.
Refill.
Clean thoroughly.
Refill.
Change pump.
Clean and flush thoroughly.
Replace engine thermostat.
Replace the switch.
Replace the switch (Caterpillar part)
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1600 Open Frame Operator’s Manual and Parts List
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MAINTENANCE
SYMPTOM
Engine warning flashing light
PROBABLE CAUSE
Count number of flashes. This will flash trouble code.
NOTE
Additional troubleshooting tips are available in the Compass Controller
Manual, Sullair Part No.
02250167-454.
REMEDY
Determine trouble code and call Caterpillar
Service Representative to correct problem.
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SECTION 5
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Section 6
PARTS LISTS
6.1 PROCEDURE FOR ORDERING PARTS
When ordering parts, always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading
for the compressor or from the Serial Number Plate located on the compressor. Refer to Figure 6-1.
xxxxxxx xxxx-xxxxx
2007XXXXXXXX xxx/xx xxxx/xxxxxxx
xxxx-xxxxx
2007XXXXXXXX xxxxxxx xxxx/xxxxxxx
SU_0000054
Figure 6-1: Serial Plate - Serial Number Location
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SECTION 6
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, phone or fax numbers listed.
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55
SECTION 6
6.2 RECOMMENDED SPARE PARTS LIST
Key Description
1 replacement for air filter element - primary
2
3
4
5 replacement for air filter element - secondary (safety) replacement for compressor oil filter replacement for engine (CAT) oil filter - 1R1808 replacement for engine (CAT) fuel filter - primary: 1R0771
6
7
KITS
replacement for engine (CAT) fuel filter - secondary: 1R0749 replacement for primary afterfilter element (AF machines only)
8
9 replacement kit for receiver tank separator elements (3 element pack) replacement for starter solenoid
10 repair kit for inlet valve (springs included)
11 repair kit for inlet valve (no springs included)
12 repair kit for recirculation solenoid - air control manifold
13 repair kit for start/run solenoid - air control manifold
14 master repair kit for air control manifold (XH & XHH machines only)
15 repair kit for hi/lo solenoid - air control manifold
16 replacement for air control manifold solenoid (coil only)
17 repair kit for blowdown valve 02250069-820
18 repair kit for pressure differential valve 02250115-269
19 repair kit for control pressure reducing regulator
20 repair kit for internal check valve - air control manifold
21 repair kit for back pressure regulator
22 repair kit for spiral valve solenoid
23 repair kit for compressor oil thermostat (230°F [110°C])
24 rebuild kit for compressor oil stop valve
25 master maintenance kit - 50 Hour filter element filter
26 master maintenance kit - 250 Hour replacement for engine (CAT) oil filter - 1R1808 replacement for engine (CAT) fuel filter - primary: 1R0771 replacement for engine (CAT) fuel filter - secondary: 1R0749 filter element replacement for air filter element - primary replacement for air filter element - secondary (safety) filter
Note
(I)
Part Number
02250155-691
02250155-692
02250139–996
02250154-063
02250154-066
02250154-065
02250153-297
02250167-378
02250051-629
02250112-531
02250056-278
02250166-773
02250166-774
02250166-770
02250166-775
02250166-777
02250077-469
02250163-466
02250166-779
02250166-782
02250166-784
02250166-921
02250167-366
02250167-369
02250166-379
02250139-996
02250117-782
02250166-380
02250154-063
02250154-066
02250154-065
02250139-996
02250155-691
02250155-692
02250117-782
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
Quantity
2
2
1
1
1
1
1
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Key Description
MISCELLANEOUS
27 replacement for engine/compressor drive coupling
28 replacement for 2" SAE split-flange w/viton o-ring
29 replacement for 3" SAE split-flange w/viton o-ring
30 replacement for compressor intake filter restriction switch
31 replacement for engine intake filter restriction switch
32 replacement for afterfilter auto drain (AF machines only)
33 replacement for exhaust muffler
34 replacement for engine coolant radiator
35 replacement for compressor oil cooler
36 replacement for engine charge air cooler
37 replacement for compressor discharge aftercooler (AC machines only)
38 replacement for fuel level sender (if equipped with on board fuel tank)
39 replacement for compressor interstage temperature (IT) switch
40 replacement for receiver tank temperature (RTT) switch
41 replacement for Compass Controller
42 replacement for Compass Controller enclosure access key
43 replacement for containment frame adjustable drain plug
44 replacement for fuel supply quick disconnect - male
45 replacement for fuel return quick disconnect - male
46 replacement for battery disconnect switch
47 replacement for ambient temperature sensor
48 replacement for compressor discharge temperature sensor
49 replacement for fuel tank vent (if equipped with on board fuel tank)
50 replacement for fuel tank filler cap
51 replacement for engine coolant level sensor
52 replacement for compressor lubricant - AWF (5 gallons/18.9 liters)
53 replacement for 0-750 psi transducer (XH and XHH machines only)
54 replacement for receiver tank lid o-ring
LUBRICATION
55 replacement for compressor lubricant - AWF (55 gallons/208 liters)
56 replacement for compressor lubricant - AWF (5 gallons/18.9 liters)
(I) CAT C-18 requires 2 oil filters
CAUTION
Mixing of other lubricants within the compressor unit will void all warranties.
Part Number
02250069-601
02250099-415
02250100-926
02250141-305
02250143-881
02250153-280
02250155-693
02250157-344
02250157-345
02250157-346
02250157-346
02250158-368
02250163-929
02250159-105
02250159-205
02250159-425
02250160-013
02250160-020
02250160-023
02250160-837
02250161-276
02250161-277
02250162-229
02250166-195
02250165-908
250030-757
02250144-311
826502-464
250030-758
250030-757
PARTS LISTS
Quantity
1
1
1
1
3
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
2
2
1
1
1
1
1
1
3
1
Note
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SECTION 6
6.3 COMPRESSOR SYSTEM 750 - 1350 XHH/XH
A1
A2
A3
A4
A4
A5
58
02250169-696R01_01
P1
P2
P3
T1
T2
T3
A4
A5
A1
A2
A3
Optional: Cold air louvers
Standard air
Aftercooled air
Moisture drain
Optional: Discharge air cooler
Dry side pressure
Control pressure
Wet side pressure
Compressor discharge temperature sensor
Interstage temperature switch
Receiver tank temperature switch (RTT)
1600 Open Frame Operator’s Manual and Parts List
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PARTS LISTS
6.3 COMPRESSOR SYSTEM 750 - 1350 XHH/XH (CONTINUED)
Key Description
1 filter, air
2
3
4
5 gauge, air filter restriction inlet valve compressor valve, relief
6
7
8 switch, temperature sensor, temperature sensor, pressure
9 valve, discharge check
10 receiver, air/oil
11 glass, sight oil level
12 valve, minimum pressure
13 valve, ball
14 cooler, air (optional)
15 separator, moisture
16 trap, drain
17 orifice
18 valve, blowdown N.C.
19 strainer
20 sightglass, orifice block
21 valve, thermal bypass
22 cooler, oil
23 filter, oil
24 valve, oil stop
25 valve, pilot actuated recirc sol.
26 valve, regulator backpressure
27 gauge, pressure
28 valve, pressure regulator
29 valve, check
30 valve, solenoid 3-way run/start
31 valve, solenoid 2–way elect
32 seperator, element
33 valve, spiral
34 vent, air
35 cylinder, air (optional)
36 valve, pressure diff. bypass
37 valve, back pressure regulator
38 manifold, oil control
39 manifold, air control
Part Number Note
1
2
1
8
1
1
12
1
1
3
1
1
1
1
1
2
2
1
1
1
1
2
1
2
2
1
1
3
1
3
1
2
1
3
Quantity
1
1
1
2
1
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SECTION 6
6.4 ENGINE SYSTEM 750 XHH - 1350 XH
A1
A2
A3
A4
A10
A5
A6
A7
A8
A9
A11
A10
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02250169-696R01_02
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PARTS LISTS
6.4 ENGINE SYSTEM 750 XHH - 1350 XH (CONTINUED)
Key Description
1 turbocharger, engine
2
3
4
5 cooler, charge air muffler, engine sender, fuel level rain cap, exhaust system
6
7
8 filter, fuel w/ water separator pump, fuel (internal to engine) pump, fuel hand operated priming
9 filter, fuel
10 vent, fuel tank
11 cap, fuel tank fill
12 thermostat, thermocord (optional)
13 kit, ether assembly
14 pump, oil (integral to engine)
15 by-pass valve (internal to engine)
16 cooler, oil (internal to engine)
17 filter, oil
18 pump, water (integral to engine)
19 radiator, engine
20 engine thermo (integral to engine)
21 sensor, inlet air press (turbo boost)
22 switch, coolant level
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 heater, water jacket (optional)
30 oil level (dipstick)
31 filter, air
32 tank, fuel (optional)
33 pan, engine oil
34 gauge, filter restriction
35 sensor, inlet air temperature
36 valve, relief (integral to engine)
37 valve, air stop (optional)
38 valve, ball 3-way (dual port)
39 coupling, quick connect 1/2” supply
40 coupling, quick connect 3/8” return
Part Number Note
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Quantity
1
1
1
1
1
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SECTION 6
6.4 ENGINE SYSTEM 750 XHH - 1350 XH (CONTINUED)
A9
A1
A2
A3
A4
A10
A5
A6
A11
A7
A10
A8
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PARTS LISTS
6.4 ENGINE SYSTEM 750 XHH - 1350 XH (CONTINUED)
Key Description
A1 Compressor
A2 Intake manifold
A3 Turbine
A4 Optional: air stop system
A5 Injector
A6 ECM
A7 Heads and cylinders
A8 Engine lube system/block and turbo
A9 Air intake and exhaust system
A10 Fuel system
A11 Cooling system
A12 Lubrication system
L1 Coolant level
L2 Fuel level
L3 Oil level (dipstick)
P5 Inlet manifold air pressure
P6 Fuel pressure
P7 Oil pressure
T7 Inlet air temperature
T8 Fuel temperature
T9 Coolant temperature
S1 Cam speed
S2 Crank speed
Part Number Note Quantity
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SECTION 6
6.5 FRAME ASSEMBLY
A1
64
02250170-414R00
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6.5 FRAME ASSEMBLY (CONTINUED)
Key Description
1 support, enclosure compass $ manf blk
2
3
4
5 plug,frame drain hole eye, tow ss of/lrg eye, tow cs of/lrg chain, tether frame drain plug
6
7
8 guard, formed ss rear 1600d t3 of guard, formed ss front 1600d t3 of guard, formed cs rear 1600d t3 of
9 guard, formed cs front 1600d t3 of
10 support,formed guard 1600d t3 of
11 plate, diamond anti-slip grating
12 fastener, diamond anti-slip grate
13 valve,ball 1/2"npt
14 nut,hex f pltd 5/16-18
15 nut,hex locking 5/16-18
16 capscrew,hex gr5 3/8-16 x 1 1/2
17 capscrew,hex gr5 3/4-10 x 2 1/2
18 bolt, carriage 5/16 x 3"
19 screw, hex ser washer 5/16-18 x 1 1/4
20 washer, spr lock reg pltd 3/8
21 washer, spr lock reg pltd 3/4
22 washer, pl-b reg pltd 5/16
23 washer, pl-b reg pltd 3/8
24 nipple,pipe-xs plt 1/2 x cl
25 frame assembly
A1 Use 2440 Loctite & Torque To 220 FT/LBS
FRAME ASSEMBLY P/N
02250158-305
02250162-847
FRM ASSY, 1600 T3 NO TNK NO RG
FRM ASSY, 1600 T3 NO RG (DLQ)
PARTS LISTS
Note Part Number
02250157-352
02250160-013
02250161-125
02250161-126
02250167-767
02250169-689
02250169-690
02250169-691
02250169-692
02250169-693
02250169-694
02250169-695
047117
825305-283
825505-166
829106-150
829112-250
829505-300
829705-125
837806-094
837812-188
838205-071
838206-071
866408-000
SEE_CHART
36
6
20
3
12
20
12
36
6
24
34
3
1
4
20
1
2
1
1
1
Quantity
1
4
1
1
4
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SECTION 6
6.6 COMPRESSOR, FRAME AND DRIVE
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PARTS LISTS
6.6 COMPRESSOR, FRAME AND DRIVE (CONTINUED)
Key Description
1 support, unit/eng h900/350
2
3
4
5 bushing,taper lock 4040 w/2.75 bore spacer, fan cat c15 49.63" fan orifice,.040".25 fnpt *.25 mnpt cover, air end rack dual capacity
6
7
8 bellows, actuator rack neoprene support, engine front 1600 fam tier iii ventilator, fuel tank
9 switch, high temp 280 deg f
10 hose, ball vlv drain to sep tnk
11 valve, pressure relief 100psi, 125 cfm
12 sub assembly, inlet vlv 8" 1600d t3 hp
13 gasket, 11 x 8 5/8 x 1/32
14 clamp, hose 13/16" to 1-1/2"
15 washer, snubbing 1" bolt
16 adapter, eng/compr 900xh
17 isolator, vibration 500 lb. capacity
18 valve, drain 1-1/8-12unf
19 nut, thin hex 3/4-10
20 washer, .500 hardened
21 key, square cl1 5/8" x 3
22 nut, hex f pltd 3/8-16
23 nut, hex locking 3/4-10
24 capscrew, ferry head hd 1/2-13 x 1 3/4
25 capscrew, hex gr5 7/16-14 x 3
26 capscrew, hex gr5 1/2-13 x 3 1/2
27 capscrew, hex gr5 5/8-11 x 1 3/4
28 capscrew, hex gr5 3/4-10 x 2 1/2
29 capscrew, hex gr5 3/4-10 x 3
30 capscrew, hex gr5 3/4-10 x 5 1/2
31 capscrew, hex gr5 1-8 x 6 1/2
32 screw, hex ser washer 3/8-16 x 1 1/4
33 washer, spr lock reg pltd 7/16
34 washer, spr lock reg pltd 1/2
35 washer, spr lock reg pltd 5/8
36 washer, spr lock reg pltd 3/4
37 washer, spr lock reg pltd 1
38 washer, pl-b reg pltd 5/8
39 washer, pl-b reg pltd 3/4
40 connector,37 fl/mpt pltd 1/4 x 1/4
040422
040513
222607
231811
250010-330
250031-046
250034-077
250040-099
821110-300
825306-347
825512-382
828408-175
829107-300
829108-350
829110-175
829112-250
829112-300
829112-550
829116-650
829706-125
837807-112
837808-125
837810-156
837812-188
837816-250
838210-112
838212-112
860104-025
Part Number
02250043-377
02250069-226
02250133-590
02250145-912
02250155-102
02250155-103
02250156-382
02250162-229
02250163-929
02250165-555
02250167-606
02250169-844
Note
6
4
6
4
20
24
6
4
2
2
8
6
4
24
12
4
4
1
1
6
1
1
2
8
1
4
2
6
1
1
1
1
1
1
1
Quantity
1
1
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
67
SECTION 6
6.6 COMPRESSOR, FRAME AND DRIVE (CONTINUED)
68
1600 Open Frame Operator’s Manual and Parts List
02250159-174R09
®
SULLAIR
®
PARTS LISTS
6.6 COMPRESSOR, FRAME AND DRIVE (CONTINUED)
Key Description
41 connector,37 fl/mpt pltd 5/16 x 1/4
42 elbow, 37fl 90m 1/4 x 1/4
43 elbow, 37fl 90m 1/2 x 1/2
44 cross, pipe 1/4" plt
45 nut, hex jam rh pltd 1/2-20
46 nipple,pipe-hx pltd 1/4 x 1/4
47 bushing,red hex pltd 1/4 x 1/8
48 connector, straight x jic 1 1/16 x 3/4
49 connector,90d str x jic 3/4 x 9/16
50 stud, threaded 3/4-10 x 3 plt
51 plug,str thd hol hx 9/16-18
52 coupling, drive act6
Part Number
860105-025
860204-025
860208-050
867830-010
868208-323
868504-025
868900-005
870108-012
870608-006
873812-030
875706-056
SEE_CHART_CPLG
Note Quantity
1
1
1
1
1
1
1
1
2
2
5
1
53 engine, diesel cat c15 tier iii
54 fan,58" dia.
55 compressor, unit and parts
SEE_CHART_ENG
02250154-560
SEE_CHART_UNIT
1
1
1
Notes:
1
2
Make sure threads are clean and free of oil, apply loctite 242 sullair p/n 005898-250 to threads of screw and torque to 77 ft-lbs.
Install taper lock per manufacturer's instructions provided with part. Screws are supplied with taper lock.
A1 Remove filters from engine and mount to supts 02250159-072 and 02250159-073 on lifting bail.
A2 Connect to engine fuel pump
A3 Fuel supply to engine
A4 Fuel return from engine
B1 Engine oil drain
B2 Engine coolant drain
B3 Starter positive
Q1
Refer to Inlet Valve Assembly on page 72
MACHINE SIZE SPECIFIC PARTS (OF = OPEN FRAME)
MACHINE SIZE (CFM/PSI) ENGINE
750/500 & 900/350-OF
900/500 & 1150/350-OF
02250155-316
02250153-564
1150/500 & 1350/350-OF
1350/500 & 1500/350-OF
02250157-875
02250165-629
UNIT
02250160-926
02250164-821
02250154-401
02250154-401
COUPLING
02250069-601
02250069-601
02250157-193
02250157-193
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
69
SECTION 6
6.7 ENGINE EXHAUST SYSTEM
02250159-182R03
70
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.7 ENGINE EXHAUST SYSTEM (CONTINUED)
Key Description
1 rain-cap, exhaust 5.75" to 6.35" dia pipe
2
3
4
5 muffler, exhaust engine t3 pipe, exhaust elbow cat c15 tieriii support,muffler turbo side support,muffler 1600 t3 cs
Part Number
02250051-589
02250155-693
02250157-158
02250158-466
02250158-467
6
7
8 clamp, exhaust cat c15 t3 clamp, seal 5" capscrew,hex gr5 3/8-16 x 1 1/4
02250161-511
241260
829106-125
9 capscrew,hex gr5 1/2-13 x 1 1/4
10 washer, nord-lock pl 3/8" sp
11 washer, nord-lock pl 1/2" sp
829108-125
878606-083
878608-100
(I) For maintenance on exhaust muffler, order replacement muffler no. 02250155-693
Note
(I)
4
4
6
1
1
6
Quantity
1
1
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
71
SECTION 6
6.8 INLET VALVE ASSEMBLY
B1
B2
72
02250169-842R02
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
6.8 INLET VALVE ASSEMBLY (CONTINUED)
Key Description
1 sub assembly,8" inlet valve
2
3
4
5 orifice,.062 .25 fnpt x .25 mnpt valve, blowdown n.c. 8:1 ratio orifice, .125 .50m x .50m
hose,assy 7/16-20 x 15"lg
6
7
8 valve, inline check(1/4"npt)dc nut,cap 37f x .25
cap, pipe 1/4 300#
9 elbow, 37fl 45m 1/2 x 1/2
10 connector,37 fl/mpt pltd 1/4 x 1/4
11 elbow, 37fl 90m 1/4 x 1/4
12 elbow, 37fl 90m 1/2 x 1/2
13 tee, 37fl male br 1/4 x 1/4
14 tee, 37fl male rn 1/4 x 1/4
15 nipple,pipe-xs plt 1/4 x 3
16 nipple,pipe-xs plt 1/2 x 6
17 elbow, pipe 90 deg 300# plt 1/4"
18 elbow, pipe 90 deg 300# plt 1/2"
19 tee, pipe pltd 1/4
20 nipple,pipe-hx pltd 1/4 x 1/4
21 bushing,red hex pltd 1/2 x 1/4
A1 Blowdown Valve Flow Direction
A2 Check valve flow direction
B1 Bottom View
B2 Side View
Q1
Refer to Air Inlet Valve Sub-assembly on page 74
PARTS LISTS
Note
861704-025
861804-025
866404-030
866408-060
867030-010
867030-020
868430-010
868504-025
868902-010
Part Number
02250045-626
02250118-585
02250120-888
02250154-059
02250162-246
045244
250034-587
806130-010
860008-050
860104-025
860204-025
860208-050
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
Quantity
1
1
1
1
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
73
SECTION 6
6.9 AIR INLET VALVE SUB-ASSEMBLY
02250045-625R05
74
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.9 AIR INLET VALVE SUB-ASSEMBLY (CONTINUED)
Key Description
1 housing, body 8" inlet valve
2
3
4
5 cover, assembly 8" inlet valve plate, flow control 8" inlet valve cover, inter 8" inlet valve piston, 8" inlet valve
6
7
8 spring, camp. 144 lbs inter shaft, 8" inlet valve spring, camp. 109 lbs outer
9 spring, camp. 2.61 lbs
10 capscr hx. gr. 5 1/4-20 x 3/4
11 washer, sprlock reg. 1/4
12 o-ring, viton 45/8 x 1/4
13 o-ring, viton 1 x 1/8
14 screw, ferry hd,3/8-16 x 1 3/4 lg
15 plug, pipe 1/4 -18 npt; stl 3000#
16 orifice, .093 x .125m x .125f
Part Number
250042-276
02250048-491
250042-297
250042-301
250042-299
250042-384
02250139-188
250042-383
250042-656
828604-075
837504-062
826502-426
826502-214
828406-175
807800-010
250014-060
NOTE
For maintenance on air inlet valve, order repair kit no. 02250112-531
(contains springs), or 02250056-278
(contains no springs).
Note
1
18
1
1
1
1
1
1
1
1
1
Quantity
1
1
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
75
SECTION 6
6.10 RECEIVER TANK ASSEMBLY
A1
76
A2
02250162-219R07
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.10 RECEIVER TANK ASSEMBLY (CONTINUED)
Key Description
1 flange,3" sae j518 code 61
2
3
4
5 filter, assembly screen filter orifice,plug brass 1/8"npt x 3/32" sightglass, orf block sae valve,relief 1" mnpt 600 psig
6
7
8 transducer, pressure 0-750psi 5volt n4 tank, air-oil sep 600psig - 1350cfm valve, discharge check h.p.
9 valve, min press check h.p.
10 switch, high temperature 300 deg f - 3/4"-16 sae
11 sensor, temperature thermistor brass
12 plug,o-ring boss sae 1 1/4
13 valve, inline check(1/4"npt)dc
14 mount, vibration (50 durometer)
15 mount, vibration isolator 185q
16 glass, sight oil level 2"
17 adapter, oil fill high press
18 strainer, 1/2" "y"
19 nut,hex locking 5/8-11
20 o-ring, viton 3 3/8 x 1/8"
21 capscrew,hex gr5 5/8-11 x 2 1/2
22 capscrew,hex gr5 5/8-11 x 4
23 washer, spr lock reg pltd 5/8
24 washer, pl-b reg pltd 5/8
25 connector,37 fl/mpt pltd 1/2 x 1/2
26 connector,37 fl/mpt pltd 3/4 x 1/2
27 elbow, 37fl 90m 5/16 x 1/4
28 elbow, pipe-90m 1/4 x 1/4
29 nipple,pipe pltd 1 1/2 x 22
30 nipple,pipe-xs plt 1/2 x cl
31 nipple,pipe-xs plt 2 x 3
32 plug, pipe 1/8" 3000# stl plt
33 bushing,red pltd 3/4 x 1/2
34 tee, pipe pltd 1/2
35 tee, pipe pltd 2
36 nipple,pipe-hx pltd 1/4 x 1/4
37 connector, straight x jic 7/16 x 7/16
38 connector, straight x jic 3/4 x 3/4
39 connector, 37fl sw f 1/4 x 1/4"
A1 CE approved tank P/N 02250158-985
A2 Receiver tank port
045244
047628
047630
048046
234342
406480
825510-329
826502-237
829110-250
829110-400
837810-156
838210-112
860108-050
860112-050
860205-025
860504-025
866324-220
866408-000
866432-030
866900-005
Part Number
02250105-534
02250117-782
02250125-776
02250126-129
02250140-725
02250144-311
02250154-809
02250157-697
02250157-698
02250159-105
02250161-277
040029
867103-020
868430-020
868430-080
868504-025
870104-004
870108-008
873004-002
Note
1
1
1
8
8
1
1
1
1
2
21
1
1
1
4
4
8
4
4
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
Quantity
2
1
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
77
SECTION 6
6.11 RECEIVER TANK SUB-ASSEMBLY
78
02250154-809R06
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.11 RECEIVER TANK SUB-ASSEMBLY (CONTINUED)
Key Description
1 davit assy, welded
2
3
4
5 tube, oil scavenge boom,lid lifting plate, grounding ss 1600 t3 baffle, rec tank 1600 t3 hp
6
7
8 element, seperator elp 1600 fam t3 coupling, pipe 1/4 3000# coupling, half 1/8 3000#
9 coupling, half 3/4 3000#
10 coupling, half 1 3000#
11 coupling, half 2 3000#
12 nut,hex unfin 1-8
13 nut,hex pltd 3/4-10
14 o-ring, viton 17 1/2 x 1/4"
15 pin,dowel unfin 1/4 x 1"
16 pin,dowel unfin 1/4 x 1 1/4"
17 capscrew,hex gr5 1/2-13 x 3
18 capscrew,hex gr5 3/4-10 x 4
Part Number
-
-
02250127-249
02250166-858
02250166-859
02250160-845
807200-010
807900-005
807900-030
807900-040
807900-080
824216-887
826412-665
826502-464
827204-100
827204-125
829108-300
829112-400
19 capscrew,hex gr5 7/8-9 x 4
20 washer, spr lock 1/2
21 washer, pl-b reg pltd 1/2
22 washer, pl-b hardened pltd 7/8
23 washer, nord-lock 1/4" sp ss
24 capscrew,hex gr5 1/4-20 x 3/4 ss
829114-400
837508-125
838208-112
875114-174
878704-053
881804-075
(I) For maintenance on receiver tank, order replacement kit P/N 02250167-378 (contains three elements per pack).
16
2
2
16
1
1
(I)
Note
3
2
1
1
3
1
1
Quantity
1
1
1
1
1
1
2
1
1
1
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
79
SECTION 6
6.12 COOLING SYSTEM
B6
80
A8
1600 Open Frame Operator’s Manual and Parts List
002250159-183R06
®
SULLAIR
®
6.12 COOLING SYSTEM (CONTINUED)
Key Description
1 clamp, t-bolt ss band 4.50"id
2
3
4
5 hose, hump chrg air 4" id x 6" lg flange, kit sae splt 2" - viton clamp, hose const torque 57-79 clamp, hose const torque 70-92
6
7
8 clamp,cushion omega for 2" pipe support,coolers 1600 t3 support, cooler mount
9 element, filter corless
10 bowl,oil fltr 1600 fam tier 3
11 hose,eng rad upper cat c15 t3
12 pipe,cac hot/upper cat c15 t3
13 pipe,cac cool/lower cat c15 t3
14 cooler, assembly 600 psi 1600 t3
15 hose,ball vlv drn-sep tnk
16 hose,rad drain-tee ftg
17 hose,tee-ball vlv drain
18 hose,assy hp oil 2" clr in
19 hose,assy hp oil 2" clr out
20 hose,assy hp oil 2" unit in
21 pipe,eng rad lower 1600 t3
22 hose,rad lower 3" id x 5" lg
23 bucket,engine fluid recovery
24 shroud, fan 58" fbrgls 1600 t3 of
25 hose,assy hp oil 2" rec oil rt
26 guard, fan/belt wireform ss 1600 t3
27 guard, fan/belt wireform cs 1600 t3
28 sensor,engine coolant cat
29 hose,assy oil 2" ss braid 1600
30 pipe, assembly oil 2" 1600 fam t3
31 hose,assy lp oil 2" unit in
32 hose,3/4" eng oil drain
33 seal,alum 2" jic 37deg flare
34 support,gusset fan guard 1600d-t3
35 clamp, hose 13/16" to 1-1/2"
36 clamp, hose 1/2"
37 hose,rad upper 2-1/2 x 6"
38 clamp, hose 2 3/8" i.d.
39 nut,hex f pltd 1/4-20
40 nut,hex f pltd 3/8-16
41 nut, hex locking 5/16-18
42 nut, hex locking 1/2-13
43 capscrew, hex 8.8 m10 x 30mm
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
PARTS LISTS
Note Part Number
02250084-842
02250085-094
02250099-415
02250138-968
02250138-969
02250148-710
02250155-695
02250155-696
02250156-345
02250156-351
02250157-153
02250157-156
02250157-157
02250162-201
02250162-235
02250162-249
02250162-251
02250162-426
02250162-427
02250162-428
02250162-645
02250162-700
02250162-740
02250163-231
02250164-585
02250164-797
02250164-798
02250165-908
02250166-181
02250166-182
02250166-302
02250168-614
02250169-646
02250170-413
040513
043197
407749
408300-010
825304-236
825306-347
825505-166
825508-262
828010-030
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
2
3
4
1
1
4
12
4
4
12
1
1
1
1
2
2
2
Quantity
8
4
6
4
4
81
SECTION 6
6.12 COOLING SYSTEM (CONTINUED)
B6
82
A8
1600 Open Frame Operator’s Manual and Parts List
002250159-183R06
®
SULLAIR
®
PARTS LISTS
6.12 COOLING SYSTEM (CONTINUED)
Key Description
44 capscrew, hex gr5 5/16-18 x 1 1/4
45 capscrew, hex gr5 5/16-18 x 3 1/2
46 capscrew, hex gr5 1/2-13 x 1
47 capscrew, hex gr5 1/2-13 x 3 1/2
48 screw, hex ser washer 3/8-16 x 1 1/4
49 washer, spr lock reg pltd 5/16
50 washer, pl-b reg pltd 5/16
51 washer, pl-b reg pltd 3/8
52 washer, pl-b reg pltd 1/2
53 washer, pl-b wide pltd 3/8
54 hose, fuel line 3/8 (ft)
55 connector, 37 fl/mpt pltd 1/2 x 1/2
56 connector, 37 fl/mpt pltd 3/4 x 1/2
57 bushing, red pltd 3/8 x 1/4
58 connector, 45 deg str x jic 2 1/2 x 2 1/2
59 connector, 90d str x jic 2 1/2 x 2 1/2
60 tee, 37fl union 1/2
61 plug, str thd hol hx 3/4-16
62 washer, nord-lock pl m10
63 hose, heater heavy wall 1 (ft)
64 adaptor, 3/8 nptf x m22 str thd
65 elbow, 45 deg str thd 1 1/16 x 1" hose
66 manifold, compr filter & flow control
A1 To Receiver Tank
A2 To Low-Press Compressor
A3 To High-Press Compressor
A4 To Engine Radiator
A5 To Engine Coolant Conn.
A6 To Engine Oil Pan
A7 To Receiver Tank Drain
A8 Oil Cooler Port Orientation
B1 Mount to frame
B2 Mount to inlet
B3 Oil manf support 02250159-074
02250157-159
B4 Engine coolant sensor 02250165-908
B5 Sensor installed in AC for AC machines
B6 02250156-345 is bulk packaged for factory. For replacement element use: 02250139-996
Q1
Refer to Cooling System Assembly on page 84
Part Number
829105-125
829105-350
829108-100
829108-350
829706-125
837805-078
838205-071
838206-071
838208-112
838306-112
842315-038
860108-050
860112-050
867101-010
870532-032
870632-032
873308-008
875708-075
883210-166
886117-100
886303-022
886416-106
Note
1
2
1
1
1
1
2
12
8
1
1
8
16
2
3
10
8
10
Quantity
9
4
4
4
13
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
83
SECTION 6
6.13 COOLING SYSTEM ASSEMBLY
A1 A2
02250162-201R02
84
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.13 COOLING SYSTEM ASSEMBLY (CONTINUED)
Key Description
1 support, cooler assy bottom 1600 t3
2
3
4
5 radiator, engine c15 1600 t3 cooler, oil 600 psi 1600 t3 cooler, air eng (cac) 1600 t3 support, cooler vert ss 1600 t3
6
7
8 support, cooler vert ss 1600 t3 support, cooler top front 1600 t3 support, cooler top rear 1600 t3
9 heater, compressor oil blanket 1600 t3
A1 Air flow
A2 Air flow
Part Number
02250155-301
02250157-344
02250157-345
02250157-346
02250161-831
02250161-832
02250161-833
02250161-834
02250166-590
Note
1
1
1
1
Quantity
1
1
1
1
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
85
SECTION 6
6.14 LIFT BAIL ASSEMBLY
86
A1
1600 Open Frame Operator’s Manual and Parts List
02250162-126R03
®
SULLAIR
®
6.14 LIFT BAIL ASSEMBLY (CONTINUED)
Key Description
1 bail,lifting 1600 family tier iii
2
3
4
5 gasket, sponge-rubber black shield, heat turbo c15 tier iii support,primary fuel fltr c15 t3 support,second fuel fltr 1600 t3
6
7
8 support,oil filter manf block enclosure,lift bail eye front enclosure,lift bail eye rear
9 support, pipe 4" cac
10 support, relay & switch
11 cover, access relay & switch
12 fitting, hose male pipe
13 clamp, hose 3/8"
14 weatherstrip, ribbed 3/16" x 3/8" (ft)
15 nut,hex pltd 3/8-16
16 nut,hex f pltd 5/16-18
17 nut,hex locking 3/8-16
18 capscrew,hex gr5 1-8 x 2 1/2
19 capscrew,hex gr5 3/8-16 x 1 1/4
20 capscrew,hex gr5 3/8-16 x 4
21 screw, hex ser washer 1/4-20 x 1/2
22 screw, hex ser washer 1/4-20 x 1
23 screw, hex ser washer 5/16-18 x 1 1/2
24 washer, spr lock reg pltd 3/8
25 washer, spr lock reg pltd 1
26 washer, pl-b reg pltd 3/8
27 washer, pl-b reg pltd 1
28 hose,fuel line 3/8 (ft)
29 u-bolt,3/8" x 3 1/2" pipe pltd
A1 Drain tube for lifting eye encl.
Open Frame Machines Do Not Require The Following:
02250161-112 Enclosure
02250161-113 Enclosure
020022-436 Weatherstrip
825305-283 Nut
829705-150 Screw
842315-038 Hose
044845 Fitting
047235 Clamp
PARTS LISTS
Note
047235
250022-436
825206-337
825305-283
825506-198
828616-250
829106-125
829106-400
829704-050
829704-100
829705-150
837806-094
837816-250
838206-071
838216-174
842315-038
868306-350
Part Number
02250154-803
02250158-314
02250159-070
02250159-072
02250159-073
02250159-074
02250161-112
02250161-113
02250161-509
02250162-209
02250168-418
044845
9
4
5
6
7
4
1
6
2
4
1
3
5
4
2
2
5
1
1
1
1
1
1
1
Quantity
1
2
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
87
SECTION 6
6.15 AIR INLET SYSTEM
88
02250159-181R02
A4
B1
B2
A1
A2
A3
Mount to cooler assembly
Mount to lifting bail
Mount to frame
Use existing hardware
Reference: engine and compressor
Reference: engine fluid recovery tank
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
6.15 AIR INLET SYSTEM (CONTINUED)
Key Description
1 tube, nylon .25"od x .04w black (ft)
2
3
4
5 tube, alum air inlet 8"od x 6"lg ind,swt flr elem cmacs right ind,swt flr elem cmacs left aid, starting elec 24v c15
6
7
8 filter, air 18" 1600 t3 clp, 18" air filter 1600t3 supt, air fltrs hp leg1 tieriii
9 supt, air fltrs hp leg2 tieriii
10 supt, air fltrs hp myg tieriii
11 hose, hump reducing 8 x 6
12 tube, alum air inlet 8"od x 17"lg
13 tube, alum air inlet 8"od x 32"lg
14 support, air inlet tubes 1600t3 o.f.
15 tube, alum air inlet 8"od x 4"lg
16 tube, alum air inlet assy 8"od x 100"
17 supt, air inlet tube t3 o.f.
18 supt, eng fluid rec cntr
19 tube, alum air inlet assy 8"od x 93"
20 clamp, hose 6 1/2"
21 band, mounting 8"
22 elbow, air inlet 90 rubber
23 hose, hump 8 x 5"
24 clamp, hose 8"
25 hose, hump 8 x 8"
26 elbow, rubber 8" x 45 degrees
27 tube, alum air inlet 8"od x 12"lg
28 elbow, 90d 1/4" tube x 1/8"fnpt
29 nut, hex f pltd 5/16-18
30 nut, hex f pltd 3/-16
31 nut, hex locking #6-32
32 capscr, hex gr5 3/8-16 x 1
33 capscr, hex gr5 3/8-16 x 1 1/2
34 screw, hex ser washer 5/16-18 x 3/4
35 screw, hex ser washer 3/8-16 x 1
36 screw, mach-pan hd #6-32 x 3/4
37 washer, spr lock reg pltd 3/8
38 washer. pl-b reg pltd 3/8
PARTS LISTS
Note Part Number
02250054-861
02250134-182
02250141-305
02250143-881
02250144-566
02250155-690
02250156-380
02250157-148
02250157-149
02250157-150
02250160-133
02250160-134
02250160-629
02250160-631
02250160-984
02250162-919
02250162-920
02250163-022
02250165-286
40305
40598
43406
43596
43598
44733
250005-776
250006-651
250041-286
825305-283
825306-347
825500-102
829106-100
829106-150
829705-075
829706-100
831300-075
837806-094
838206-071
1
2
2
3
21
2
16
8
4
3
4
9
9
6
16
12
1
2
1
1
1
1
6
4
1
1
1
1
1
1
2
4
1
Quantity
4
2
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
89
SECTION 6
6.16 ELECTRICAL SYSTEM
A6
A7
A1
A5
A5
A8
A4
A3
90
A1
A2
A3
A4
A5
A6
A7
A8
A2
Reference: 02250162-209 support, relay and switch (mounts to lifting bail).
E-stop assembly mounts to front panel.
See work-center instructions for location of clamps and tie wraps.
Reference: 02250154-804 fuel tank (export only).
+ to disconnect switch
– to connection at starter
– connection at frame
+ connection to starter
02250159-188R02
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
6.16 ELECTRICAL SYSTEM (CONTINUED)
Key Description
1 solenoid,spno 24vdc cont-duty
2
3
4
5 grip, cord n4 .187-.250 x 1/2" washer, external serrated m10 rod,3/8-16 x 11.25" harness, main 1600 fam tier iii
6
7
8 channel, batt hold down switch, battery disconnect 6-36v; 175 amps continuou cable,battery 2/0 36"lg red
9 cable,battery 2/0 139"lg red
10 cable,battery 2/0 164"lg black
11 switch, e-stop hd push-pull red
12 gasket, e-stop large portable mach
13 enclosure,large portable e-stop
14 plate, cover large portable e-stop
15 lock, batt disconnect switch
16 mat, anti-slip battery
17 isolator, vibration 1"od x 3/4"tall
18 battery, 12 volt - wet
19 cable,battery universal terminals
20 cable,battery 1/0 34"lg black
21 clamp, hose 5/8" i.d. -
22 clamp, hose 7/8" i.d. -
23 nut,hex pltd 3/8-16
24 nut,hex f pltd 1/4-20
25 nut,hex locking #10-24
26 nut,hex locking 3/8-16
27 screw, hex ser washer 1/4-20 x 3/4
28 screw, hex ser washer 1/4-20 x 1 1/4
29 screw, hex ser washer 3/8-16 x 1 1/4
30 washer, spr lock reg pltd 3/8
31 washer, pl-b reg pltd 3/8
32 wrap,tie nylon ty 23mx
33 wrap,tie nylon tf4-8x
34 screw,rnd phillips 10-24 x 1/2"
35 capscrew, socket btn hd m4 x 16mm
PARTS LISTS
Note
825206-337
825304-236
825502-083
825506-198
829704-075
829704-125
829706-125
837806-094
838206-071
843201-023
843201-025
876002-050
882304-016
Part Number
02250051-629
02250071-380
02250092-169
02250123-122
02250158-093
02250160-154
02250160-837
02250163-018
02250163-019
02250163-020
02250163-818
02250163-819
02250163-820
02250163-821
02250165-472
02250167-768
40091
40703
250019-646
250034-212
408300-005
408300-006
1
1
1
1
2
1
1
Quantity
1
1
1
4
1
2
2
2
1
1
1
3
1
1
1
4
8
3
8
20
2
4
4
1
1
8
6
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
91
SECTION 6
6.17 HIGH PRESSURE ELECTRICAL AND PNEUMATIC CONTROL SYSTEM
92
A1
A3
A3
A4
A6
A5
A4
A2
A7
02250162-896R06
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.17 HIGH PRESSURE ELECTRICAL AND PNEUMATIC CONTROL SYSTEM
(CONTINUED)
Key Description
1 transducer, pressure 0-750psi 5volt n4
2
3
4
5
6 manifold, air controls h.p.
enclosure,comp & manif blk t3 support,compass enclosure 1600 t3 controller, compass h.p.
weatherstrip,epdm 65 shore/spge rubber black
7
8
9 harness,manifold-block support,manifold 900haf & 1600 t3 hose,manf-recirc valve
10 hose,manf-run/start
11 hose,manf-ctl sys vent
12 hose,manf-control air
13 bolt, shoulder 5/16-18 x .75
14 fitting, hose blkhd elbow 1/4 37 flr
15 gauge, pressure 2.5" cbm 600 psi
16 decal,hose ctl line loc-encl
17 plug,plastic .75 dia
18 bushing,open/closed 1.250
19 connector, hose 5/16"hose x 1/4"npt
20 clamp, hose 3/8" -
21 nut,hex f pltd 5/16-18
22 screw, hex ser washer 5/16-18 x 1/2
23 screw, hex ser washer 5/16-18 x 3/4
24 screw, hex ser washer 3/8-16 x 1
25 screw, hex ser washer 3/8-16 x 1 1/4
26 washer, pl-b reg pltd 7/16
27 hose,fuel line 5/16 (ft)
28 connector, hose #10 x 1/8
29 union,37fl bhd 1/2
30 nut,hex locking ss 4-40
31 capscrew, socket btn hd ss #4-40 x 1/2
32 hose,viton 1/4od x 1/8"id
A1 Mount to PEM nuts in 02250157-351
A2 Use on open frame machines only
A3 Start/Run - Wiring Harness Detail
A4 P2 - Wiring Harness Detail
A5 Hi/Low - Wiring Harness Detail
A6 Recirculate - Wiring Harness Detail
A7 Decal location
Note Part Number
02250144-311
02250144-972
02250157-351
02250157-696
02250159-205
02250160-095
02250162-204
02250162-222
02250162-245
02250162-246
02250162-247
02250162-248
02250162-255
02250162-703
02250163-427
02250163-467
02250163-473
02250166-766
43258
47235
825305-283
829705-050
829705-075
829706-100
829706-125
838207-071
842315-031
842910-125
862108-050
879611-081
880411-050
886702-062
1
2
4
2
1
1
2
6
7
2
4
4
2
2
2
1
1
1
1
1
1
1
Quantity
1
1
1
1
1
2
1
1
1
3
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
93
SECTION 6
6.18 INSTRUMENT PANEL
A2
A1
02250159-189R00
94
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
6.18 INSTRUMENT PANEL (CONTINUED)
Key Description
1 connector, electrical ecm module
2
3
4
5 cap, receptacle ecm module gasket, elect. conn. ecm module gag, press 0-600 psi w/lcd gag, temp/tach/fuel
6
7
8 instrument, warning bank mod gag, press 0-300 psi w/lcd swt, start-on-off cntrls
9 swt, reset cntrls
10 swt, hi/lo controls
11 heater,24v w/mntg plt & thermostat
12 connector, deutsch hdp24-24-29pn
13 connector, deutsch hdp24-18-14pn
14 panel, sub electrical controls
15 decal, overlay 14x14 encl
16 relay,75vdc
17 socket, relay 18-20ga wire
18 breaker, cir50a auto restart controls
19 gasket, neoprene cl cell
20 enclosure, compass n4x
21 screw, mach-rd hd 1/4-20 x ½
22 screw, pan hd ph #4-40 x ½ ss
23 nut, hex #4-40 ss
A1 Attached to 02250157-350
A2 Included with gauges
(I) Gauge is for machines from 300 to 600 PSI.
(II) Gauge is for machines less than 300 PSI.
PARTS LISTS
Part Number
02250130-488
02250130-489
02250131-087
02250140-536
02250140-537
02250140-539
02250140-692
02250141-139
02250141-140
02250141-141
02250141-630
02250144-332
02250144-333
02250145-274
02250146-623
02250146-682
02250146-683
02250147-476
02250147-531
02250157-350
831604-050
880511-050
880711-092
(II)
Note
(I)
1
1
1
1
1
1
1
Quantity
1
1
1
1
1
4
4
3
1
1
1
4
4
2
1
4
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
95
SECTION 6
6.19 AIR CONTROL MANIFOLD
02250159-190R00
96
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.19 AIR CONTROL MANIFOLD (CONTINUED)
Key Description
1 kit,repair recirculation solenoid
2
3
4
5 kit,repair run/start solenoid kit,repair hi/lo solenoid kit,repair solenoid coil (fits all) kit,repair pressure reducing valve
6
7
8 kit,repair blowdown valve kit,repair check valve kit,repair cp valve (low pressure)
9 kit,repair cp valve (high pressure)
(I) Not required for single pressure machines
(II) Not required for XH and XHH machines
Part Number
02250166-773
02250166-774
02250166-775
02250166-777
02250166-779
02250166-781
02250166-782
02250166-783
02250166-784
(II)
(I)
Note
(I)
Quantity
1
1
1
1
1
1
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
97
SECTION 6
6.20 DISCHARGE SYSTEM, NON-AFTERCOOLED
A1
02250159-192R01
98
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.20 DISCHARGE SYSTEM, NON-AFTERCOOLED (CONTINUED)
Key Description
1 flange,3" sae j518 code 61
2
3
4
5 hose,assembly 3" discharge h.p.
support, pipe 3"npt disch 1600 t3 hose,assy 3" disch 1600t3 lp hose,assy 3" disch 1600 t3
6
7
8 gasket, 2-1/2" flange nut,hex pltd 1/2-13 capscrew,hex gr5 3/8-16 x 1
9 washer, spr lock reg pltd 5/8
10 washer, pl-b reg pltd 3/8
11 washer, pl-b reg pltd 1/2
12 capscrew, ferry head hd pltd 5/8-11 x 1 3/4
13 u-bolt,1/2" x 3" pipe pltd
A1 Mount supports to frame
Part Number
02250105-534
02250158-445
02250161-316
02250162-413
02250164-590
46053
825208-448
829106-100
837810-156
838206-071
838208-112
867310-175
868308-300
Note
4
8
8
4
2
1
4
4
Quantity
1
1
2
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
99
SECTION 6
6.21 CONTROL LINES, HIGH PRESSURE
100
02250163-024R03
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.21 CONTROL LINES, HIGH PRESSURE (CONTINUED)
Key Description
1 hose,3/4-16 x 3/4-16 jic x 22"lg
2
3
4
5 hose,spiral vlv sol-spiral vlv hose,bndl ctl lines 1600-t3 hp hose,ctl pnl-dry press rec tn solenoid,spiral vlv 24v nc 2way
6
7
8 nut,hex locking #10-24 connector,37 fl/mpt pltd 1/4 x 1/4 connector,37 fl/mpt pltd 1/4 x 1/4
A1 Green Line
A2 Orange Line
A3 Red Line
A4 Yellow Line
A5 White Line
A6 Blue Line
Part Number
02250162-237
02250163-455
02250163-460
02250163-492
02250166-921
825502-083
860104-025
884302-050
Note
2
2
2
Quantity
1
2
1
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
101
SECTION 6
6.22 OPEN FRAME ASSEMBLY COMPONENTS
A1
A2
A3
A4
A5
A6
A7
A8
A9
Engine fuel filter
Engine fuel pump
Fuel line to engine
Return line from engine
These parts only required for aftercooled machines
Reference: frame assembly 02250159-176
Engine filter connection detail
Reference: instrument panel 02250160-092
These two fittings are supplied with engine
02250163-021R09
102
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.22 OPEN FRAME ASSEMBLY COMPONENTS (CONTINUED)
Key Description
1 catch, pad-lockable
2
3
4
5 enclosure, manual-pak door, canopy top inspnl 1600t3 sst hinge, canopy door 16 in-lbs black coupling, quick disc fm 1/2"
6
7
8 coupling, quick disc fm 3/8" coupling, quick disc male x 1/2" coupling, quick disc male 3/8"
9 support,instrument panel 1600 t3 o.f.
10 guard, cooler pack 1600 t3 o.f.
11 door,ctrl lwr pnl bare 1600 t3
12 panel, instrument ss 1600 t3 of
13 support,batteries 1600 t3 o.f.
14 support, pipe 3" disch 1600 t3 o.f.
15 support, fuel conn. 1600 t3 o.f.
16 cover, dust fuel conn. 3/8 fm
17 cover, dust fuel conn. 1/2 fm
18 support, cooler guard ss
19 support, cooler guard cs
20 hose, ball vlv drain to sep tnk
21 support, manual encl 1600 t3 of
22 hose, fuel conn to eng 1600 of
23 hose, fuel conn to fltr 1600 of
24 insert, 1/4-20 blind
25 nut, hex f pltd 1/4-20
26 nut, hex f pltd 5/16-18
27 nut, hex locking #10-24
28 nut, hex locking 3/8-16
29 capscrew, hex gr5 3/8-16 x 1 1/2
30 screw, hex ser washer 1/4-20 x 1
31 screw, hex ser washer 5/16-18 x 3/4
32 screw, hex ser washer 3/8-16 x 1 1/4
33 washer, spr lock reg pltd 3/8
34 washer, pl-b reg pltd #10
35 washer, pl-b reg pltd 5/16
36 washer, pl-b reg pltd 3/8
37 connector, 90d str x jic 9/16 x 9/16
38 screw, hex ser washer #10-24 x 3/4
39 union, 37fl/nptf bhd 3/8
40 union, 37fl/nptf bhd 1/2
Part Number
02250131-747
02250157-353
02250157-885
02250158-992
02250160-014
02250160-017
02250160-020
02250160-023
02250160-630
02250161-750
02250162-227
02250162-845
02250162-846
02250162-921
02250163-822
02250164-184
02250164-185
02250165-367
02250165-368
02250165-555
02250166-304
02250168-082
02250168-083
250034-538
825304-236
825305-283
825502-083
825506-198
829106-150
829704-100
829705-075
829706-125
837806-094
838202-045
838205-071
838206-071
870606-038
884302-075
885406-038
885408-050
Note
6
2
6
1
4
2
6
10
8
2
14
1
20
1
1
8
4
6
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
Quantity
2
1
1
4
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
103
SECTION 6
6.23 FUEL SYSTEM, OPTIONAL - EXPORT ONLY
A5
A4
A1
A2
104
A3
A7
A6
02250159-187R06
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.23 FUEL SYSTEM, OPTIONAL - EXPORT ONLY (CONTINUED)
Key Description
1 tube, nyl .25 od x .040w blk (ft)
2
3
4
5 valve, check fuel 1/2" npt clamp, t-bolt ss band 2.75"id filler, fuel w/screen 2.6" dia valve, fuel diversion 3-way
6
7
8 hose,fuel filler neck 1600 t3 sender, fuel level 1600 t3 flange, fuel pick-up & rtn 1600 t3
9 coupling, quick disc male x 1/2"
10 coupling, quick disc male 3/8"
11 ventilator, fuel tank
12 hose, ball vlv 3way-fuel tnk sup
13 hose, ball vlv 3way-fuel tnk ret
14 hose, ball vlv 3way-rem tnk sup
15 cover, dust fuel conn. 3/8 fm
16 cover, dust fuel conn. 1/2 fm
17 hose, fuel conn to eng 1600 of
18 hose, fuel conn to fltr 1600 of
19 decal, fuel selr sw 750 t3
20 gasket, fuel gauge neoprene
21 connector, tube-strt 1/4mnpt x1/4"t
22 connector, fem tube 1/4 x 1/8 nptf
23 clamp, hose 9/16"id
24 elbow, tube 90 deg m 1/2 x 1/2
25 nut,hex locking 5/16-18
26 capscrew, hex gr5 3/8-16 x 1 1/2
27 screw, hex ser washer 1/4-20 x 3/4
28 screw, hex ser washer 5/16-18 x 1 3/4
29 screw, mach-rd hd #10-32 x 1/2
30 washer, spr lock reg pltd #10
31 washer, pl-b reg pltd 3/8
32 washer, spr lock reg pltd 3/8
33 connector ,37 fl/mpt pltd 3/8 x 3/8
34 connector, 37 fl/mpt pltd 1/2 x 1/2
35 elbow, 37fl 90m 3/8 x 3/8
36 adapter, pltd 3/8 x 9/16-18
37 union, 37fl/nptf bhd 3/8
38 union, 37fl/nptf bhd 1/2
Part Number
02250054-861
02250111-934
02250152-375
02250157-011
02250158-104
02250158-112
02250158-368
02250159-071
02250160-020
02250160-023
02250162-229
02250162-239
02250162-240
02250162-242
02250164-184
02250164-185
02250168-082
02250168-083
02250168-292
250004-752
250024-685
250025-922
408300-001
810508-050
825505-166
829106-150
829704-075
829705-175
831702-050
837802-047
838206-071
838506-094
860106-038
860108-050
860206-038
876106-056
885406-038
885408-050
(III)
(IV)
(V)
(VI)
(II)
Note
(I)
6
4
2
1
1
2
6
6
5
5
1
1
1
1
4
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
Quantity
2
1
2
1
1
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
105
SECTION 6
6.23 FUEL SYSTEM, OPTIONAL - EXPORT ONLY (CONTINUED)
A5
A4
A1
A2
106
A3
A7
A6
02250159-187R06
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.23 FUEL SYSTEM, OPTIONAL - EXPORT ONLY (CONTINUED)
Key Description
A1 Hardware is included with sending unit
A2 To engine fuel pump
A3 Reference: 02250154-804 fuel tank (tank is included with frame assembly)
A4 Center decal as shown around fuel selector switch and on lifting bail
A5 Mount fuel valve to lifting bail
Part Number Note Quantity
A6 Reference: hose connection; 02250160-017 coupling, quick disconnect 3/8”
A7
Reference: hose connection; 02250160-014 coupling, quick disconnect 1/2” (these items are not shipped with machine but are available from Sullair parts department)
(I) Handle shown at internal position
(II) Fuel line from internal tank
(III) Fuel line to internal tank
(IV) Fuel line from external tank
(V) Fuel line from engine filter
(VI) Fuel line to engine filter
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
107
SECTION 6
6.24 DISCHARGE SYSTEM, AFTERCOOLED ONLY, OPTIONAL
A2
A1
A3
D
A4
D
A1
A1
02250159-185R03
108
1600 Open Frame Operator’s Manual and Parts List
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®
PARTS LISTS
6.24 DISCHARGE SYSTEM, AFTERCOOLED ONLY, OPTIONAL (CONTINUED)
Key Description
1 flange,3" sae j518 code 61
2
3
4
5 cooler, air discharge 1600 fam t3 hose, assembly 3" discharge h.p.
sensor, temperature rtd 3/4 o-ring support, pipe 3"npt disch 1600 t3
6
7
8 support,3" disch pipe 1600 t3 ac support, ac to clr assy 1600 t3 01 hose, assy 3" disch 1600t3 lpac
9 pipe, assembly flex 3" ac 1600t3
10 pipe, assembly flex 3"-2.5" rdc ac
11 pipe, assembly elb 3"-2.5" rdc ac
12 pipe, assembly 3" ac disch 1600t3
13 sub assembly, rec tank h.p. Ce
14 sub assembly, ac water-sep h.p. 1600 t3
15 sub assembly, receiver tank h.p. 1600 t3
16 hose, assy 3" ac wtr sep
17 hose, manf bhd-inl vlv - 4 x 63
18 hose, assy 3" disch 1600 t3
19 clamp, pipe 3" 1600 tier iii ac
20 support, hp ac disch pipe 1600 t3
21 gasket, 2-1/2" flange
22 nut, hex pltd ½-13
23 capscrew, hex gr5 3/8-16 x 1
24 capscrew, hex gr5 7/16-14 x 1 1/2
25 screw, hex ser washer 3/8-16 x 1
26 washer, spr lock reg pltd 7/16
27 washer, spr lock reg pltd 5/8
28 washer, pl-b reg pltd 3/8
29 washer, pl-b reg pltd 7/16
30 washer, pl-b reg pltd ½
31 connector,37 fl/mpt pltd 1/4 x 1/4
32 capscrew, ferry head hd pltd 5/8-11 x 1 3/4
33 u-bolt,1/2" x 3" pipe pltd
A1 Mount to frame
A2 Hardware is part of 02250163-031 SA
A3 To drain port on frame
A4 Mount to support on cooler pack
A5 Mount to cooler pack
Note Part Number
02250105-534
02250157-347
02250158-445
02250161-276
02250161-316
02250161-754
02250162-202
02250162-346
02250162-418
02250162-419
02250162-420
02250162-482
02250162-577
02250163-031
02250163-033
02250163-279
02250163-352
02250164-590
02250165-366
02250166-180
46053
825208-448
829106-100
829107-150
829706-100
837807-112
837810-156
838206-071
838207-071
838208-112
860104-025
867310-175
868308-300
4
8
16
16
4
4
1
8
4
8
5
1
1
1
1
1
1
1
10
2
1
1
1
1
1
1
2
1
Quantity
6
2
1
1
3
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
109
SECTION 6
6.25 WATER SEPARATOR, AFTERCOOLED ONLY, OPTIONAL
02250162-221R07
110
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.25 WATER SEPARATOR, AFTERCOOLED ONLY, OPTIONAL (CONTINUED)
Key Description
1 valve, blwdwn n.c. 5.4:1 ratio
2
3
4
5 orifice,.062 .25 fnpt x .25 mnpt separator, t type gas/liq 2" npt float, water sep trap hose,37fl 1/2" x 18 lg
6
7
8 support, ac water sep h.p. t3 support,wtrtrap flt 1600t3 fam hp gasket, asa flange 150# 2"
9 nut,hex pltd 5/8-11
10 nut,hex locking 1/2-13
11 capscrew,hex gr5 1/2-13 x 2
12 capscrew,hex gr5 5/8-11 x 2 3/4
13 washer, spr lock reg pltd 1/2
14 washer, spr lock reg pltd 5/8
15 washer, pl-b reg pltd 1/2
16 stud,with 2 nuts 5/8-11x3 1/2
17 connector,37 fl/mpt pltd 1/4 x 1/4
18 connector,37 fl/mpt pltd 1/2 x 1/2
19 elbow, 37fl 90m 5/16 x 1/4
20 nipple,pipe-xs plt 1 x cl
21 nipple,pipe-xs plt 1 x 4
22 bushing,red pltd 1/2 x 1/4
23 bushing,red pltd 1 x 1/4
24 bushing,red pltd 1 x 1/2
25 union,pipe-brs seat 1 300# plt
26 u-bolt,1/2" x 6" pipe pltd
27 tee, pipe pltd 1
28 nipple,pipe-hx pltd 1/4 x 1/4
29 tee,37fl union 1/2
30 elbow, pipe 90 deg 1/4" 3000# plt
Part Number
02250069-820
02250118-585
02250131-542
02250163-061
02250165-559
02250165-640
02250167-436
240621-006
825210-559
825508-262
829108-200
829110-275
A1 Reference: Included with hose
A2 To air signal from unit
A3 To drain port on frame
A4 To discharge air cooler drain port
A5 Included with 842810-035
(I) For maintenance on blowdown valve no. 02250069-820, order repair kit no. 02250077-469.
837808-125
837810-156
838208-112
842810-035
860104-025
860108-050
860205-025
866416-000
866416-040
867102-010
867104-010
867104-020
868030-040
868308-600
868430-040
868504-025
873308-008
877900-010
Note
(I)
2
1
3
2
18
6
2
1
1
1
2
1
2
1
1
1
1
1
16
4
2
14
1
1
2
Quantity
1
1
1
1
3
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
111
SECTION 6
6.26 SHUTTERS ASSEMBLY, OPTIONAL
A2
A3
A1
02250167-082R00
112
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.26 SHUTTERS ASSEMBLY, OPTIONAL (CONTINUED)
Key Description
1 valve, pressure differential
2
3
4
5 hose,clr-wtr sep 4 x 123 hose,inlet vlv orifice-tee solenoid,spiral vlv 24v nc 2way support,shutter mtg 1600 t3 of
6
7
8 shutter, air cntrld 1600 t3 of nut,hex f pltd 5/16-18 nut,hex locking #10-24
9 screw, hex ser washer 5/16-18 x 1 1/2
10 screw, hex ser washer 3/8-16 x 1 1/2
11 connector,37 fl/mpt pltd 1/4 x 1/8
12 connector,37 fl/mpt pltd 1/4 x 1/4
13 elbow, 37fl 90m 1/4 x 1/8
14 nipple,pipe-hex 1/4 x 1/4
15 screw, hex ser washer #10-24 x 1/2
Part Number
02250115-269
02250163-009
02250163-452
02250166-921
02250166-922
02250166-923
825305-283
825502-083
829705-150
829706-150
860104-012
860104-025
860204-012
860404-025
884302-050
A1 Connected to minimum pressure check valve on separator tank
A2 Mounted to air filter support
A3 Set at 100 psi
(I) For maintenance on differential pressure valve no. 02250115-269, order repair kit no. 02250163-466.
(II) For maintenance on
Note
(I)
(II)
1
2
6
4
1
6
2
1
1
1
Quantity
1
1
1
1
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
113
SECTION 6
6.27 AIR START TANK, OPTIONAL
02250171-504R01
114
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.27 AIR START TANK, OPTIONAL (CONTINUED)
Key Description
1 insert, nylon tubing 1/4"od
2
3
4
5 tube,nyl .25 od x .040w blk (ft) valve, check fuel 1/2" npt coupling, 1/2" male npt hose, air jic 1/4" x 123"lg
6
7
8 valve, relief 1 1/4" x 1 1/2" 200psig ce solenoid,valve 24v nc 2way tank, air 20"dia 60gal 200psi
9 support, air tank 1600d o.f.
10 silencer, air 1-1/4"npt 1600d
11 lubrication system, one-shot 3/8"npt 1600d
12 valve, relay 1-1/4"npt 1600d
13 hose, air jic 1 1/4" x 100"lg
14 hose, air jic 1/4" x 175"lg
15 valve, pressure reg 600psi
16 valve, inline check(1/4"npt)dc
17 valve,ball 1/2"npt
18 gauge, ctl air press 0-200 psi
19 conn, 1/4"tube x 1/4"npt
20 nut,hex f pltd 3/8-16
21 screw, hex ser washer 3/8-16 x 1
22 washer, pl-b wide pltd 3/8
23 connector,37 fl/mpt pltd 1/4 x 1/4
24 elbow, 37fl 90m 1/4 x 1/4
25 elbow, 37fl 90m 1 1/4 x 1 1/4
26 elbow, pipe 90 deg plt 1/4"
27 elbow, pipe 90 deg plt 1 1/4"
28 nipple,pipe pltd 1/4 x 4
29 nipple,pipe pltd 1/2 x 1 1/2
30 nipple,pipe pltd 1 1/4 x 2
31 tee, pipe 150# plt 1/2
32 nipple,pipe-hx pltd 1/4 x 1/4
33 plug, pipe 1" 150# plt
34 bushing,red hex pltd 1/2 x 1/4
35 bushing,red hex pltd 1 x 1/4
36 bushing,red hex pltd 2 x 1 1/4
37 tee,f branch npt 1/4 x 1/4
38 cross, pipe 1/2" 3000# plt
A1 Connect to rec. tank (replace tee)
A2 Connect to frame drain
A3 Connect to water trap
A4 Connect to gauge on guard
B1 Wire tie drain hose through these holes
B2 Reference air starter on 02250171-085
Part Number
02250052-841
02250054-861
02250111-934
02250126-794
02250163-009
02250166-251
02250168-257
02250170-908
02250171-086
02250171-501
02250171-502
02250171-503
02250171-510
02250171-716
02250171-724
45244
47117
48448
250018-428
825306-347
829706-100
838306-112
860104-025
860204-025
860220-125
866215-010
866215-050
866304-040
866308-015
866320-020
866815-020
868504-025
868815-040
868902-010
868904-010
868908-050
873104-004
877700-020
Note
2
2
1
6
2
2
1
3
4
3
2
1
1
1
3
2
1
2
1
1
2
1
4
4
1
4
1
1
1
1
1
1
1
Quantity
2
5
1
1
2
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
115
SECTION 6
6.28 OPEN FRAME COMPONENTS WITH AIR START, OPTIONAL
02250171-505R00
116
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
PARTS LISTS
6.28 OPEN FRAME COMPONENTS WITH AIR START, OPTIONAL (CONTINUED)
Key Description
1 gauge, press 2.5" cbm 300 psi
2
3
4
5 catch,pad-lockable enclosure, manual-pak door, canopy top inspnl 1600t3 sst hinge,canopy door 16 in-lbs black
6
7
8 support,instrument panel 1600 t3 o.f.
door,ctrl lwr pnl bare 1600t3 panel, instrument ss 1600 t3 of
9 support, cooler guard ss
10 support, cooler guard cs
11 guard, cooler pack o.f. w/fuel tank
12 support,manual encl 1600 t3 of
13 support, pipe 3" ac out 1600d of
14 panel, gauge air tank
15 module, dc multiplexer
16 harness, dc multiplexer 1600d
17 enclosure,comp & manif 1600d spl
18 controller,air stop vlv opt
19 connector,1/4t x 1/4 npt str
20 nut,hex f pltd 1/4-20
21 nut,hex f pltd 5/16-18
22 nut,hex locking #10-24
23 nut,hex locking 3/8-16
24 capscrew,hex gr5 3/8-16 x 1 1/2
25 screw, hex ser washer 1/4-20 x 3/4
26 screw, hex ser washer 5/16-18 x 3/4
27 screw, hex ser washer 5/16-18 x 1
28 screw, hex ser washer 5/16-18 x 1 1/2
29 screw, hex ser washer 3/8-16 x 1 1/4
30 screw, tc-hex 3/8-16 x 3/4
31 washer, spr lock reg pltd 3/8
32 washer, pl-b reg pltd #10
33 washer, pl-b reg pltd 5/16
34 washer, pl-b reg pltd 3/8
35 coupling, pipe 1/4 150# plt
36 screw, hex ser washer #10-24 x 3/4
A1 Reference cooler assy support
A2 Req'd for ac machines only
A3 Air tank drain connection
B1 Optional
Part Number
02250043-341
02250131-747
02250157-353
02250157-885
02250158-992
02250160-630
02250162-227
02250162-845
02250165-367
02250165-368
02250166-221
02250166-304
02250170-907
02250171-087
02250171-377
02250171-378
02250171-572
02250172-277
250018-428
825304-236
825305-283
825502-083
825506-198
829106-150
829704-075
829705-075
829705-100
829705-150
829706-125
834206-075
837806-094
838202-045
838205-071
838206-071
869015-010
884302-075
Note
1
1
1
1
2
1
1
Quantity
1
2
1
1
4
1
1
1
1
1
1
6
2
1
6
9
12
6
8
6
4
1
24
6
2
1
6
2
4
®
SULLAIR
®
1600 Open Frame Operator’s Manual and Parts List
117
SECTION 6
THIS PAGE INTENTIONALLY LEFT BLANK
118
1600 Open Frame Operator’s Manual and Parts List
®
SULLAIR
®
A
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
®
W
ORLDWIDE
S
ALES AND
S
ERVICE
Printed in the U.S.A
Specifications subject to change without prior notice
E07KCC
advertisement
Key Features
- Caterpillar Engine
- Open Frame Design
- Aftercooled or Non-Aftercooled
- Durable and Reliable
- 500 PSIG or 350 PSIG
- 750, 900, 1150, or 1350 CFM
- Easy to Maintain
- Wide Range of Applications