600H, 750, 750H, 750HH, 825, 900, 900H, 1050 CAT T2 & T3 User

600H, 750, 750H, 750HH, 825, 900, 900H, 1050 CAT T2 & T3 User
USER MANUAL
Portable Air Compressor
600H, 750, 750H, 750HH,
825, 900, 900H, 1050
Tier 3
Caterpillar
PART NUMBER:
02250197-981 R01
SAFETY WARNING
Users are required to read the
entire User Manual before handling or using the product.
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
The information in this manual is current as of its
publication date and applies to compressors with
serial number:
201509010000
and all subsequent serial numbers.
Publication date: 10/14/2015
Copyright © 2013 – 2015 Sullair, LLC. All rights reserved.
Subject to EAR, ECCN EAR99 and related export control restrictions.
Air Care Seminar Training
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Portable compressors are offered at regular intervals
throughout the year at Sullair’s training facility located in Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
Sullair Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write Sullair, LLC
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Table of Contents
Table of Contents
Section 1: Safety.......................................................................................................1
1.1
1.2
1.3
1.4
1.5
1.6
General....................................................................................................... 1
Personal protective equipment ................................................................... 1
Pressure release ........................................................................................ 1
Fire and explosion ...................................................................................... 2
Moving parts ............................................................................................... 3
Hot surfaces, sharp edges and sharp corners............................................ 4
1.7
1.8
1.9
1.10
1.11
1.12
1.13
Toxic and irritating substances ................................................................... 4
Electrical shock........................................................................................... 6
Lifting .......................................................................................................... 6
Entrapment ................................................................................................. 6
Implementation of lockout/tagout................................................................ 6
Jump starting .............................................................................................. 7
Towing1 ...................................................................................................... 8
1.6.1
Tier 4 emissions module—if equipped...................................................................4
1.13.1 Preparing to tow.....................................................................................................8
1.13.2 Towing .................................................................................................................10
1.13.3 Parking or locating compressor ...........................................................................10
1.14
1.15
California proposition 65........................................................................... 11
Symbols and references........................................................................... 12
Section 2: Description............................................................................................17
2.1
2.2
2.3
2.4
2.5
Introduction............................................................................................... 17
Description of components ....................................................................... 17
Sullair compressor unit, functional description ......................................... 20
Compressor cooling and lubrication system, functional description ......... 20
Capacity control system, functional description........................................ 22
2.5.1
2.5.2
2.5.3
2.5.4
2.6
2.7
Start—0 to 65 psig (0 to 4.5 bar) .........................................................................22
Low pressure—80 to 100 psig (5.5 to 6.9 bar) ....................................................22
High Pressure—80 to 150 psig (5.5 to 10.3 bar) for “H” models or
80 to 175 psig (5.5 to 12.1 bar) for “HH” models .................................................22
Shutdown.............................................................................................................22
Compressor discharge system, functional description ............................. 25
Aftercooled air system, functional description .......................................... 25
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
i
Table of Contents
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
Air inlet system, functional description...................................................... 27
Piping and instrumentation—compressor ................................................. 28
Piping and instrumentation—engine ......................................................... 30
Instrument panel group, functional description .........................................32
Engine control module, functional description .......................................... 32
Electrical system, functional description ................................................... 35
Wiring diagram, Tier 3............................................................................... 36
Compass® Controller wiring diagram .......................................................37
Section 3: Specifications....................................................................................... 39
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Table of specifications—all models........................................................... 39
Tables of specifications—600H, 750, 750H, 750HH................................. 40
Tables of specifications—825, 900, 900H, 1050 ...................................... 41
Lubrication guide, compressor.................................................................. 42
Application guide....................................................................................... 42
Lubrication guide, engine.......................................................................... 42
ID, tandem axle......................................................................................... 44
ID, 4-wheel................................................................................................ 46
ID, without running gear............................................................................48
Section 4: Operation .............................................................................................. 51
4.1
4.2
4.3
4.4
General ..................................................................................................... 51
Purpose of controls ...................................................................................51
Compressor start-up procedure ................................................................ 53
Shutdown procedure................................................................................. 54
Section 5: Maintenance ......................................................................................... 55
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
General ..................................................................................................... 55
Daily operation ..........................................................................................55
Engine coolant ..........................................................................................55
Maintenance after initial 50 hours of operation .........................................56
Maintenance every 100 hours................................................................... 56
Maintenance every 250 hours................................................................... 56
Maintenance every 300 hours................................................................... 56
Maintenance every 600 hours................................................................... 56
Maintenance every 1000 hours................................................................. 56
Maintenance every 1500 hours................................................................. 57
Parts replacement and adjustment procedures ........................................ 57
5.11.1 Compressor fluid change procedure ................................................................... 57
5.11.2 Running gear lubrication ..................................................................................... 57
ii
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Table of Contents
5.11.3 Wheel bearing lubrication ....................................................................................58
5.11.4 Main fluid filter servicing ......................................................................................60
5.11.5 Air filter maintenance ...........................................................................................60
5.12
Troubleshooting guide .............................................................................. 65
Section 6: Noise Control........................................................................................69
6.1
6.2
6.3
Noise emissions warranty......................................................................... 69
Tampering with the noise control system is prohibited............................. 69
Noise emissions maintenance and maintenance record log .................... 70
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
iii
Table of Contents
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Notes:
iv
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1: Safety
Section 1
Safety
factory approval.
NOTE
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.
Operator is required to read
entire instruction manual.
1.1 General
Sullair designs and manufactures all of its products so
they can be operated safely. However, the responsibility
for safe operation rests with those who use and maintain
these products. The following safety precautions are
offered as a guide which, if conscientiously followed, will
minimize the possibility of accidents throughout the
useful life of this equipment. Read the AEM Safety
Manual prior to compressor operation and towing, if
applicable in your area.
The air compressor should be operated only by those
who have been trained and delegated to do so, and who
have read and understood this Operator’s Manual.
Failure to follow the instructions, procedures and safety
precautions in this manual can result in accidents and
injuries.
1.2 Personal protective equipment
A. Prior to installing or operating the compressor, owners, employers and users should become familiar
with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local
codes, standards, and regulations relative to personal protective equipment, such as eye and face
protective equipment, respiratory protective equipment, equipment intended to protect the extremities,
protective clothing, protective shields and barriers
and electrical protective equipment, as well as noise
exposure administrative and/or engineering controls
and/or personal hearing protective equipment.
1.3 Pressure release
A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
otherwise disabled.
NEVER start the air compressor unless it is safe to do so.
DO NOT attempt to operate the air compressor with a
known unsafe condition. Tag the air compressor and
render it inoperative by disconnecting and locking out all
power at source or otherwise disabling its prime mover
so others who may not know of the unsafe condition
cannot attempt to operate it until the condition is
corrected.
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.
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.
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.
DO NOT modify the compressor except with written
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
1
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
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.
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
2
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.
B. Clean up spills of lubricant or other combustible substances immediately, if such spills occur.
C. Shut off air compressor and allow it to cool. Then
keep sparks, flames and other sources of ignition
away and DO NOT permit smoking in the vicinity
when adding fuel, checking or adding electrolyte to
batteries, checking or adding fluid, checking diesel
engine ether starting aid systems, replacing cylinders, or when refilling air line anti-icer systems antifreeze compound.
D. DO NOT permit fluids, including air line anti-icer system antifreeze compound or fluid film, to accumulate
on, under or around acoustical material, or on any
external surfaces of the air compressor. Wipe down
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical
material. Any acoustical material with a protective
covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
uids or fluid film within the material. DO NOT use
flammable solvents for cleaning purposes.
E. Disconnect and lock out all power at source prior to
attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F.
Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace any
wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure
connectors clean and tight.
G. Turn off battery charger before making or breaking
connections to the battery.
H. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
terminals to avoid arcing which might serve as a
source of ignition.
I.
Replace damaged fuel tanks or lines immediately
rather than attempt to weld or otherwise repair them.
DO NOT store or attempt to operate the compressor
with any known leaks in the fuel system. Tag the
compressor and render it inoperative until repair can
be made.
J. Remove any acoustical material or other material
that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempting weld repairs.
K. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as
serious personnel injury or property damage may
result.
Q. DO NOT spray ether into compressor air filter or into
an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result.
R. Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use
systems and refill with compound only in well-ventilated areas away from heat, open flames or sparks.
DO NOT expose any part of these systems or the
antifreeze compound to temperatures above 150 °F
(66 °C). Vapors from the antifreeze compound are
heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas.
DO NOT store containers of antifreeze compound in
direct sunlight.
S. Store flammable fluids and materials away from your
work area. Know where fire extinguishers are and
how to use them, and for what type of fire they are
intended. Check readiness of fire suppression systems and detectors if so equipped.
T.
DO NOT operate the compressor without proper flow
of cooling air or water or with inadequate flow of lubricant or with degraded lubricant.
U. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
1.5 Moving parts
M. Open all access doors and allow the enclosure to
ventilate thoroughly prior to attempting to start the
engine.
N. DO NOT operate compressor under low overhanging
leaves or permit such leaves to contact hot exhaust
system surfaces when operating the compressor in
forested areas.
O. Ethyl ether used in diesel engine ether starting aid
systems is extremely flammable. Change cylinders,
or maintain or troubleshoot these systems only in
well-ventilated areas away from heat, open flame or
sparks. DO NOT install, store or otherwise expose
ether cylinders to temperatures above 160°F (71°C).
Remove ether cylinder from the compressor when
operating in ambient temperatures above 60°F
(16°C).
1: Safety
WARNING
Disconnect and lock out all power at source and
verify at the compressor that all circuits are deenergized to minimize the possibility of accidental start-up, or operation, prior to attempting
repairs or adjustments. This is especially important when compressors are remotely controlled.
A. Keep hands, arms and other parts of the body and
also clothing away from couplings, fans and other
moving parts.
B. DO NOT attempt to operate the compressor with the
fan, coupling or other guards removed.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
3
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
C. Wear snug-fitting clothing and confine long hair when
working around this compressor, especially when
exposed to hot or moving parts.
D. Make sure all personnel are out of and/or clear of the
compressor prior to attempting to start or operate it.
E. When adjusting the controls, it may require operation
of the equipment during adjustment. DO NOT come
in contact with any moving parts while adjusting the
control regulator and setting the engine RPM. Make
all other adjustments with the engine shut off. When
necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut
off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment.
F.
Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to
minimize the possibility of slips and falls.
1.6 Hot surfaces, sharp edges and
sharp corners
A. Avoid bodily contact with hot fluid, hot coolant, hot
surfaces and sharp edges and corners.
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.
1.6.1
Tier 4 emissions module—if
equipped
General Guidelines: Thermal Protection. The main
exhaust piping routes exhaust gas from the engine to the
Clean Emissions Module (CEM). Normal operating
temperatures can reach up to 530°C (986°F). During
4
regeneration of the Diesel Particulate Filter (DPF), the
Auxiliary Regeneration Device (ARD) will be in operation,
this creating temperatures above normal engine exhaust
temperatures. Gas temperatures during the regeneration
period can reach 750°C (1382°F).
T4—WARNING
Increased DPF skin temperature and exhaust
gas temperature may occur in the event of an
unexpected engine/aftertreatment failure. An
unexpected failure of the engine/aftertreatment
may increase temperature at the DPF as high as
900°C (1652°F) gas temperature and 750°C
(1382°F) skin temperature. This may result in
fire, burn, or explosion hazards, which may
result in personal injury or death. Do not expose
flammable material or explosive atmospheres to
exhaust gas or exhaust system components during regeneration. The aftertreatment skin temperature and the gas temperature are difficult to
measure and/or simulate and are dependent
upon many factors including the following: the
nature of the engine/aftertreatment failure, the
design and packaging of the aftertreatment, the
engine speed/load conditions, the condition of
the aftertreatment and ambient conditions.
Therefore, the potential temperatures are provided as a guideline even under conditions of
unexpected engine and/or aftertreatment failure.
Proper precautions should be taken to ensure
that the aftertreatment device is not mounted in
close proximity to components that may be damaged by heat.
1.7 Toxic and irritating substances
A. DO NOT use air from this compressor for respiration
(breathing) except in full compliance with OSHA
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Standards 29 CFR 1920 and any other Federal, State
or Local codes or regulations.
DANGER
1: Safety
pound to air line anti-icer systems. Keep openings of
valve or atomizer tube of ether starting aid system
pointed away from yourself and other personnel.
J. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operator’s cabs or in
other similar confined areas.
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 adequately
ventilated areas.
D. Locate the compressor so that exhaust fumes are not
apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of
any portable or stationary compressor.
E. Fuels, fluids and lubricants used in this compressor
are typical of the industry. Care should be taken to
avoid accidental ingestion and/or skin contact. In the
event of ingestion, seek medical treatment promptly.
Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to the specific fluid.
F.
Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems.
G. Wear an acid-resistant apron and a face shield or
goggles when servicing the battery. If electrolyte is
spilled on skin or clothing, immediately flush with
large quantities of water.
H. Ethyl ether used in diesel engine ether starting aid
systems is toxic, harmful or fatal if swallowed. Avoid
contact with the skin or eyes and avoid breathing the
fumes. If swallowed, DO NOT induce vomiting and
call a physician immediately.
I.
Wear goggles or a full face shield when testing ether
starting aid systems or when adding antifreeze com-
L. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
fatal if swallowed. Avoid contact with the skin or eyes
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt, in
each glass of clean, warm water until vomit is clear,
then administer two teaspoons of baking soda in a
glass of clean water. Have patient lay down and
cover eyes to exclude light. Call a physician immediately.
M. If your compressor is equpped with DEF (Diesel
Emissions Fluid), when handling DEF wear protective clothing. Tools and clothing that come in contact
with DEF must be cleaned.
IMPORTANT
It is very important that all electrical connectors
are protected from coming in contact with DEF. If
not, there is a risk that DEF will cause oxidation
in the wiring that is not possible to clean. The
resulting oxidation will result in a wiring/connection failure. Water and compressed air fail to
remove DEF. If a connector has been in contact
with DEF, it must be changed immediately to
prevent the chemical from further migrating into
the wiring cable harness, which happens at a
speed of 0.6 m/h.
WARNING
In case of DEF contact with eyes or skin, the
affected area must be thoroughly rinsed with
lukewarm water. If you breathe any fumes, make
sure and breathe fresh air.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
5
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1.8 Electrical shock
I.
A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10
feet (3 m) from power lines and buried cables.
B. Stay clear of the compressor during electrical storms!
It can attract lightning.
C. Keep all parts of the body and any hand-held tools or
other conductive objects away from exposed live
parts of electrical system. Maintain dry footing, stand
on insulating surfaces and DO NOT contact any
other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical
system.
D. Attempt repairs in clean, dry and well lighted and
ventilated areas only.
1.9 Lifting
A. If the compressor is provided with a lifting bail, then
lift by the bail provided. If no bail is provided, then lift
by sling. Compressors to be air lifted by helicopter
must not be supported by the lifting bail, but by
slings instead. In any event, lift only in full compliance
with OSHA Standards 29 CFR 1910 subpart N or any
other Local, State, Military and Federal regulations
that may apply.
B. Inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts or
nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has
a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight
of water, snow, ice, mud, stored tools, and equipment. If your are unsure of the weight, then weigh
compressor before lifting.
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.
6
Keep lift operator in constant attendance whenever
compressor is suspended.
J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional 10% allowance for the weight of water, snow,
ice, mud, stored tools, and/or equipment.
K. If the compressor is provided with parking brakes,
make sure they are set, and in any event, block or
chock both sides of all running wheels before disengaging the lifting hook.
1.10 Entrapment
A.
Make sure all personnel are out of compressor
before closing and engaging enclosure doors.
B.
If the compressor is large enough to hold a man and
if it is necessary to enter it to perform service 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 Implementation of lockout/tagout
The energy control procedure defines actions necessary
to lockout a power source of any machine to be repaired,
serviced or set-up, where unexpected motion, or an
electrical or other energy source, would cause personal
injury or equipment damage. The power source on any
machine shall be locked out by each employee doing the
work except when motion is necessary during setup,
adjustment or trouble-shooting.
A. The established procedures for the application of
energy control shall cover the following elements and
actions and shall be initiated only by Authorized Persons and done in the following sequence:
1. Review the equipment or machine to be
locked and tagged out.
2. 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
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1: Safety
reservoir tanks. Lockout or tag lines or
valves.
made to inform him or her that the lockout or tagout device has been removed.
b. Any mechanism under tension or pressure, such as springs, should be
released and locked out or tagged.
d. ensured that the “Authorized” person is
notified of lock removal before returning
to work.
c.
Block any load or machine part prior to
working under it.
2. Tagout System—Tags are warning devices
affixed at points of power disconnect and are
not to be removed by anyone other that the
person placing tag on power lockout. Tags
shall never be by-passed, ignored, or otherwise defeated.
d. Electrical circuits should be checked with
calibrated electrical testing equipment
and stored energy and electrical capacitors should be safely discharged.
6. Lockout and/or Tagout each energy source
using the proper energy isolating devices
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person performing work. Each person shall be provided with
their own padlock and have possession of
the only key. If more than one person is
working on a machine each person shall affix
personal lock and tag using a multi-lock
device.
7. Tagout devices shall be used only when
power sources are not capable of being
locked out by use of padlocks and lockout
hasp devices. The name of the person affixing tag to power source must be on tag along
with date tag was placed on power source.
8. Release stored energy and bring the equipment to a “zero mechanical state”.
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
1. The lock shall be removed by the “Authorized” person who put the lock on the
energy-isolating device. No one other than
the person/persons placing padlocks and
lockout hasps on power shall remove padlock and lockout hasps and restore power.
However, when the authorized person who
applied the lock is unavailable to remove it
his/her Supervisor may remove padlock/padlocks and lockout hasps and restore power
only if it is first:
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
1.12 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 60°F (16°C)
before attempting to jump start or it may explode.
G. Cover open cells of all compressor batteries with
clean dampened cloths before attempting to jump
start.
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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
7
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
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 when jump starting 24V
compressors, to the positive (POS) (+) terminal of
the ungrounded battery in the compressor.
Q. Connect one end of the other jumper cable to the
grounded negative (NEG) (-) terminal of the battery
in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with
two (2) 12V batteries connected in series, connect
the jumper cable to the negative (NEG) (-) terminal of
the grounded battery.
R. Check your connections. DO NOT attempt to start a
24V compressor with one 12V battery in the starting
vehicle. DO NOT apply 24V to one 12V battery in the
compressor.
S. Connect the other end of this same jumper cable to a
clean portion of the compressor engine block away
from fuel lines, the crank case breather opening and
the battery.
1
8
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.
1.13 Towing1
1.13.1 Preparing to tow
WARNING
Do NOT tow the compressor should its weight
exceed the rated limit of the tow vehicle, as the
vehicle may not brake safely with excess weight.
See rated limit in tow vehicle Operator's Manual,
and review its instructions and other requirements for safe towing.
A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment,
checking for (I) signs of excessive wear or corrosion,
(II) parts that are cracked, bent, dented or otherwise
deformed or degraded, and (III) loose nuts, bolts or
other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected.
B. Back the tow vehicle to the compressor and position
it in preparation for coupling the compressor.
C. If the compressor is provided with a drawbar latched
in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not,
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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
raise drawbar with the jack to engage coupling
device or otherwise couple the compressor to the
towing vehicle.
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.
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.
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.
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 the front of
drawbar before passing them through points of
attachment on towing vehicle to support the front of
drawbar in case it should accidentally become
uncoupled.
F.
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.
1: Safety
H. On two-wheeled models, fully retract front screw jack
and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack,
and can not be removed. Follow the same procedure
for stowing away the wheeled jack as you would for
the standard screw jack. Pull the pin connecting the
jack to the drawbar and raise the screw jack to its full
upright position. Rotate the screw jack to its stowed
position, parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to towing.
I.
Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire size or
type. Also, make sure wheel bolts, lugs or nuts are
tightened to the specified torques.
J. If provided, make sure all dual stop, tail directional
and clearance lights are operating properly and that
their lenses are clean and functional. Also, make
sure all reflectors and reflecting surfaces, including
the slow moving vehicle emblem on compressors
provided with same, are clean and functional.
K. Make sure all service air hoses (not air brake hoses)
are disconnected or are fully stowed and secured on
hose reels, if provided.
L. Make sure all access doors and tool box covers are
closed and latched. If the compressor is large
enough to hold a man, make sure all personnel are
out before closing and latching access doors.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
9
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
M. Make sure parking brakes in towing vehicle are set,
or that its wheels are chocked or blocked, or that it is
otherwise restrained from moving. Then, release the
compressor parking brakes, if provided.
N. Make sure the compressor wheels are not chocked
or blocked, and that all tie-downs, if any, are free.
O. Test running brake operation, including breakaway
switch operation if provided, before attempting to tow
the compressor at its rated speed or less when conditions prevail.
P. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor.
Q. DO NOT load this equipment with accessories or
tools such that it is unbalanced from side to side or
front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility
of tipping, rolling over, jackknifing, etc. Loss of control
of the towing vehicle may result.
1.13.2 Towing
A. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed).
B. DO NOT exceed the towing speeds listed below
under ideal conditions. Reduce your speed according
to posted speed limits, weather, traffic, road or terrain
conditions:
C. Two axle four-wheel or three axle six-wheel steerable
models: 15 mph (24 km/h).
D. All other models: 55 mph (88 km/h).
E. Remember that the portable air compressor may
approach or exceed the weight of the towing vehicle.
Maintain increased stopping distances accordingly.
DO NOT make sudden lane changes, U-turns or
other maneuvers. Such maneuvers can cause the
compressor to tip, roll over, jackknife or slide and
cause loss of control of the towing vehicle. Tipping,
rolling over, etc. can occur suddenly without warning.
U-turns especially should be made slowly and carefully.
F.
Avoid grades in excess of 15° (27%).
ing forward or backing up, regardless of the terrain
being traversed.
I.
DO NOT permit personnel to ride in or on the compressor.
J. Make sure the area behind, in front of, and under the
compressor is clear of all personnel and obstructions
prior to towing in any direction.
K. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compressor
and the towing vehicle.
1.13.3 Parking or locating compressor
A. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade
so the compressor does not tend to roll downhill. DO
NOT park or locate compressor on grades exceeding
15° (27%).
B. Make sure compressor is parked or located on a firm
surface that can support its weight.
C. Park or locate compressor so the wind, if any, tends
to carry the exhaust fumes and radiator heat away
from the compressor air inlet openings, and also
where the compressor will not be exposed to excessive dust from the work site.
D. On steerable models, park compressor with front
wheels in straight-ahead position.
E. Set parking brakes and disconnect breakaway switch
cable and all other interconnecting electrical and/or
brake connections, if provided.
F.
Block or chock both sides of all wheels.
G. If provided, unhook chains and remove them from
the points of chain attachment on the towing vehicle,
then hook chains to bail on drawbar or wrap chains
around the drawbar and hook them to themselves to
keep chains off the ground which might accelerate
rusting.
H. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has
sufficient load bearing capability to support the
weight of the compressor.
G. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain.
H. Maneuver in a manner that will not exceed the freedom of motion of the compressor’s drawbar and/ or
coupling device, in or on the towing vehicle’s coupling device and/or adjacent structure whether tow-
10
WARNING
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
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
1: Safety
handle. Use a screwjack or chain fall if you cannot lift
or raise the drawbar without avoiding injury to yourself or others.
K. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barricades
and/or flares (if at night) if compressor is parked on
or adjacent to public roads. Park so as not to interfere with traffic.
NOTE
While not towed in the usual sense of the word,
many of these instructions are directly applicable
to skidmounted portable air compressors as well.
1.14 California proposition 65
WARNING
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and other compounds known to the
State of California to cause cancer and birth
defects and other reproductive harm. Wash
hands after handling.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
11
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1.15 Symbols and references
The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable
symbols.
DIESEL FUEL
HEARING PROTECTION
ROTARY COMPRESSOR
HARD HAT
TEST RUN
DRAIN
SAFETY GLASSES
HIGH PRESSURE
HOOK HERE
SHUT-OFF VALVE
W/ SAFETY
DO NOT REMOVE
MANUAL
NO
ENGINE
DO NOT BREATHE
COMPRESSED AIR
COMPRESSOR
DO NOT STAND ON
SERV. VALVE
ENGINE OIL
DO NOT OPERATE
W/ DOORS OPEN
ENGINE COOLANT
WATER
DO NOT OPEN
OIL
DO NOT STACK
ELECTRICAL SHOCK
DO NOT
CLOSED MECHANICAL
AIR FLOW
FUSE
HOT SURFACE
LOW PRESSURE
PRESSURIZED VESSEL
READ MANUAL
BRAKES
12
PRESSURIZED
COMPONENT
SAFETY SYMBOLS 1
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1: Safety
ENGINE START
DANGEROUS OUTLET
ENGINE ECM
REMOTELY
CONTROLLED
READ/WRITE DATA
CORROSIVE
INTAKE AIR
EXHAUST GAS
WARNING
FAN GUARD
DO NOT
MAINTENANCE
BELOW TEMPERATURE
BELT GUARD
DO NOT TOW
SERVICE POINT
BAR/PSI
LOW TEMPERATURE
BATTERY
BATTERY DISCONNECT
STD AIR
OFF
A/C AIR
ON
24 HOURS
RESET
BELTS
FILTER
NO FORKLIFT
STRAINER
FORK LIFT HERE
SAFETY SYMBOLS 2
DIRECTION OF ROTATION
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
13
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
RADIATOR
HOUR METER
AIR-CIRCULATING
FAN
COMPRESSOR AIR
PRESSURE
AIR-COOLED
OIL COOLER
START
CONTROL
LIQUID-COOLED
OIL COOLER
ENGINE PREHEAT
LOW TEMP AID
LUBRICATION
ENGINE WARNING
TRAILER TOWING
MODE
FUEL LEVEL
AXEL
ENGINE RPM
LUBRICANT GREASE
EXAMINE, CHECK
ENGINE OIL
PRESSURE
CRUSH/PINCH POINT
ENGINE COOLANT
TEMPERATURE
FUNCTIONAL ARROW
COMPRESSOR
TEMPERATURE
DO NOT MIX
COOLANTS
ENGINE INTAKE
AIR FILTER
AFTERCOOLER
BYPASS VALVE
PRESSURE CONTROL
INLET VALVE SPRING
DRAIN HEATER
INTERNAL FUEL
BATTERY HEATER
EXTERNAL FUEL
COMPRESSOR
OIL HEAT
SIDE DOOR T-LATCH
STACKING LIMIT
BY NUMBER
SAFETY SYMBOLS 3
14
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1: Safety
DO NOT OPERATE
WHILE STACKED
WATER DRAIN
PRESSURIZED SPRING
SEVER (FAN)
DO NOT MIX FLUIDS
DEF FLUID ONLY
AUTO START/STOP
RUN
SAFETY SYMBOLS 4
FLUID DRAIN
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
15
1: Safety
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Notes:
16
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2: Description
Section 2
Description
2.1 Introduction
Sullair Portable Air Compressor models offer superior
performance and reliability while requiring only minimal
maintenance.
The compressor is equipped with a Sullair rotary screw
compressor unit. Compared to other compressors, 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 Section 5: Maintenance 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 Service
Department.
2.2 Description of components
Refer to Figure 2-1 and Figure 2-2. The components and
assemblies of the Sullair Portable 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 machine is also supplied with
sound deadening insulation to lower noise emissions to
meet EPA or CE, and/or any Federal, State, or local noise
requirement. The Sullair compressor unit is driven by an
industrial engine designed to provide enough horsepower 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 engines intake air supply by
passing air through an air to air aftercooler. As air passes
through the aftercooler heat is removed which was introduced by the engine’s turbo charger. The engine is coupled to the compressor unit with a non-lubricated,
vulcanized rubber disk and a drive flange-type coupling.
All compressor models are supplied with a fuel tank large
enough to keep the compressor running through a full 8hour shift.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
17
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Moisture separator
8. Engine radiator
2. Thermal valve
9. Discharge air filter
3. Regulator valve
10. Receiver tank
4. Engine coolant fill
11. E-Stop
5. Fluid cooler
12. Engine muffler
6. Aftercooler
13. Manual enclosure
7. Engine charge air-cooler
14. Battery disconnect switch
Figure 2-1: Compressor
18
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Moisture separator
8. Engine radiator
2. Thermal valve
9. Discharge air filter
3. Regulator valve
10. Receiver tank
4. Engine coolant fill
11. E-Stop
5. Fluid cooler
12. Engine muffler
6. Aftercooler
13. Manual enclosure
7. Engine charge air-cooler
14. Battery disconnect switch
2: Description
Figure 2-2: Compressor
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
19
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.3 Sullair compressor unit,
functional description
Sullair compressors feature the Sullair compressor unit, a
single-stage, positive displacement, flood lubricated-type
compressor. This unit provides continuous compression
to meet your needs.
NOTE
With a Sullair compressor, there is no maintenance or inspection of the internal parts of the
compressor unit permitted in accordance with
the terms of the warranty.
Sullair compressors are factory-filled with Sullair AWF®
lubricant. For more information on fluid fill, refer to Section 3.5: Application guide on page 42.
Fluid is injected into the compressor unit hoses and
mixes directly with the air as the rotors turn, compressing
the air. The fluid flow has three basic functions:
• As coolant, it controls the rise of air temperature normally associated with the heat of compression.
• Seals the clearance paths between the rotors
and the stator and also between the rotors
themselves.
• Acts as a lubricating film between the rotors
allowing one rotor to directly drive the other,
which is an idler.
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.
20
2.4 Compressor cooling and
lubrication system, functional
description
Refer to Figure 2-2 and Figure 2-3. The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating
temperature of the compressor. In addition to the cooler
and fan, the system consists of a main filter and thermal
valve.
Fluid is used in the system as a coolant and a lubricant.
The fluid is housed in the receiver tank.
Upon start up, the fluid temperature is cool, and routing
to the cooler is not required. The fluid first enters the thermal valve and then flows on to the compressor unit,
bypassing the cooler. As the compressor continues to
operate, the temperature of the fluid rises and the thermal valve element begins to shift. This forces a portion of
the fluid to the fluid cooler. The cooler is a radiator-type
that works in conjunction with the engine fan. The fan
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 170°F (77°C), the thermal element shifts completely causing all fluid to flow to
the cooler. The thermal valve incorporates a pressure
relief valve, which allows fluid to bypass the cooler, if the
cooler becomes plugged or frozen. This helps assure
that fluid will continue to be provided to the compressor
for lubrication. After the fluid passes through the thermal
valve it is then directed through the main fluid filter.
There, the fluid is filtered in preparation for injection into
the compression chamber and bearings of the compressor unit. The filter has a replaceable element and a builtin bypass valve which allows the fluid to flow even when
the filter element becomes plugged and requires changing or when the viscosity of the fluid is too high for adequate flow. 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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Receiver tank
3. Thermal valve
2. Fluid cooler
4. Fluid filter
2: Description
Figure 2-3: Compressor oil, cooling and lubrication—all models
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
21
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.5 Capacity control system,
functional description
Refer to Figure 2-4. The purpose of the control system is
to regulate the amount of air intake in accordance with
the amount of compressed air demand. The control system consists of an inlet valve, 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.
2.5.1
Start—0 to 65 psig (0 to 4.5 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 65 psig (4.5 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 65 psig
(4.5 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.
2.5.2
Low pressure—80 to 100 psig (5.5 to
6.9 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
regulator opens up the inlet valve and the Compass Con-
22
troller 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. If the machine is not
marked with an “H” or “HH”, it is a single pressure
machine and will not have a HIGH/LOW switch. The
machine will run as if it is in the “LOW” position.
2.5.3
High Pressure—80 to 150 psig (5.5 to
10.3 bar) for “H” models or 80 to 175
psig (5.5 to 12.1 bar) for “HH” models
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 psig (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.
2.5.4
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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Blowdown valve
8. P1 pressure transducer
2. P2 pressure transducer
9. Reducing regulator
3. High pressure bypass regulator
10. Run/Start solenoid
4. Low pressure bypass regulator
11. Start orifice
5. Hi/lo solenoid
12. Check valve
6. Recirculating solenoid
13. Run orifice
2: Description
7. Recirculating valve
Figure 2-4: Control manifold—all models
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
23
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Compressor air filter
11. Fluid cooler
2. Engine air filter
12. Thermal valve/fluid filter assembly
3. Engine
13. Receiver tank
4. Compressor unit
14. Fluid level sight gauge
5. Service air (aftercooled)
15. Final fluid separator element
6. Discharge air filters
16. Ball valve
7. Air inlet valve
17. P3 pressure transducer
8. Moisture separator
18. Service air (non-aftercooled)
9. Aftercooler
19. Minimum pressure check valve
10. Relief valve
20. Temperature shutdown switch
Figure 2-5: Compressor flow diagram—all models
24
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.6 Compressor discharge system,
functional description
Refer to Figure 2-5. The Sullair compressor unit discharges compressed air/fluid mixture into the receiver
tank.
Fluid is added to the receiver tank via a capped fluid filler.
A fluid level gauge glass enables the operator to visually
monitor the receiver tank fluid level.
WARNING
The receiver tank has three functions:
• It acts as a primary fluid separator.
• Serves as the compressor fluid storage sump.
• Houses the final fluid separator.
The compressed air/fluid mixture enters the receiver tank
and is directed against the tank side wall. By change of
direction and reduction of velocity, large droplets of fluid
separate and fall to the bottom of the receiver tank. The
fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator
element as the compressed air flows through the separator. As more and more fluid collects on the element’s surface, the fluid descends to the bottom of the separator. A
return line (or scavenge tube) leads from the bottom of
the separator element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator
element is returned to the compressor by the pressure
difference between the area surrounding the separator
element and the compressor inlet. An orifice (protected
by a strainer) is included in this return line to help assure
proper flow.
The receiver tank is code rated. A minimum pressure/
check valve, located downstream from the separator,
helps assure a minimum receiver pressure during all conditions. This pressure is necessary for proper air/fluid
separation and proper fluid circulation.
A minimum pressure/check valve at the outlet of the
receiver is installed 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.
2: Description
Do not remove caps, plugs and/or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
2.7 Aftercooled air system,
functional description
Refer to Figure 2-6. The purpose of the aftercooled air
system is to operate the air compressor in conditions
when compressed air temperatures are required to be 10
to 25°F (5 to 13°C) over ambient temperature. 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 from the cooler air and discharged. This condensation does carry some oil and it
should be disposed of properly in accordance with local
regulations. A condensation drain port is located in the
frame on the front of the machine for convenience of condensate removal. This drain port should never be
plugged or closed off in any way. From the moisture separator the compressed air goes through the discharge filters (if equipped) and on to the service valve.
NOTE
Aftercooled system should not be operated in
ambient conditions below 32°F (0°C). 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 non-aftercooled valve.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
25
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Receiver tank
6. Discharge filter
2. Minimum pressure check valve
7. Pneumatic valves
3. Air valve
8. Standard air out
4. Aftercooler
9. Aftercooled air out
5. Moisture separator
Figure 2-6: Aftercooled air system
26
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.8 Air inlet system, functional
description
Refer to Figure 2-7. The compressor inlet system consists of one air filter, a compressor air inlet valve and
interconnecting piping to the engine and compressor.
Also, air filter restriction indicator gauges are located next
to the air filter housings.
The air filter is 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
2: Description
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 Section 5.11.5: Air filter maintenance on page 60. 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.
1. Engine air filter
4. Compressor
2. Compressor air filter
5. Engine inter-cooler
3. Air inlet valve
Figure 2-7: Air inlet system
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
27
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250170-299 R00 (sh1)
2: Description
28
2.9 Piping and instrumentation—compressor
Key Description
Qty Notes
Key Description
Qty Notes
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
1
FILTER, AIR
1
33
VALVE, SPIRAL
1
2
GAUGE, AIR FILTER RESTRICTION
1
34
VENTILATOR, AIR
2
3
INLET VALVE
1
35
CYLINDER, AIR (OPTIONAL)
1
4
COMPRESSOR
1
36
VALVE, PRESSURE DIFF. BYPASS
2
5
VALVE, RELIEF
2
37
VALVE, BACK PRESSURE REGULATOR
1
6
SWITCH, TEMPERATURE
2
38
MANIFOLD, OIL CONTROL
1
7
SENSOR, TEMPERATURE
1
39
MANIFOLD, AIR CONTROL
1
8
SENSOR, PRESSURE
3
9
VALVE, DISCHARGE CHECK
1
10
RECEIVER, AIR/OIL
1
P1
DRY SIDE PRESSURE
CONTROL PRESSURE
Component Description
11
GLASS, SIGHT OIL LEVEL
12
P2
12
VALVE, MINIMUM PRESSURE
1
P3
WET SIDE PRESSURE
13
VALVE, BALL
2
T1
COMPRESSOR DISCHARGE TEMPERATURE SENSOR
14
COOLER, AIR (OPTIONAL)
1
T3
RECEIVER TANK TEMPERATURE SWITCH (RTT)
15
SEPARATOR, MOISTURE
1
16
TRAP, DRAIN
1
17
ORIFICE
8
18
VALVE, BLOWDOWN N.C.
2
19
STRAINER
2
20
SIGHTGLASS, ORIFICE BLOCK
1
21
VALVE, THERMAL BYPASS
1
22
COOLER, OIL
1
23
FILTER, OIL
1
24
VALVE, OIL STOP
1
25
VALVE, PILOT ACTUATED RECIRC SOL.
1
26
VALVE, REGULATOR BACKPRESSURE
2
27
GAUGE, PRESSURE
1
VALVE, PRESSURE REGULATOR
1
29
VALVE, CHECK
3
30
VALVE, SOLENOID 3-WAY RUN/START
1
31
VALVE, SOLENOID 2-WAY ELECT
3
32
SEPERATOR, ELEMENT
3
29
2: Description
28
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.9 Piping and instrumentation—compressor
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250170-299 R00 (sh2)
2: Description
30
2.10 Piping and instrumentation—engine
Key Description
Qty Notes
Key Description
Qty Notes
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
1
TURBOCHARGER, ENGINE
1
33
PAN, ENGINE OIL
1
2
COOLER, CHARGE AIR
1
34
GAUGE, FILTER RESTRICTION
1
3
MUFFLER, ENGINE
1
35
SENSOR, INLET AIR TEMPERATURE
1
4
SENDER, FUEL LEVEL
1
36
VALVE, RELIEF (INTEGRAL TO ENGINE)
1
5
RAIN CAP, EXHAUST SYSTEM
1
37
VALVE, AIR STOP (OPTIONAL)
1
6
FILTER, FUEL W/ WATER SEPARATOR
1
38
VALVE, BALL 3-WAY (DUAL PORT)
1
7
PUMP, FUEL (INTERNAL TO ENGINE)
1
39
COUPLING, QUICK CONNECT 1/2" SUPPLY
1
40
COUPLING, QUICK CONNECT 3/8" RETURN
1
8
PUMP, FUEL HAND OPERATED PRIMING
1
9
FILTER, FUEL
1
10
VENTILATOR, FUEL TANK
1
11
CAP, FUEL TANK FILL
1
L1
COOLANT LEVEL
12
THERMOSTAT, THERMOCORD(OPTIONAL)
1
L2
FUEL LEVEL
13
KIT, ETHER ASSEMBLY
1
L3
OIL LEVEL (DIPSTICK)
14
PUMP, OIL (INTEGRAL TO ENGINE)
1
P5
INLET MANIFOLD AIR PRESSURE
15
BY-PASS VALVE (INTERNAL TO ENGINE)
1
P6
FUEL PRESSURE
OIL PRESSURE
Component Description
16
COOLER, OIL (INTERNAL TO ENGINE)
1
P7
17
FILTER, OIL
1
T7
INLET AIR TEMPERATURE
18
PUMP, WATER (INTEGRAL TO ENGINE)
1
T8
FUEL TEMPERATURE
19
RADIATOR, ENGINE
1
T9
COOLANT TEMPERATURE
CAM SPEED
CRANK SPEED
ENGINE THERMO (INTEGRAL TO ENGINE)
1
21
SENSOR, INLET AIR PRESS(TURBO BOOST)
1
S2
22
SWITCH, COOLANT LEVEL
1
23
SENSOR, FUEL PRESSURE
1
24
SENSOR, FUEL TEMPERATURE
1
25
SENSOR, COOLANT TEMPERATURE
1
26
SENSOR, ENGINE OIL PRESSURE
1
27
SENSOR, CAM SPEED TIMING
1
28
SENSOR, CRANK SPEED TIMING
1
29
HEATER, WATER JACKET (OPTIONAL)
1
30
OIL LEVEL (DIPSTICK)
1
31
FILTER, AIR
1
32
TANK, FUEL
1
31
2: Description
20
S1
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.10 Piping and instrumentation—engine
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.11 Instrument panel group,
functional description
The diagnostic FLASH CODE may be retrieved using this
lamp.
Refer to the Compass® Controller User Manual (Sullair
part number 02250167-454) for how to use the Compass
Controller.
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).
2.12 Engine control module,
functional description
Diagnostic Fault Codes are provided to indicate an electrical or electronic problem has been detected by the
ECM (Engine Control Module). In some cases, the
engine performance can be affected when the condition
causing the code exists. More frequently, however, the
operator cannot detect any difference in the engine performance.
The 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.
32
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 text 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 33 for possible performance
of active diagnostic codes.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2: Description
Table 2-1: Possible performance of active diagnostic codes
Flash
Code Description of Code
12
13
21
24
25
26
CID-FMI SPN-FMI Engine
Code
Code
Misfires
Incorrect crank-without-inject inputs
266-02
266-02
Fuel Temperature open/short to +batt
174-03
174-03
Fuel temperature short to ground
174-04
174-04
5-volt sensor DC power supply short to +batt
262-03
620-03
5-volt sensor DC power supply short to ground
262-04
620-04
Digital sensor supply short to +batt
262-03
678-03
Digital sensor supply short to ground
263-04
678-04
Engine oil pressure open/short to +batt
100-03
100-03
Engine oil pressure open/short to ground
100-04
100-04
Turbo outlet pressure above normal
273-00
102-00
Low
Power
Reduced
Engine
Engine
Speed
Shutdown
x
Turbo outlet pressure open/short to +batt
273-03
102-03
x
Turbo outlet pressure short to ground
273-04
102-04
x
Atmospheric pressure open/short to +batt
274-03
108-03
Atmospheric pressure short to ground
274-04
108-04
Engine coolant temperature open/short to +batt
110-03
110-03
x
x
x
Engine coolant temperature short to ground
110-04
110-04
x
x
x
28
Throttle position calibration required
91-13
91-03
x
x
32
Throttle position signal abnormal
91-08
91-08
x
x
Speed/timing sensor loss of signal
320-02
190-02
x
x (I)
Speed/timing sensor mechanical failure
320-11
190-11
x
x (I)
Loss of secondary engine speed signal
342-02
723-02
x
x (I)
Secondary engine speed sensor mechanical failure
342-11
723-11
x
x (I)
Engine overspeed shutdown
004
0190-16
Engine overspeed warning
190
0190-00
Fuel pressure open/short to +batt
94-03
94-03
Fuel pressure short to ground
94-04
94-04
Engine oil temperature open/short to +batt
175-03
175-03
Engine oil temperature short to ground
175-04
175-04
Intake manifold air temp open/short to +batt
172-03
172-03
x
x
x
Intake manifold air temp short to ground
172-04
172-04
x
x
x
x
x
x
x
x (I)
x (I)
x (I)
27
34
35
37
38
42
46
51
Engine timing calibration required
261-13
228-13
Low engine oil pressure warning
100
0100-17
Low engine oil pressure derate
039
0100-18
Low engine oil pressure shutdown
040
0100-01
System voltage intromittent/erratic
168-02
168-02
x
x
x
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
33
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Table 2-1: Possible performance of active diagnostic codes
Flash
Code Description of Code
53
56
58
61
62
64
65
72
73
74
00
CID-FMI SPN-FMI Engine
Code
Code
Misfires
Electronic Control Module error
254-12
No code
Personality Module mismatch
253-02
234-02
Check programmable parameters
268-02
111-02
J1939 Data Link communications
247-09
639-09
High engine coolant temperature derate
015
0110-16
High engine coolant temperature shutdown
016
0110-00
High engine coolant warning
017
0110-15
Fuel filter restriction derate
005
0094-15
Fuel filter restriction shutdown
006
0094-16
Fuel filter restriction warning
095
0094-00
High fuel pressure
096
0094-00
HIgh inlet temperature derate
025
0172-16
High inlet temperature shutdown
027
0172-05
High fuel temperature derate
054
0174-16
x
Low
Power
x
x
x
x (II)
x
High fuel temperature shutdown
055
0174-00
High fuel temperature warning
056
0174-15
Injector cylinder #1 fault
1-11
651-11
x
x
Injector cylinder #2 fault
2-11
652-11
x
x
Injector cylinder #3 fault
3-11
653-11
x
x
Injector cylinder #4 fault
4-11
654-11
x
x
Injector cylinder #5 fault
5-11
655-11
x
x
Injector cylinder #6 fault
6-11
656-11
x
x
Either start relay open/short to +batt
545-05
545-05
Either start relay short to ground
545-06
545-06
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier
SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
34
Reduced
Engine
Engine
Shutdown
Speed
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
x
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.13 Electrical system, functional
description
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, a
breaker protected alternator with a built-in voltage regulator, a breaker protected engine air inlet heater (for cold
weather starting), a compressor discharge temperature
sensor and receiver tank temperature switch (both will
shut down the compressor should the compressor temperature exceed 250°F [121°C]), an ambient temperature
sensor, and a fuel level sensor. This compressor also
incorporates an engine coolant level sensor. This device
is located in the top of the engine radiator. It will shut the
compressor down or prevent it from being started if the
2: Description
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. Also, should fuel
supply level drop near the bottom of the fuel tank, the
Compass® Controller will shut down the machine before
the engine runs out of fuel. There are also several connectors in the main harness that are designed to receive
wiring for factory options such as remote start, cold
weather louvers, engine air stop valve, and ether start
system. The electrical system also incorporates a lockable battery disconnect to be utilized for extended periods of non use and during machine maintenance. In case
of emergency, an emergency stop switch is located just
above the Compass Controller on the canopy of the
machine. Section 2.15 on page 37 shows the wiring diagram for the Compass Controller.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
35
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250163-092 R13
2: Description
36
2.14 Wiring diagram, Tier 3
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
2: Description
37
02250172-331 R00
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
2.15 Compass® Controller wiring diagram
2: Description
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Notes:
38
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3: Specifications
Section 3
Specifications
3.1 Table of specifications—all models
Table 3-1: Overall specifications
Length1
Model series
Height2
Width
Weight (wet)
Weight (dry)
in
mm
in
mm
in
mm
lb
kg
lb
kg
DTQ (tandem axle)
189
4801
87
2210
88
2234
10050
4559
9210
4178
DWQ (4-wheel)
203
5156
90
2286
94
2388
10200
4627
9360
4246
DLQ (LRG)
131
3327
87
2210
77
1956
9075
4116
8235
3735
1
Length over drawbar where applicable
2Over lifting bail
Table 3-2: Trailer specifications
Trailer
Track width
Tire size (load range)
Tire pressure
DTQ
DWQ
77 in (1956 mm)
79.5 in (2019 mm)
ST 235/80 R16 (E)
75 psig (5.2 bar)
Wheel size
16 x 6
Wheel bolt/lugnut torque
80 to 90 ft. lbs (108.5 to 12.0 Nm)
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
39
3: Specifications
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3.2 Tables of specifications—600H, 750, 750H, 750HH
Table 3-3: Compressor specifications
Compressor
600H
750
Type
750H
750HH
Rotary screw
Delivery @ operating pressure
600 cfm
17.0 m3/min)
/ 750 cfm
(21.2 m3/min)
750 cfm
(21.2 m3/min)
750 cfm
(21.2 m3/min)
Maximum operating pressure
150 psig (10.3 bar)
125 psig (8.5 bar)
150 psig (10.3 bar)
175 psig (12.1 bar)
Rated pressure
150 psig (10.3 bar)
125 psig (8.5 bar)
150 psig (10.3 bar)
175 psig (12.1bar)
Cooling
Pressurized compressor fluid
Lubricating compressor fluid
See Lubrication guide, compressor
Receiver tank capacity
26 US gallons (98 liters)
Operating tilt (maximum)
15°
Electrical system—engine
24 volt
Electrical system—instrument system
Battery (2)
Alternator
50 amp
Sound Level (US EPA)
Sound Level (CE)
24 volt
1000 CCA @ 0°F (−18°C)
1
76 dBA
2
72 dBA
1Sound
level measured per U.S. 40 CFR Ch. 1 Part 204
2
Sound level measured per 2000/14/EC Outdoor Noise Directive
Table 3-4: Engine specifications
Engine
600 / 750 / 750H / 750HH
Make
Caterpillar
Type
C9 Tier 3/Stage III
Rated speed
Horsepower, SAE
300 hp (224 kW)
Cylinders
6
Cycles
4
Bore x stroke
4.41 x 5.87 in (112 x 149 mm)
Displacement
538 cu. in (8.8 liters)
Lubricating system
Type of motor oil
Fuel tank capacity
Engine cooling system capacity
Idle speed
40
1800 rpm
Full pressure fluid
See Engine Operator’s Manual
115 U.S. gallons (435 liters)
6 U.S. gallons (22.7 liters)
1400 rpm
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3: Specifications
3.3 Tables of specifications—825, 900, 900H, 1050
Table 3-5: Compressor specifications
Compressor
825
900
Type
900H
1050
Rotary screw
Delivery @ operating pressure
825 cfm
(23.4 m3/min)
900 cfm
(25.5 m3/min)
900 cfm
(25.5 m3/min)
1050 cfm
(29.7 m3/min)
Maximum operating pressure
125 psig (8.5 bar)
125 psig (8.5 bar)
150 psig (10.3 bar)
125 psig (8.5 bar)
Rated pressure
125 psig (8.5 bar)
125 psig (8.5 bar)
150 psig (10.3 bar)
125 psig (8.5 bar)
Cooling
Pressurized compressor fluid
Lubricating compressor fluid
See Lubrication guide, compressor
Receiver tank capacity
21 US gallons (80 liters)
Operating tilt (maximum)
15°
Electrical system—engine
24 volt
Electrical system—instrument system
Battery (2)
Alternator
50 amp
1
76 dBA
Sound Level (US EPA)
Sound Level (CE)
24 volt
1000 CCA @ 0°F (−18°C)
2
72 dBA
1Sound
level measured per U.S. 40 CFR Ch. 1 Part 204
2
Sound level measured per 2000/14/EC Outdoor Noise Directive
Table 3-6: Engine specifications
Engine
825 / 900 / 900H / 1050
Make
Caterpillar
Type
C9 Tier 3/Stage III
Rated speed
Horsepower, SAE
1800 rpm
300 hp (224 kW)
Cylinders
6
Cycles
4
Bore x stroke
4.41 x 5.87 in (112 x 149 mm)
Displacement
550 cu. in (9 liters)
Lubricating system
Full pressure fluid
Type of motor oil
See Engine Operator’s Manual
Fuel tank capacity
120 U.S. gallons (454 liters)
Engine cooling system capacity
14.7 U.S. gallons (55.6 liters)
Idle speed
1400 rpm
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
41
3: Specifications
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3.4 Lubrication guide, compressor
Fluid type
Sullair AWF
1
®1
Change period, hours
Ambient temperature range °F (°C)
1500
−20 to 120 (−29 to 49)
Sullair part numbers for multi-viscosity lubricants are 250030-757 (5 gallons/18.9 liters), 250030-758 (55 gallons, 208 liter drum)
3.5 Application guide
Refer to Figure 3-1. Sullair Air Compressors are supplied
with Sullair AWF® which is heavy duty multi-viscosity, all
weather fluid. Sullair AWF also allows an extended
change interval. The fluids in Section 3.4: 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 tank periodically.
In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a “milky” color. ATF or SAE 10W is especially prone
to this condition. 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.
1. Sight glass1
2. Fluid fill port
1
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 offers a
fluid analysis program for Sullair AWF. Contact your local
Sullair representative for details.
42
If fluid is seen in the sight glass when the
machine is not running, no fluid is needed.
Figure 3-1: Fluid fill location
3.6 Lubrication guide, engine
For engine oil specifications, refer to the Engine Operator’s Manual.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3: Specifications
Notes:
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
43
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250162-745 R01
3: Specifications
44
3.7 ID, tandem axle
Key Part number
Qty Description
Drawing notes
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS.
ALL DOORS REQUIRE 5 FOOT [1524] CLEARANCE.
REAR DOOR ACCESS BATTERIES AND COOLERS.
REFERENCE: A STANDARD 40’ CONTAINER SIZE IS 88” WIDE X 89” TALL X 234” LONG.
REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’ HIGH CUBE CONTAINER.
COOLING AIR INTAKE (3)
WATER CONDENSATE DRAIN (DO NOT PLUG)
ENGINE COOLANT DRAIN
ENGINE OIL DRAIN
COMPRESSOR OIL DRAIN
DRAIN PLUG
HAND BRAKE
TIEDOWN (4)
100% SPILL CONTAINMENT FRAME
FUEL FILL
AUX. FUEL PORTS
LIFTING BAIL
COOLING AIR EXHAUST (3)
HYDRAULIC SURGE BRAKE (OPTIONAL)
AIR CONTROL DOOR
INSTRUMENT PANEL DOOR (COMPASS)
E-STOP
DOOR
OVERALL HEIGHT
SEPARATOR TANK FILTER
ENGINE EXHAUST AIR OUT
ENGINE COOLANT PORT ACCESS COVER
ENGINE AIR INTAKE
UNIT AIR INTAKE
BREAK AWAY BOX (ELECTRIC BRAKES ONLY)(STANDARD)
STABILIZING JACK
TOWING RING
TOW CHAIN (2)
2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-COOLED MODELS ONLY)
2” NPT STANDARD AIR DISCHARGE
TRACK WIDTH
3: Specifications
45
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32
A33
A34
A35
A36
Notes
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3.7 ID, tandem axle
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250162-746 R01
3: Specifications
46
3.8 ID, 4-wheel
Key Part number
Qty Description
Drawing notes
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
A1
DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS.
A2
ALL DOORS REQUIRE 5 FOOT [1524]CLEARANCE.
A3
REAR DOOR ACCESS BATTERIES AND COOLERS.
A4
REFERENCE A STANDARD 40’ CONTAINER SIZE IS88” WIDE X 89” TALL X 234” LONG.
A5
REFERENCE THREE COMPRESSORS CAN FIT IN A 40’HIGH CUBE CONTAINER.
A6
COOLING AIR INTAKE (3)
A7
WATER CONDENSATE DRAIN (DO NOT PLUG)
A8
ENGINE COOLANT DRAIN
A9
ENGINE OIL DRAIN
A10 COMPRESSOR OIL DRAIN
A11 DRAIN PLUG (4)
A12 TIEDOWN (4)
A13 100% SPILL CONTAINMENT FRAME
A14 FUEL FILL
A15 AUX. FUEL PORTS
A16 LIFTING BAIL
A17 COOLING AIR EXHAUST (3)
A18 AIR CONTROL DOOR
A19 INSTRUMENT PANEL DOOR (COMPASS)
Notes
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3.8 ID, 4-wheel
A20 E-STOP
A21 DOOR
A22 OVERALL HEIGHT
A23 SEPARATOR TANK FILTER
A24 ENGINE EXHAUST AIR OUT
A25 ENGINE COOLANT PORT ACCESS COVER
A27 UNIT AIR INTAKE
A28 TOWING RING
A29 2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-COOLED MODELS ONLY)
A30 2” NPT STANDARD AIR DISCHARGE
47
A31 TRACKWIDTH
3: Specifications
A26 ENGINE AIR INTAKE
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250165-379 R01
3: Specifications
48
3.9 ID, without running gear
Key
Part number
Qty Description
Drawing notes
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
A1
DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS.
A2
ALL DOORS REQUIRE 5 FOOT [1524] CLEARANCE.
A3
REAR DOOR ACCESS BATTERIES AND COOLERS.
A4
REFERENCE A STANDARD 40’ CONTAINER SIZE IS 88” WIDE X 89” TALL X 234” LONG.
A5
REFERENCE THREE COMPRESSORS CAN FIT IN A 40’ HIGH CUBE CONTAINER.
A6
COOLING AIR INTAKE (3)
A7
WATER CONDENSATE DRAIN (DO NOT PLUG)
A8
ENGINE COOLANT DRAIN
A9
ENGINE OIL DRAIN
A10 COMPRESSOR OIL DRAIN
A11 DRAIN PLUG (4)
A12 TIEDOWN (4)
A13 100% SPILL CONTAINMENT FRAME
A14 FUEL FILL
A15 AUX. FUEL PORTS
A16 LIFTING BAIL
A17 COOLING AIR EXHAUST (3)
A18 AIR CONTROL DOOR
A19 INSTRUMENT PANEL DOOR (COMPASS)
Notes
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
3.9 ID, without running gear
A20 E-STOP
A21 DOOR
A22 OVERALL HEIGHT
A23 SEPARATOR TANK FILTER
A24 ENGINE EXHAUST AIR OUT
A25 ENGINE COOLANT PORT ACCESS COVER
A27 UNIT AIR INTAKE
A28 2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-COOLED MODELS ONLY)
A29 2” NPT STANDARD AIR DISCHARGE
49
3: Specifications
A26 ENGINE AIR INTAKE
3: Specifications
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Notes:
50
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
4: Operation
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 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.
4.2 Purpose of controls
Control or indicator
Purpose
The engine switch is used to both energize the compressor’s electrical
system and engage the engine/starter. It also has a built-in 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.
OFF/ON/START Switch (Start Up)
NOTE
When restarting 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.
Voltmeter
Monitors the condition of the batteries and the charging circuit. The normal reading is 24 to 48 volts.
Air Pressure Gauge
Continually monitors the pressure inside the receiver tank at various
load and unload conditions.
Engine Water Temperature Gauge
Monitors the temperature of the engine water. The normal operating
temperature should read approximately 160ºF to 210ºF (71ºC to 99ºC).
Compass Controller
Depicts system related diagnostics. Can be used for system performance monitoring.
Compressor Discharge Temperature Gauge
Monitors the temperature of the air/fluid mixture leaving the compressor
unit. The normal reading should be approximately 210ºF to 250ºF (99ºC
to 121ºC).
System Pressure Sensor
Prevents starter engagement when the air system is pressurized.
Fluid Level Sight Glass
Monitors the fluid level in the receiver tank. Proper level is always visible
in the sight glass. Check the level when the compressor is shutdown.
Receiver Tank Temperature Switch
Opens the electrical circuit to shut down the compressor when then
receiver tank temperature reaches 250ºF (121ºC).
Reducing Regulator Valve
Provides regulated air pressure to the inlet valve.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
51
4: Operation
52
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Control or indicator
Purpose
Control Regulating Valve
Provides an air signal to the inlet valve and engine to close the inlet
valve and reduce engine speed to control air delivery according to
demand.
Minimum Pressure/Check Valve
Maintains a minimum of 65 psig (4.5 bar) in the compressor receiver
tank. This valve restricts receiver air discharge from receiver/receiver
tank when pressure falls to 65 psig (4.5 bar). Also prevents back flow
into the receiver tank during upload conditions and after shutdown.
HI/LO Selector Switch
Select high pressure 150 psig (10.3 bar) or low pressure 100 psig
(6.9 bar) at instrument panel to correspond to operator’s needs.
Pressure Relief Valve
Opens receiver tank pressure to atmosphere should pressure inside the
receiver tank exceed the pressure relief valve setting.
Air Inlet Valve
Regulates the amount of air allowed to enter the air inlet. This regulation
is determined by the amount of air being used at the service line.
Blowdown Valve
Vents receiver tank pressure to the atmosphere at shutdown.
Thermal Valve
Regulates flow of fluid to and around the fluid cooler. Designed to maintain a minimum operating temperature; used for fast warm-up at start-up
and to eliminate condensation during operation.
Running Blowdown Valve
Vents surplus receiver tank pressure to the atmosphere during operation.
Coolant Level Switch
Shuts the compressor down and/or prevents it from being started if the
engine coolant level drops too low.
Recirculation Valve
Provides limited air supply back to inlet valve during unload/no load conditions to prevent cavitation in the unit.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
4.3 Compressor start-up procedure
1. Turn the ON/OFF/START switch, located on
the Compass® Controller, to the “ON” position. The controller will power up and a selfdiagnostic 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:
4: 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
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:
When the system has successfully initialized, the following message will be displayed
on the LCD graphic display:
Once the proper operating conditions are
met, the machine will automatically switch
into run mode and provide pressurized serviced air.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
53
4: Operation
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
4.4 Shutdown procedure
1. Close the service valve.
2. Turn Place the OFF/ON/START switch in the
“OFF” position. The following message will
be displayed in the LCD graphic display:
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 3 to 5 minutes. Operator interaction is not necessary
during this time as the controller will automatically disconnect power to all systems so
that the battery is not inadvertently drained
after shutdown.
WARNING
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:
54
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 EStop 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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5: Maintenance
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 Section 2.2: Description of components on page
17 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 Section 5.12: Troubleshooting guide on page 65 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.
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 Section 5.11.5:
Air filter maintenance on page 60.
5.3 Engine coolant
The coolant provided with Sullair portable air compressors is ethylene glycol based, 50/50 mixture, colored
green, and should never be mixed with a coolant of a different color such as yellow, orange, or pink. If radiator
coolant is to be added, for any reason, be sure that the
coolant added is the same as what is in the cooling system, as well as what is recommended. Refer to the Maintenance section of the Engine Operators Manual for
proper engine coolant specifications and instructions.
Ensure that the proper coolant is used when adding
engine coolant to the machine and never mix different
color coolants. An engine originally filled with a conventional green coolant should not be “upgraded” to an
extended life coolant unless the cooling system is completely flushed and filled with water several times to
remove all traces of the old coolant. If you are not sure of
the coolant that is installed originally it is always best to
flush the system using water as a base until flushed
water is clear. Then, fill the system with the recommended coolant using only one brand/type. Cross contamination which is caused by adding different types of
engine coolants will result in the coolant additives to
deplete (dropout); thus leaving radiator surfaces unpro-
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
55
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
tected. Corrosion to radiator surfaces will occur, thus
reducing radiator life expectancy.
eign materials, if any. Perform the following maintenance
operations to prevent unnecessary problems.
• Clean the return line orifice and strainer.
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 anti-freeze. Should a
100% water solution be used, a non chromate
rust inhibitor must be added.
CAUTION
Dispose of fluids in accordance with applicable
federal, state and local regulations.
Table 5-1: Coolant Service Life
Coolant Type
Service Life
Caterpillar ELC
Six Years/12,000 Hours
Caterpillar DEAC
Three Years/3,000 Hours
Commercial Heavy-Duty
Coolant/Antifreeze that meets Two Years/3,000 Hours
“ASTM D5345”
Commercial Heavy-Duty
Coolant/Antifreeze that meets One Years/3,000 Hours
“ASTM D4985”
• Change compressor fluid filter.
• Check Engine Operator’s Manual for required
service.
5.5 Maintenance every 100 hours
After 100 hours of operation, it will be necessary to perform the following:
• Check the battery level and fill with water if necessary.
• Check Engine Operator’s Manual for required
service.
5.6 Maintenance every 250 hours
Perform the following after every 250 hours of operation:
• Check fan belt tension and adjust if needed.
• Clean the radiator and cooler exterior. Depending on how contaminated the atmosphere may
be, more frequent cooler and radiator cleaning
may be necessary.
• Check Engine Operator’s Manual for required
service.
5.7 Maintenance every 300 hours
When not using Sullair AWF®, change the compressor
fluid and replace the fluid filter element. Refer to Main
Fluid Filter Servicing on page 62.
5.8 Maintenance every 600 hours
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.
When not using Sullair AWF, replace the fluid filter element only. Refer to Main Fluid Filter Servicing on page
62.
5.9 Maintenance every 1000 hours
Perform the following after every 1000 hours of operation:
• Clean the return line orifice and strainer.
5.4 Maintenance after initial
50 hours of operation
• Repack the wheel bearings on wheel-mounted
units.
After the initial 50 hours of operation, a few simple maintenance routines can rid the system of any possible for-
56
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5: Maintenance
Figure 5-1: Running gear lubrication
5.10 Maintenance every 1500 hours
When using Sullair AWF®, change the compressor fluid
and replace the fluid filter element.
Refer to Section 5.11: Parts replacement and adjustment
procedures.
5.11 Parts replacement and
adjustment procedures
5.11.1 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 appropriate drain valve located in the frame at the
front of the machine. Close the valve when draining is
complete. Change the compressor fluid and replace the
fluid filter element. For element replacement see procedure for servicing the fluid filter in this section. Fill the
receiver tank with fluid according to Section 3.4: Lubrication guide, compressor on page 42.
5.11.2 Running gear lubrication
Refer to Figure 5-1. An inspection of the running gear
should be made on a routine basis. On four-wheel steerable running gear models, front-axle pivot joints and rod
ends are fitted with grease zerks which should be lubricated every six months.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
57
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Rubber plug
5. Grease fitting
2. Outer bearing
6. Metal end cap
3. Inner bearing
7. Spring-loaded double lip seal
4. Grease flow
Figure 5-2: Typical E-Z Lube axle
5.11.3 Wheel bearing lubrication
Refer to Figure 5-2. Proper lubrication is essential to the
proper functioning and reliability of your portable compressor axle. Wheel bearings should be lubricated at
least once every 12 months, or more frequently to help
insure proper performance. Use wheel bearing grease
that conforms to military specification MIL-G-10924 or a
high temperature wheel bearing grease such as lithium
complex NLGI Consistency #2.
If your axle is equipped with the E-Z Lube feature, the
bearings can be periodically lubricated without removing
the hubs from the axle. This feature consists of axle spindles that have been specially drilled and fitted with a
grease zerk in their ends. When grease is pumped into
the zerk, it is channeled to the inner bearing and then
flows back to the outer bearing and eventually back out
58
of the grease cap hole (refer to Figure 5-2). The procedure is as follows:
1. Remove the rubber plug from the end of the
grease cap.
2. With a standard grease gun filled with a quality wheel bearing grease, place the gun onto
the grease zerk located in the end of the
spindle. Make sure the grease gun nozzle is
fully engaged on the fitting.
3. Pump grease into the zerk. The old, displaced grease will flow back out of the cap
around the grease gun nozzle.
4. When new, clean grease is observed,
remove the grease gun, wipe off any excess,
and replace the rubber plug in the cap.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Capscrew
5. Thermostat element1
2. Washer
6. O-ring
3. Upper housing
7. Lower housing
4. O-ring
5. Filter elements2
1Repair
5: Maintenance
kit for thermostat element, part number 02250087-682
2Replacement
filter element (2 required), part number 250025-526
Figure 5-3: Main fluid filter assembly and thermostat
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
59
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5.11.4 Main fluid filter servicing
Refer to Figure 5-3. The main fluid filters are located
schematically in the coolant line between the receiver
tank and the compressor unit. The main filter elements
are replaceable. For installation of the filter elements, follow the procedure explained below:
1. The compressor MUST be shut off and system pressure MUST be relieved.
2. Position a suitable container beneath the
elements to catch fluid drainage.
3. Remove elements using a suitable tool.
4. Rotate each element counterclockwise to
remove.
5. Remove element and discard. These elements are not cleanable.
6. Make certain that the mounting surfaces and
filter heads are clean.
7. Apply a light film of clean fluid to each element gasket surface.
8. Center the new elements on filter housing
heads and tighten until the filter gaskets
make contact with the filter housing. After
gaskets make contact, tighten 1/2 to 2/3 of a
turn.
9. Run compressor and check for leaks.
5.11.5 Air filter maintenance
Refer to Figure 5-4. Air filter maintenance should be performed when indicated on instrument panel. The air filters are both equipped with a primary element and
secondary element each.
The secondary element must be replaced after every
third primary element change. DO NOT reconnect the
secondary element once it is removed.
5.11.5.1 Element removal
1. Clean the exterior of the air filter housing.
60
2. Remove the cover/element assembly by
loosening the wingnut securing the cover/
element assembly.
3. Remove the cover/element assembly from
the housing by unscrewing the wingnut.
4. Clean the interior of the housing by using a
damp cloth. DO NOT blow out dirt with compressed air as this may introduce dust downstream of the filter.
5. When it becomes necessary to remove the
secondary element, pull the element out of
the housing.
6. Install the new secondary element over the
rod.
7. With the secondary element in place, replace
the primary element.
5.11.5.2 Element inspection
1. Place a bright light inside the element to
inspect for damage or leak holes. Concentrated light will shine through the element
and disclose any holes.
2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets
be evident, correct the condition immediately.
3. If the clean element is to be stored for later
use, it must be stored in a clean container.
4. After the element has been installed, inspect
and tighten all air inlet connections prior to
resuming operation.
5.11.5.3 Primary element replacement
1. Place the element in position over the secondary element.
2. Install the cover with clean-out port pointing
down. Clamp in place using all latches
located on canister.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Housing
4. Primary element1
2. Secondary element2
5. Sealing washer
3. Dust collector
5. Wing nut
1Primary
5: Maintenance
Filter Element, Part No. 048462
2Secondary
Filter Element, Part No. 048463
Figure 5-4: Air filter assembly
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
61
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5.11.5.4 Control system adjustment
Refer to Figure 5-5. 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.
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 backpressure regulator so the service pressure is
between 115 to 125 psig (7.9 to 8.6 bar) with
the engine at 1400 rpm. Open the service
valve to load the compressor to maintain 100
psig (6.9 bar) discharge pressure. Operating
speed should be 1800 RPM on the instrument panel. If not, repeat step, but adjust the
62
unload service pressure up or down as
needed until 100 psig (6.9 bar) is maintained
when engine speed is 1800 rpm.
3. For 150 psig (10.3 bar) “H” machines, turn
the “HI/LO” switch to “HI” position. Close the
service valve and set the “HI” pressure control regulator to maintain 165 to 175 psig
(11.4 to 12.1 bar) discharge pressure. Open
the service valve to maintain 150 psig (10.3
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.
4. For 175 psig (12.1 bar) “HH” machines, turn
the “HI/ LO” switch to “HI” position. Close the
service valve and set the “HI” pressure control regulator to maintain 190 to 200 psig
(13.1 to 13.8 bar) discharge pressure. Open
the service valve to maintain 175 psig (12.1
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.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
1. Pneumatic inlet valve
6. Low pressure regulator
2. Manifold block
7. Start/Run solenoid
®
3. Compass controller
8. Recirculation solenoid
4. Hi/lo solenoid
9. Reducing pressure regulator
5: Maintenance
5. High pressure regulator
Figure 5-5: Control system components
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
63
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5.11.5.5 Separator element replacement
2. Remove the fluid return line from the fitting in
the cover.
3. Remove the twelve (12) 5/8 x 2.25 in capscrews and lock washers and lift the cover
from the receiver tank with the minimum
pressure/check valve in place.
4. Remove the separator element.
5. Scrape the old gasket material from the
cover and the flange on the receiver tank. Be
sure to keep all scrapings from falling inside
the tank.
6. Install the gaskets.
7. Make sure grounding staples are attached to
separator gasket. DO NOT REMOVE STAPLES.
8. Replace the receiver tank cover. Install the
twelve (12) 5/8 x 2.25 in capscrews and lock
washers in 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. Never tighten capscrews
adjacent to each other. Torque capscrews to
112 to 127 ft.lbs (151 to 172 N·m).
9. Reconnect all piping. The fluid return line
should extend to the bottom of the separator
element or no more than 1/16 in (1.6 mm) up
from the bottom. This will assure the proper
fluid return flow.
10. Clean the fluid return line strainer and clear
the orifice prior to restarting the compressor.
1. Capscrew
2. Lockwasher
3. Cover
3. Separator element1
3. Receiver tank
1
Repair kit, part number 250034-086
Figure 5-6: Figure name
Refer to Figure 5-6. When fluid carry-over is evident after
the fluid return-line strainer and orifice, as well as the
blowdown valve diaphragm, have been inspected and
found to be in satisfactory condition, or if the separator
restriction gauge reads in excess of 10 psig (0.7 bar),
separator element replacement is necessary. Follow the
procedure explained below:
1. Remove all piping connected to the receiver
tank cover to allow removal (return line, service line, etc.).
64
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
5.12 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 parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your nearest Sullair representative or Sullair.
NOTE
Additional troubleshooting tips are available in
the Compass® Controller Manual. Sullair Part
No. 02250167-454.
• Check for damaged piping.
Symptom
5: Maintenance
Probable cause
Remedy
No fuel
Check fuel level and add fuel if necessary.
Plugged fuel filter
Replace the fuel filter element.
Battery
Compressor will not start
Check electrolyte level and add distilled
water and recharge if necessary.
Loose battery cables; tighten cables.
Dirty battery cables; clean thoroughly.
Plugged air filter
Replace the air filter element.
Engine problems may have developed
Refer to Engine Operator’s Manual
Instrument panel problems may
have developed
Refer to Compass Controller Manual
(Sullair part number 02250167-454).
No fuel
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.
Compressor shuts down
with air demand present
Compressor discharge temperature switch is open
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
Refer to Compass Controller Manual
(Sullair part number 02250167-454).
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
65
5: Maintenance
Symptom
Compressor will not build
up full discharge pressure
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Probable cause
Remedy
Air demand is too great
Check service lines for leaks of open
valves.
Dirty air filter
Check the filter gauges on instrument
panel and change element if required.
Pressure regulator out of adjustment
Adjust regulator according to control
adjustment instructions in the Maintenance section.
Defective pressure regulator
Check diaphragm and replace if necessary (kit available).
Defective air inlet cylinder
Replace cylinder
Fluid charge lost from spring chamber on inlet valve pressure regulating valve is set too high
Improper unloading with an
excessive pressure buildup causing pressure relief
valve to open
Running blowdown valve pressure
regulating valve set too high
Some fluid may leak from the control
regulator at first but will stop leaking
when fluid level in the spring chamber
equalizes.
Readjust.
Check control lines.
Leak in control system causing loss
of pressure signal
Inlet valve jammed
Restriction in the control system
Worn seals in inlet valve. Replace
seals (kit available).
Defective pressure regulating valves;
repair valves (kits available).
Free or replace valve.
Check all control lines and components.
Ice and other contaminants could
cause restrictions.
Defective pressure relief valve
Replace pressure relief valve.
Plugged air filter
Replace.
Plugged air/fluid separator
Replace separator element and also
change compressor fluid and fluid filter
at this time.
Defective pressure regulator
Adjust or repair.
Engine speed too low
Readjust engine speed.
Control air cylinder defective
Replace cylinder.
Insufficient air delivery
66
Add fluid to inlet valve spring chamber
by removing plugs in the top of the
spring chamber and filing with compressor fluid.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Symptom
5: Maintenance
Probable cause
Remedy
Clogged return line
Clear orifice.
Leak in the lubrication system
Check all pipes, connections and components
Separator element damaged or not
functioning properly
Change separator element.
Defective minimum pressure/check
valve
Repair or replace.
Fluid receiver tank overfilled
Drain to proper level.
Loose or broken fan belt
Tighten or change belt
Dirty fluid cooler core
Clean core thoroughly.
Dirty aftercooler
Clean core thoroughly.
Dirty radiator core
Clean core thoroughly.
Faulty thermostat element
Change thermostat element.
Plugged fluid cooler tube (internal)
Clean tube thoroughly.
Low receiver tank fluid level
Refill.
Plugged compressor fluid filter
Change element.
Loose or broken fan belt
Tighten or change belt.
Dirty radiator core
Clean thoroughly.
Dirty oil cooler
Clean thoroughly.
Low water level
Refill.
Dirty aftercooler
Clean thoroughly.
Low fluid level
Refill.
Faulty water pump
Change pump.
Plugged radiator
Clean and flush thoroughly.
Defective engine thermostat
Replace engine thermostat.
Shutdown panel lights
Faulty switch indicated by light
Replace the switch.
Check engine light
Engine safety switch (low coolant)
fault
Replace the switch (Caterpillar part).
Engine warning flashing
light
Count number of flashes. This will
flash trouble code.
Determine trouble code and call Caterpillar Service Representative to correct
problem.
Excessive compressor
fluid consumption
Compressor overheating
Engine overheating
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
67
5: Maintenance
600H, 700, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Notes:
68
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
6: Noise Control
Section 6
Noise Control
6.1 Noise emissions warranty
Sullair warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was
designed, built and equipped to conform at the time of
sale to the first retail purchaser, with all applicable U.S.
E.P.A. and/or any Federal, State or Local noise control
regulations.
This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the
design, assembly, or in any part, component, or system
of the compressor which, at the time of sale to the first
retail purchaser, caused noise emissions to exceed Federal standards are covered by this warranty for the life of
the air compressor.
control prior to its sale or delivery to the ultimate purchaser or while it is in use.
2. The use of the compressor after such device
or element of design has been removed or
rendered inoperative by any person.
Among those acts included in the prohibition against tampering are the acts listed below:
1. Removal or rendering inoperative any of the
following:
• Engine exhaust system or parts thereof
• Compressor air intake system or part
thereof
• Enclosure of part thereof
2. Removal of any of the following:
6.2 Tampering with the noise control
system is prohibited
Federal Law prohibits the following acts or the causing
thereof:
1. The removal or rendering inoperative by any
persons, other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any
new compressor for the purpose of noise
• Vibration isolators
• Control silencer
• Floor panel
• Fan shroud
• Acoustical materials including fiberglass
foam or foam tape
3. Operation with canopy doors open for any
purpose other than starting, stopping, adjustment, repair, replacement of parts or maintenance.
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
69
6: Noise Control
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
6.3 Noise emissions maintenance and maintenance record log
The following instructions and maintenance record log book, for the proper maintenance, use and repair of this compressor, is intended to prevent noise emission degradation.
Table 6-1: Annual muffler and exhaust system inspection
At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints and
connections are tight, and that the muffler is in good condition. Do not operate compressor with defective exhaust system.
Remove and replace any defective parts by ordering with part numbers indicated in the Parts List.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Table 6-2: Annual air filter(s) and air inlet system inspection
In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet system
should be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight,
that there are no other leaks in the system, and that the filter element(s) are intact. Do not operate compressor with defective
air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts List.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
70
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
6: Noise Control
Table 6-3: Annual engine vibration mount inspection
At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. Do
not operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part
numbers indicated in Parts List.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Table 6-4: Annual frame, canopy and parts inspection
At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any missing or
deformed members, including all hinged doors, covers and their fastening devices. Do not operate compressor with defective
frame, canopy and parts. Remove and replace defective parts by ordering with part numbers indicated in Parts List.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
71
6: Noise Control
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 T3 CAT User Manual
Table 6-5: Annual acoustical materials inspection
At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material
missing or damaged (refer to Parts List). Clean or replace, if necessary. Do not operate compressor with defective acoustical
material. Remove and replace defective parts by ordering with part numbers indicated in the Parts List.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Table 6-6: Annual inspections for proper operation of all systems
In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to make sure all
systems are operating properly and that engine runs at rated speed and pressure. Do not operate malfunctioning or
improperly adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required.
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
Maintenance performed:
By:
Location:
Date:
72
02250197-981 R01
Subject to EAR, ECCN EAR99 and related export control restrictions.
Subject to EAR, ECCN EAR99 and related export control restrictions.
Sullair, LLC
3700 East Michigan Boulevard
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)
Information and specifications are subject to change without prior notice.
Subject to EAR, ECCN EAR99 and related export control restrictions.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising