CATERPILLAR IT4 C9 - multiquipparts.com · CATERPILLAR IT4 C9.3. AIR CARE SEMINAR TRAINING Sullair...

Failure to follow the instructions and procedures in this manual or,

misuse of this equipment will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

©COPYRIGHT 2012 SULLAIR The information in this manual is currentas of its publication date, and applies tocompressor serial number:

and all subsequent serial numbers.

02250201-740 R01

201200000

PORTABLE AIR COMPRESSOR600H, 600HH, 750, 750H, 750HH, 825, 900H, 1050

CATERPILLAR IT4 C9.3

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 and compressor electricalsystems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facilitylocated at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting commonfaults 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 or219-879-5451 (ext. 5623)

[email protected]

- Or Write -

Sullair3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTS

SECTION 1—SAFETY 5 1.1 GENERAL

5 1.2 TOWING

8 1.3 PRESSURE RELEASE

9 1.4 FIRE AND EXPLOSION

10 1.5 MOVING PARTS

11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

12 1.7 TOXIC AND IRRITATING SUBSTANCES

12 1.8 ELECTRICAL SHOCK

13 1.9 LIFTING

13 1.10 ENTRAPMENT

13 1.11 JUMP STARTING

14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

15 1.13 CALIFORNIA PROPOSITION 65

16 1.14 SYMBOLS AND REFERENCES

SECTION 2—DESCRIPTION 19 2.1 INTRODUCTION

19 2.2 DESCRIPTION OF COMPONENTS

22 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

22 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-AL DESCRIPTION

24 2.5 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

28 2.6 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

28 2.7 AFTERCOOLED AIR SYSTEM, FUNCTIONAL DESCRIPTION

30 2.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

32 2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP SINGLE)

34 2.10 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP DU-AL)

36 2.11 PIPING AND INSTRUMENTATION DIAGRAM—HYDRAULIC FAN DRIVE

38 2.12 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE

40 2.13 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

41 2.14 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION

TABLE OF CONTENTS

46 2.15 HYDRAULIC FAN DRIVE SYSTEM

47 2.16 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION

54 2.17 ENGINE EXHAUST AFTERTREATMENT, FUNCTIONAL DESCRIPTION

SECTION 3—SPECIFICATIONS 55 3.1 TABLE OF SPECIFICATIONS—600H, 600HH, 750, 750H

57 3.2 TABLE OF SPECIFICATIONS—750HH, 825, 900H, 1050

58 3.3 LUBRICATION GUIDE—COMPRESSOR

59 3.4 APPLICATION GUIDE

59 3.5 LUBRICATION GUIDE, ENGINE

60 3.6 IDENTIFICATION, TANDEM AXLE (DTQ)

SECTION 4—OPERATION 63 4.1 GENERAL

63 4.2 PURPOSE OF CONTROLS

65 4.3 COMPRESSOR START-UP PROCEDURE

66 4.4 EXHAUST REGENERATION PROCEDURE

67 4.5 SHUTDOWN PROCEDURE

SECTION 5—MAINTENANCE 69 5.1 GENERAL

69 5.2 DAILY OPERATION

69 5.3 ENGINE COOLANT

70 5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

70 5.5 MAINTENANCE EVERY 100 HOURS






71 5.11 MAINTENANCE EVERY YEAR OR 1500 HOURS

71 5.12 MAINTENANCE EVERY YEAR

71 5.13 MAINTENANCE AFTER 4500 HOURS OF OPERATION

71 5.14 MAINTENANCE AFTER 5000 HOURS OF OPERATION

72 5.15 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

75 5.16 HYDRAULIC SYSTEM MAINTENANCE

81 5.17 TROUBLESHOOTING GUIDE

SECTION 6—NOISE CONTROL 85 6.1 NOISE EMISSIONS WARRANTY

85 6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED

86 6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

Section 1

5

SAFETY

1.1 GENERAL

Sullair designs and manufactures all of its productsso they can be operated safely. However, theresponsibility for safe operation rests with those whouse and maintain these products. The followingsafety precautions are offered as a guide which, ifconscientiously followed, will minimize the possibilityof accidents throughout the useful life of thisequipment. Read the CIMA Safety Manual prior tocompressor operation and towing, if applicablein your area.

The air compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator’sManual. Failure to follow the instructions, proceduresand safety precautions in this manual can result inaccidents and injuries.

NEVER start the air compressor unless it is safe todo so. DO NOT attempt to operate the aircompressor with a known unsafe condition. Tag theair compressor and render it inoperative bydisconnecting the battery so others who may notknow of the unsafe condition will not attempt tooperate it until the condition is corrected.

Use and operate the air compressor only in fullcompliance with all pertinent OSHA requirementsand/or all pertinent Federal, State and Local codes orrequirements.

DO NOT modify the compressor except with writtenfactory approval.

Each day, walk around the air compressor andinspect for leaks, loose or missing parts, damagedparts or parts out of adjustment. Perform allrecommended daily maintenance.

Inspect for torn, frayed, blistered or otherwisedeteriorated and degraded hoses. Replace asrequired.

1.2 TOWING

PREPARING TO TOW

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

CAUTIONEstimated hose life based on a 5-day 8-hour work week is 3 years. These conditions exist on an 8-hour shift only. Any other operation of the equipment other than 8-hour shifts would shorten the hose life based on hours of operation.

(I)

WARNINGDo NOT tow the compressor should its weight exceed the rated limit of the tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator's Manual, and review its instructions and other requirements for safe towing.

(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED PORTABLE AIR COMPRESSORS AS WELL.

SECTION 1

6

A. Prior to hitching the air compressor to the towvehicle, inspect all attachment parts and equip-ment, checking for (i) signs of excessive wear orcorrosion, (ii) parts that are cracked, bent,dented or otherwise deformed or degraded, and(iii) loose nuts, bolts or other fasteners. Shouldany such condition be present, DO NOT TOWuntil the problem is corrected.

B. Back the tow vehicle to the compressor and posi-tion it in preparation for coupling the compressor.

C. If the compressor is provided with a drawbarlatched in the vertical upright position, carefullyunlatch drawbar and lower it to engage the cou-pling device. If not, raise drawbar with the jack toengage coupling device or otherwise couple thecompressor to the towing vehicle.

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

E. If chains are provided, pass each chain throughits point of attachment on the towing vehicle;then hook each chain to itself by passing thegrab hook over (not through) a link. Cross chainsunder the front of drawbar before passing themthrough points of attachment on towing vehicle tosupport the front of drawbar in case it shouldaccidentally become uncoupled.

F. Make sure that the coupling device and adjacentstructures on the towing vehicle (and also, if uti-lized, chain adjustment, brake and/or electricalinterconnections) DO NOT interfere with orrestrict motion of any part of the compressor,including its coupling device, with respect to thetowing vehicle when maneuvering over anyanticipated terrain.

G. If provided, make sure chain length, brake andelectrical interconnections provide sufficientslack to prevent strain when cornering andmaneuvering, yet are supported so they cannotdrag or rub on road, terrain or towing vehicle sur-faces which might cause wear that could renderthem inoperative.

H. On two-wheeled models, fully retract front screwjack and any rear stabilizer legs. If a caster wheelis provided on the screw jack it is part of thescrew jack, and can not be removed. Follow thesame procedure for stowing away the wheeledjack as you would for the standard screw jack.Pull the pin connecting the jack to the drawbarand raise the screw jack to its full upright posi-tion. 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 totowing.

WARNINGThis 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.


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

SECTION 1

7

I. Make sure tires are in good condition and are thesize (load range) specified and are inflated to thespecified pressures. DO NOT change the tiresize or type. Also, make sure wheel bolts, lugs ornuts are tightened to the specified torques.

J. If provided, make sure all dual stop, tail direc-tional and clearance lights are operating properlyand that their lenses are clean and functional.Also, make sure all reflectors and reflecting sur-faces, including the slow moving vehicle emblemon compressors provided with same, are cleanand functional.

K. Make sure all service air hoses (not air brakehoses) are disconnected or are fully stowed andsecured on hose reels, if provided.

L. Make sure all access doors and tool box coversare closed and latched. If the compressor islarge enough to hold a man, make sure all per-sonnel are out before closing and latchingaccess doors.

M. Make sure parking brakes in towing vehicle areset, or that its wheels are chocked or blocked, orthat it is otherwise restrained from moving. Then,release the compressor parking brakes, if pro-vided.

N. Make sure the compressor wheels are notchocked or blocked, and that all tie-downs, if any,are free.

O. Test running brake operation, including break-away switch operation if provided, beforeattempting to tow the compressor at its ratedspeed 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 ortools such that it is unbalanced from side to sideor front to back. Such unbalance will reduce thetowability of this equipment and may increasethe possibility of tipping, rolling over, jackknifing,etc. Loss of control of the towing vehicle mayresult.

TOWING

A. Observe all Federal, State, and Local laws whiletowing this equipment (including those specifyingminimum speed).

B. DO NOT exceed the towing speeds listed belowunder ideal conditions. Reduce your speed

according to posted speed limits, weather, traffic,road or terrain conditions:

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

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

C. Remember that the portable air compressor mayapproach or exceed the weight of the towingvehicle. Maintain increased stopping distancesaccordingly. DO NOT make sudden lanechanges, U-turns or other maneuvers. Suchmaneuvers can cause the compressor to tip, rollover, jackknife or slide and cause loss of controlof the towing vehicle. Tipping, rolling over, etc.can occur suddenly without warning. U-turnsespecially should be made slowly and carefully.

D. Avoid grades in excess of 15° (27%).

E. Avoid potholes, rocks and other obstructions,and soft shoulders or unstable terrain.

F. Maneuver in a manner that will not exceed thefreedom of motion of the compressor’s drawbarand/ or coupling device, in or on the towing vehi-cle’s coupling device and/or adjacent structurewhether towing forward or backing up, regard-less of the terrain being traversed.

G. DO NOT permit personnel to ride in or on thecompressor.

H. Make sure the area behind, in front of, and underthe compressor is clear of all personnel andobstructions prior to towing in any direction.

I. DO NOT permit personnel to stand or ride on thedrawbar, or to stand or walk between the com-pressor and the towing vehicle.

PARKING OR LOCATING COMPRESSOR

A. Park or locate compressor on a level surface, ifpossible. If not, park or locate compressor acrossgrade so the compressor does not tend to rolldownhill. DO NOT park or locate compressor ongrades exceeding 15° (27%).

B. Make sure compressor is parked or located on afirm surface that can support its weight.

C. Park or locate compressor so the wind, if any,tends to carry the exhaust fumes and radiatorheat away from the compressor air inlet open-ings, and also where the compressor will not beexposed to excessive dust from the work site.

D. On steerable models, park compressor with frontwheels in straight-ahead position.

SECTION 1

8

E. Set parking brakes and disconnect breakawayswitch cable and all other interconnecting electri-cal and/or brake connections, if provided.

F. Block or chock both sides of all wheels.

G. If provided, unhook chains and remove themfrom the points of chain attachment on the towingvehicle, then hook chains to bail on drawbar orwrap chains around the drawbar and hook themto themselves to keep chains off the groundwhich might accelerate rusting.

H. Lower front screw jack and/or any front and rearstabilizer legs. Make sure the surface they con-tact has sufficient load bearing capability to sup-port the weight of the compressor.

I. If a caster wheel is provided on the screw jack, itis 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 screwjack. Raise the screw jack to its full upright posi-tion and pull the pin connecting the jack to thedrawbar. Rotate the screw jack to its stowed posi-tion, parallel to the drawbar and reinsert the pin.Make sure the jack is secured in place prior totowing.

J. Disconnect coupling device, keeping hands andfingers clear of all pinch points. If the compressoris provided with a drawbar, DO NOT attempt to liftthe drawbar or if hinged, to raise it to the uprightposition by hand, if the weight is more than youcan safely handle. Use a screwjack or chain fall ifyou cannot lift or raise the drawbar without avoid-ing injury to yourself or others.

K. Move the towing vehicle well clear of the parkedcompressor and erect hazard indicators, barri-cades and/or flares (if at night) if compressor isparked on or adjacent to public roads. Park so asnot to interfere with traffic.

1.3 PRESSURE RELEASE

A. Open the pressure relief valve at least weekly tomake sure it is not blocked, closed, obstructed orotherwise disabled.

B. Install an appropriate flow-limiting valve betweenthe 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 theshutoff (throttle) valve, to reduce pressure in caseof hose failure, per OSHA Standard 29 CFR1926.302 (b) (7) or any applicable Federal, Stateand Local codes, standards and regulations.

C. When the hose is to be used to supply a manifold,install an additional appropriate flow-limiting valvebetween the manifold and each air hose exceed-ing 1/2" (13 mm) inside diameter that is to be con-nected to the manifold to reduce pressure in caseof hose failure.

D. Provide an appropriate flow-limiting valve for eachadditional 75 feet (23 m) of hose in runs of airhose exceeding 1/2" (13 mm) inside diameter toreduce pressure in case of hose failure.


CAUTIONRetract the front screw jack only after attaching the compressor to the tow vehi-cle. Raise the screw jack to its full up posi-tion 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 posi-tion, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

NOTEWhile not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted porta-ble air compressors as well.

SECTION 1

9

E. Flow-limiting valves are listed by pipe size andrated CFM. Select appropriate valve accordingly.

F. DO NOT use tools that are rated below the maxi-mum rating of this compressor. Select tools, airhoses, pipes, valves, filters and other fittingsaccordingly. DO NOT exceed manufacturer’srated safe operating pressures for these items.

G. Secure all hose connections by wire, chain orother suitable retaining device to prevent tools orhose ends from being accidentally disconnectedand expelled.

H. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) tozero internal pressure before removing the cap.

I. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers,and before attempting to refill optional air lineanti-icer systems with antifreeze compound.

J. Keep personnel out of line with and away fromthe discharge opening of hoses, tools or otherpoints of compressed air discharge.

K. DO NOT use air at pressures higher than 30 psig(2.1 bar) for cleaning purposes, and then onlywith effective chip guarding and personal protec-tive equipment per OSHA Standard 29 CFR1910.242 (b) or any applicable Federal, Stateand Local codes, standards and regulations.

L. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

M. This equipment is supplied with an ASMEdesigned pressure vessel protected by an ASMErated relief valve. Lift the handle once a week tomake sure the valve is functional. DO NOT liftthe handle while machine is under pressure.

N. If the machine is installed in an enclosed area itis necessary to vent the relief valve to the outsideof the structure or to an area of non-exposure.

O. DO NOT remove radiator filler cap until the cool-ant temperature is below its boiling point. Thenloosen cap slowly to its stop to relieve anyexcess pressure and make sure coolant is notboiling before removing cap completely. Removeradiator filler cap only when cool enough to touchwith a bare hand.

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

under pressure. DO NOT puncture or incineratethose cylinders. DO NOT attempt to remove thecenter valve core or side pressure relief valvefrom these cylinders regardless of whether theyare full or empty.

Q. If a manual blowdown valve is provided on thereceiver, open the valve to ensure all internalpressure has been vented prior to servicing anypressurized component of the compressor air/fluid system.

1.4 FIRE AND EXPLOSION

A. Refuel at a service station or from a fuel tankdesigned for its intended purpose. If this is notpossible, ground the compressor to the dis-penser prior to refueling.

B. Clean up spills of fuel, fluid, battery electrolyte orcoolant immediately if such spills occur.

C. Shut off air compressor and allow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen adding fuel, checking or adding electrolyteto batteries, checking or adding fluid, checkingdiesel engine ether starting aid systems, replac-ing cylinders, or when refilling air line anti-icersystems antifreeze compound.

D. DO NOT permit liquids, including air line anti-icersystem antifreeze compound or fluid film, toaccumulate on bottom covers or on, under oraround acoustical material, or on any external orinternal surfaces of the air compressor. Wipedown using an aqueous industrial cleaner orsteam clean as required. If necessary, removeacoustical material, clean all surfaces and thenreplace acoustical material. Any acoustical mate-rial with a protective covering that has been tornor punctured should be replaced immediately toprevent accumulation of liquids or fluid film withinthe material. DO NOT use flammable solventsfor cleaning purposes.

WARNINGDo not attempt to operate the compressor in any classification of hazardous environ-ment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty.

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10

E. Disconnect the grounded (negative) battery con-nection prior to attempting any repairs or clean-ing inside the enclosure. Tag the batteryconnections so others will not unexpectedlyreconnect it.

F. Keep electrical wiring, including the battery ter-minals and other terminals, in good condition.Replace any wiring that has cracked, cutabraded or otherwise degraded insulation or ter-minals that are worn, discolored or corroded.Keep all terminals clean and tight.

G. Turn off battery charger before making or break-ing connections to the battery.

H. Keep grounded conductive objects such as toolsaway from exposed live electrical parts such asterminals to avoid arcing which might serve as asource of ignition.

I. Replace damaged fuel tanks or lines immediatelyrather than attempt to weld or otherwise repairthem. DO NOT store or attempt to operate thecompressor with any known leaks in the fuel sys-tem. Tag the compressor and render it inopera-tive until repair can be made.

J. Remove any acoustical material or other materialthat may be damaged by heat or that may sup-port combustion prior to attempting weld repairs.Remove diesel engine ether starting aid cylin-ders and air line anti-icer system componentscontaining antifreeze compound, prior toattempting weld repairs in any place other thanthe fuel system. DO NOT weld on or near thefuel system.

K. Keep a suitable, fully charged class BC or ABCfire extinguisher or extinguishers nearby whenservicing and operating the compressor.

L. Keep oily rags, trash, leaves, litter or other com-bustibles out of and away from the compressor.

M. Open all access doors and allow the enclosure toventilate thoroughly prior to attempting to startthe engine.

N. DO NOT operate compressor under low over-hanging leaves or permit such leaves to contacthot exhaust system surfaces when operating thecompressor in forested areas.

O. Ethyl ether used in diesel engine ether startingaid systems is extremely flammable. Change cyl-inders, or maintain or troubleshoot these sys-tems only in well-ventilated areas away from

heat, open flame or sparks. DO NOT install,store or otherwise expose ether cylinders to tem-peratures above 160 °F (71 °C). Remove ethercylinder from the compressor when operating inambient temperatures above 60 °F (16 °C).

P. DO NOT attempt to use ether as a starting aid ingasoline engines or diesel engines with glowplugs as serious personnel injury or propertydamage may result.

Q. DO NOT spray ether into compressor air filter orinto an air filter that serves both the engine andthe compressor as serious damage to the com-pressor or personal injury may result.

R. Antifreeze compound used in air line anti-icersystems contains methanol which is flammable.Use systems and refill with compound only inwell-ventilated areas away from heat, openflames or sparks. DO NOT expose any part ofthese systems or the antifreeze compound totemperatures above 150 °F (66 °C). Vapors fromthe antifreeze compound are heavier than air.DO NOT store compound or discharge treatedair in confined or unventilated areas. DO NOTstore containers of antifreeze compound in directsunlight.

S. Store flammable fluids and materials away fromyour work area. Know where fire extinguishersare and how to use them, and for what type offire they are intended. Check readiness of firesuppression systems and detectors if soequipped.

1.5 MOVING PARTS

A. Keep hands, arms and other parts of the bodyand also clothing away from belts, pulleys andother moving parts.

B. DO NOT attempt to operate the compressor withthe fan or other guards removed.

C. Wear snug-fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts inside theenclosure.

D. Keep access doors closed except when makingrepairs or adjustments, performing service orwhen starting or stopping the compressor.

E. Make sure all personnel are out of the way andclear of the compressor prior to attempting tostart or operate it.

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11

F. Shut off engine before adding fuel, fluid, coolantlubricants, air line antifreeze compound or bat-tery electrolyte, or before replacing ether startingaid cylinders.

G. Disconnect the grounded negative battery con-nection to prevent accidental engine operationprior to attempting repairs or adjustments. Tagthe battery connection so others will not unex-pectedly reconnect it.

H. When adjusting the controls, it may require oper-ation of the equipment during adjustment. DONOT come in contact with any moving partswhile adjusting the control regulator and settingthe engine RPM. Make all other adjustments withthe engine shut off. When necessary, makeadjustment, other than setting control regulatorand engine RPM, with the engine shut off. If nec-essary, start the engine and check adjustment. Ifadjustment is incorrect, shut engine off, readjust,then restart the engine to recheck adjustment.

I. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water, antifreezeor other liquids to minimize possibility of slips andfalls.

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 ofair discharge and away from hot exhaust gases.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infec-tion.

1.6.1 TIER 4 EMISSIONS MODULE

General Guidelines: Thermal Protection. The mainexhaust piping routes exhaust gas from the engine tothe Clean Emissions Module (CEM). Normaloperating temperatures can reach up to 530 °C (986°F). During regeneration of the Diesel ParticulateFilter (DPF), the Auxiliary Regeneration Device(ARD) will be in operation, this creating temperaturesabove normal engine exhaust temperatures. Gastemperatures during the regeneration period canreach 750 °C (1382 °F).

WARNINGIncreased DPF skin temperature and exhaust gas temperature may occur in the event of an unexpected engine/aftertreat-ment failure. An unexpected failure of the engine/aftertreatment may increase temper-ature 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 per-sonal injury or death. Do not expose flam-mable 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/after-treatment failure, the design and packaging of the aftertreatment, the engine speed/load conditions, the condition of the aftertreat-ment and ambient conditions. Therefore, the potential temperatures are provided as a guideline even under conditions of unex-pected 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.

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1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi-ration (breathing) except in full compliance withOSHA Standards 29 CFR 1920 and any otherFederal, State or Local codes or regulations.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utili-zation equipment and DO NOT discharge airfrom these systems into unventilated or otherconfined areas.

C. Operate the compressor only in open or well-ventilated areas.

D. If the compressor is operated indoors, dischargeengine exhaust fumes outdoors.

E. Locate the compressor so that exhaust fumesare not apt to be carried towards personnel, airintakes servicing personnel areas or towards theair intake of any portable or stationary compres-sor.

F. Fuels, fluids, coolants, lubricants and batteryelectrolyte used in the compressor are typical ofthe industry. Care should be taken to avoid acci-dental ingestions and/or skin contact. In theevent of ingestion, seek medical treatmentpromptly. DO NOT induce vomiting if fuel isingested. Wash with soap and water in the eventof skin contact.

G. Wear an acid-resistant apron and a face shield orgoggles when servicing the battery. If electrolyte

is spilled on skin or clothing, immediately flushwith large quantities of water.

H. Ethyl ether used in diesel engine ether startingaid systems is toxic, harmful or fatal if swallowed.Avoid contact with the skin or eyes and avoidbreathing the fumes. If swallowed, DO NOTinduce vomiting and call a physician immediately.

I. Wear goggles or a full face shield when testingether starting aid systems or when adding anti-freeze compound to air line anti-icer systems.Keep openings of valve or atomizer tube of etherstarting aid system pointed away from yourselfand other personnel.

J. If ethyl ether or air line anti-icer system anti-freeze compound enters the eyes or if fumes irri-tate the eyes, they should be washed with largequantities of clean water for 15 minutes. A physi-cian, preferably any eye specialist, should becontacted immediately.

K. DO NOT store ether cylinders or air line anti-icersystem antifreeze compound in operator’s cabsor in other similar confined areas.

L. The antifreeze compound used in air line anti-icer systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact withthe skin or eyes and avoid breathing the fumes. Ifswallowed, induce vomiting by administering atablespoon of salt in a glass of clean warm water.Do this until vomit is clear, then administer twotablespoons of baking soda in a glass of cleanwater. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCK

A. Keep the towing vehicle or equipment carrier,compressor hoses, tools and all personnel atleast 10 feet (3 m) from power lines and buriedcables.

B. Keep all parts of the body and any hand-heldtools or other conductive objects away fromexposed live parts of electrical system. Maintaindry footing, stand on insulating surfaces and DONOT contact any other portion of the compressorwhen making adjustments or repairs to exposedlive parts of the electrical system.

C. Attempt repairs only in clean, dry and well-lightedand ventilated areas.

D. Stay clear of the compressor during electricalstorms! It can attract lightning.

DANGER

INHALATION HAZARD!

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA stan-dards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment.

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13

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 byhelicopter must not be supported by the liftingbail, but by slings instead. In any event, lift only infull compliance with OSHA Standards 29 CFR1910 subpart N or any other Local, State, Militaryand Federal regulations that may apply.

B. Inspect lifting bail and points of attachment forcracked welds and for cracked, bent, corroded orotherwise degraded members and for loose boltsor nuts prior to lifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condi-tion and has a rated capacity of at least the netweight of the compressor plus an additional 10%allowance for weight of water, snow, ice, mud,stored tools, and equipment. If your are unsureof the weight, then weigh compressor before lift-ing.

D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged andlatched on the bail.

E. Use guide ropes or equivalent to prevent twistingor swinging of the compressor once it has beenlifted clear of the ground.

F. DO NOT attempt to lift in high winds.

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

H. Lift compressor no higher than necessary.

I. Keep lift operator in constant attendance when-ever compressor is suspended.

J. Set compressor down only on a level surfacecapable of supporting at least its net weight plusan additional 10% allowance for the weight ofwater, snow, ice, mud, stored tools, and/or equip-ment.

K. If the compressor is provided with parkingbrakes, make sure they are set, and in anyevent, block or chock both sides of all runningwheels before disengaging the lifting hook.

1.10 ENTRAPMENT

A. Make sure all personnel are out of compressorbefore closing and engaging enclosure doors.

B. If the compressor is large enough to hold a manand if it is necessary to enter it to perform serviceadjustments, inform other personnel beforedoing so, or else secure the access door in theopen position to avoid the possibility of othersclosing and possibly latching the door with per-sonnel inside.

1.11 JUMP STARTING

A. Observe all safety precautions mentioned else-where in this manual.

B. Batteries may contain hydrogen gas which isflammable and explosive. Keep flames, sparksand other sources of ignition away.

C. Batteries contain acid which is corrosive and poi-sonous. DO NOT allow battery acid to contacteyes, skin, fabrics or painted surfaces as seriouspersonal injury or property damage could result.Flush any contacted areas thoroughly with waterimmediately. Always wear an acid-resistantapron and face shield when attempting to jumpstart the compressor.

D. Remove all vent caps (if so equipped) from thebattery or batteries in the compressor. DO NOTpermit dirt or foreign matter to enter the opencells.

E. Check fluid level. If low, bring fluid to proper levelbefore attempting to jump start (not applicable tomaintenance-free batteries).

F. DO NOT attempt to jump start if fluid is frozen orslushy. Bring batteries up to at least 60 °F (16°C) before attempting to jump start or it mayexplode.

G. Cover open cells of all compressor batteries withclean dampened cloths before attempting tojump start.

H. Attempt to jump start only with a vehicle having anegative ground electrical system with the samevoltage, and is also equipped with a battery orbatteries of comparable size or larger than sup-plied in the compressor. DO NOT attempt tojump start using motor generator sets, welders orother sources of DC power as serious damagemay result.

SECTION 1

14

I. Bring the starting vehicle alongside the compres-sor, but DO NOT permit metal to metal contactbetween the compressor and the starting vehicle.

J. Set the parking brakes of both the compressor (ifprovided) and the starting vehicle or otherwiseblock both sides of all wheels.

K. Place the starting vehicle in neutral or park, turnoff all non-essential accessory electrical loadsand start its engine.

L. Use only jumper cables that are clean, in goodcondition and are heavy enough to handle thestarting current.

M. Avoid accidental contact between jumper cableterminal clips or clamps and any metallic portionof either the compressor or the starting vehicle tominimize the possibility of uncontrolled arcingwhich might serve as a source of ignition.

N. Positive battery terminals are usually identifiedby a plus (+) sign on the terminal and the lettersPOS adjacent to the terminal. Negative batteryterminals are usually identified by the lettersNEG adjacent to the terminal or a negative (-)sign.

O. Connect one end of a jumper cable to the posi-tive (POS) (+) battery terminal in the startingvehicle. When jump starting 24V compressorsand if the starting vehicle is provided with two (2)12V batteries connected in series, connect thejumper cable to the positive (POS) (+) terminal ofthe ungrounded battery.

P. Connect the other end of the same jumper cableto the positive (POS) (+) terminal of the startermotor battery in the compressor when jump start-ing 24V compressors, to the positive (POS) (+)terminal of the ungrounded battery in the com-pressor.

Q. Connect one end of the other jumper cable to thegrounded negative (NEG) (-) terminal of the bat-tery in the starting vehicle. When jump starting24V compressors and if the starting vehicle isprovided with two (2) 12V batteries connected inseries, connect the jumper cable to the negative(NEG) (-) terminal of the grounded battery.

R. Check your connections. DO NOT attempt tostart a 24V compressor with one 12V battery inthe starting vehicle. DO NOT apply 24V to one12V battery in the compressor.

S. Connect the other end of this same jumper cableto a clean portion of the compressor engine

block away from fuel lines, the crank casebreather opening and the battery.

T. Start the compressor in accordance with normalprocedure. Avoid prolonged cranking.

U. Allow the compressor to warm up. When thecompressor is warm and operating smoothly atnormal idle RPM, disconnect the jumper cablefrom the engine block in the compressor, thendisconnect the other end of this same cable fromthe grounded negative (NEG) (-) terminal of thebattery in the starting vehicle. Then disconnectthe other jumper cable from the positive (POS)(+) terminal of the battery in the compressor, or ifprovided with two (2) 12V batteries connected inseries, from the ungrounded battery in the com-pressor, and finally, disconnect the other end ofthis same jumper cable from the positive (POS)(+) terminal of the battery in the starting vehicleor from the positive (POS) (+) terminal of theungrounded battery in the starting vehicle, if it isprovided with two (2) 12V batteries connected inseries.

V. Remove and carefully dispose of the dampenedcloths, as they may now be contaminated withacid, then replace all vent caps.

1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

The energy control procedure defines actionsnecessary to lockout a power source of any machineto be repaired, serviced or set-up, where unexpectedmotion, or an electrical or other energy source, wouldcause personal injury or equipment damage. Thepower source on any machine shall be locked out byeach employee doing the work except when motionis necessary during setup, adjustment or trouble-shooting.

A. The established procedures for the application ofenergy control shall cover the following elementsand actions and shall be initiated only by Autho-rized Persons and done in the followingsequence:

1. Review the equipment or machine to belocked and tagged out.

2. Alert operator and supervisor of whichmachine is to be worked on, and that powerand utilities will be turned off.

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

SECTION 1

15

4. Turn off the equipment using normalshutdown procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled,drained and cleaned out. There shouldbe no pressure in these lines or in thereservoir tanks. Lockout or tag lines orvalves.

b. Any mechanism under tension or pres-sure, such as springs, should bereleased and locked out or tagged.

c. Block any load or machine part prior toworking under it.

d. Electrical circuits should be checked withcalibrated electrical testing equipmentand stored energy and electrical capaci-tors should be safely discharged.

6. Lockout and/or Tagout each energy sourceusing the proper energy isolating devicesand tags. Place lockout hasp and padlock ortag at the point of power disconnect wherelockout is required by each personperforming work. Each person shall beprovided with their own padlock and havepossession of the only key. If more than oneperson is working on a machine each personshall affix personal lock and tag using amulti-lock device.

7. Tagout devices shall be used only whenpower sources are not capable of beinglocked out by use of padlocks and lockouthasp devices. The name of the personaffixing tag to power source must be on tagalong with date tag was placed on powersource.

8. Release stored energy and bring theequipment to a “zero mechanical state”.

9. Verify Isolation: Before work is started, testequipment to ensure power is disconnected.

B. General Security

1. The lock shall be removed by the“Authorized” person who put the lock on theenergy-isolating device. No one other thanthe person/persons placing padlocks and

lockout hasps on power shall removepadlock and lockout hasps and restorepower. However, when the authorizedperson who applied the lock is unavailable toremove it his/her Supervisor may removepadlock/padlocks and lockout hasps andrestore power only if it is first:

a. verified that no person will be exposed todanger.

b. verified that the “Authorized” person whoapplied the device is not in the facility.

c. noted that all reasonable efforts to con-tact the “Authorized” person have beenmade to inform him or her that the lock-out or tagout device has been removed.

d. ensured that the “Authorized” person isnotified of lock removal before returningto work.

2. Tagout System—Tags are warning devicesaffixed at points of power disconnect and arenot to be removed by anyone other that theperson placing tag on power lockout. Tagsshall never be by-passed, ignored, orotherwise defeated

1.13 CALIFORNIA PROPOSITION 65

WARNINGCALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its con-stituents are known to the State of Califor-nia to cause cancer, birth defects and other reproductive harm.

Battery posts, terminals and related acces-sories contain lead and other compounds known to the State of California to cause cancer and birth defects and other repro-ductive harm. Wash hands after handling.

SECTION 1

16

1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Pleaserefer to the decals set forth on the machine forapplicable symbols.

Safety Symbols-1 T4

DIESEL PARTICULATE FILTER

REGENERATION INHIBIT

HIGH EXHAUST SYS. TEMP

WAIT TO START

REMOTE START

CABIN LIGHTS

/ iT4

/ iT4

/ iT4

SECTION 1

17

Safety Symbols-2

SECTION 1

18

Safety Symbols-3

Section 2

19

600H, 600HH, 750, 750H, 750HH, 825, 900H, 1050 USER MANUAL

DESCRIPTION2.1 INTRODUCTION

Sullair Portable Air Compressor models offersuperior performance and reliability while requiringonly minimal maintenance.

The compressor is equipped with a Sullair rotaryscrew compressor unit. Compared to othercompressors, the Sullair is unique in mechanicalreliability and compressor durability. No inspection isrequired of the working parts within the compressorunit.

As you continue reading this manual and come tolearn how the compressor operates and is cared for,you will see how surprisingly easy it is to keep aSullair compressor in top operating condition.

Read Section 5: MAINTENANCE to keep yourcompressor in top operating condition. Should anyproblem or question arise which cannot be answeredin this text, contact your nearest Sullairrepresentative or the Sullair Service Department.

2.2 DESCRIPTION OF COMPONENTS

Refer to Figure 2-1 and Figure 2-2. The componentsand assemblies of the Sullair Portable AirCompressor models are clearly shown. The packageincludes a compressor, diesel engine, exhaustsystem including an iT4 compliant emissions module,compressor/engine inlet system, compressor coolingand lubrication system, compressor dischargesystem, capacity control system, instrument paneland electrical system. The machine is also suppliedwith sound deadening insulation to lower noise

emissions to meet EPA or CE, most federal, state, orlocal noise requirements. The Sullair compressor unitis driven by an industrial engine designed to provideenough horsepower at rated conditions. Refer toEngine Operator’s Manual for a more detaileddescription of the engine.

The engine cooling system is comprised of aradiator, high capacity fan and thermostats. The highcapacity variable speed hydraulic fan blows airthrough the radiator, keeping the engine at theproper operating temperature while optimizing thefuel consumption by effectively adjusting the fanspeed to efficiently accommodate engine conditions.

The same fan also cools the fluid in the compressorcooling and lubrication system. While passingthrough the radiator, the fan air also passes throughthe compressor fluid cooler, which is mountedadjacent to the radiator. As air passes through thecooler, some of the heat of compression is removedfrom the fluid.

The same fan also cools the return fuel supply aswell as the fan drive hydraulic fluid. The coolers forthese circuits are integrated and mounted in front ofthe compressor cooler and radiator. The cooling fanis hydraulically driven. As air passes through theaftercooler heat is removed which was introduced bythe engine’s turbo charger. The engine is coupled tothe compressor unit with a non-lubricated, vulcanizedrubber disk and a drive flange-type coupling. Allcompressor models are supplied with a fuel tanklarge enough to keep the compressor runningthrough a full 8-hour shift.

600H, 600HH, 750, 750H, 750HH, 825, 900H, 1050 USER MANUAL SECTION 2

20

1. Moisture Separator & Filter

2. Regulator Valves

3. Engine Coolant Fill

4. Engine Radiator

5. Aftercooler

6. Engine Charge Air-Cooler

7. Fuel Fill

8. Receiver Tank

9. E-Stop

10. Engine Spark Arrestor

11. Manual Enclosure

12. Battery Disconnect Switch

13. Compressor Oil Cooler

14. Hydraulic fan drive fluid tank

Figure 2-1: Compressor

Note: Canopy, engine, and compressor are removed for clarity.

SECTION 2 600H, 600HH, 750, 750H, 750HH, 825, 900H, 1050 USER MANUAL

21

1. Moisture Separator & Filter

2. Regulator Valves

3. Engine Coolant Fill

4. Engine Fluid Cooler

5. Aftercooler

6. Engine Charge Air-Cooler

7. Fuel Fill

8. Receiver Tank

9. E-Stop

10. Engine Spark Arrestor

11. Manual Enclosure

12. Battery Disconnect Switch


14. Hydraulic fan drive fluid tank

Figure 2-2: Compressor

Note: Canopy, engine, and compressor are removed for clarity.


22

2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

Sullair compressors feature the Sullair compressorunit, a single-stage, positive displacement, floodlubricated-type compressor. This unit providescontinuous compression to meet your needs.

Sullair compressors are factory-filled with SullairAWF lubricant. For more information on fluid fill, referto “Lubrication Guide—Compressor” on page 58.

Fluid is injected into the compressor unit hoses andmixes directly with the air as the rotors turn,compressing the air. The fluid flow has three basicfunctions:

1. As coolant, it controls the rise of air tempera-ture normally associated with the heat ofcompression.

2. Seals the clearance paths between therotors and the stator and also between therotors themselves.

3. Acts as a lubricating film between the rotorsallowing one rotor to directly drive the other,which is an idler.

After the air/fluid mixture is discharged from thecompressor unit, the fluid is separated from the air.At this time, the air flows through an aftercooler andmoisture separator, if equipped, then to your serviceline.

2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-2. The compressor cooling andlubrication system is designed to provide adequatelubrication as well as maintain the proper operatingtemperature of the compressor. In addition to thecooler and fan, the system consists of a main filterand thermal valve. The fan is hydraulically driven,refer to Section 2.15 for more detail.

Fluid is used in the system as a coolant and alubricant. The fluid is housed in the receiver tank.

Upon start up, the fluid temperature is cool, androuting to the cooler is not required. The fluid firstenters the thermal valve and then flows on to thecompressor unit, bypassing the cooler. As thecompressor continues to operate, the temperature ofthe fluid rises and the thermal valve element beginsto shift. This forces a portion of the fluid to the fluidcooler. The cooler is a radiator-type that works inconjunction with the hydraulic fan. The fan forces airthrough the cooler removing the heat of compressionfrom the fluid. From the cooler, the fluid is routedback to the thermal valve.

Before the temperature of the fluid reaches the valveset point, cooled fluid is mixed with warmer fluid.When the temperature of the fluid reaches 170°F(77°C), the thermal element shifts completelycausing all fluid to flow to the cooler. The thermalvalve incorporates a pressure relief valve, whichallows fluid to bypass the cooler, if the coolerbecomes plugged or frozen. This helps assure thatfluid will continue to be provided to the compressorfor lubrication. After the fluid passes through thethermal valve it is then directed through the mainfluid filter. There, the fluid is filtered in preparation forinjection into the compression chamber and bearingsof the compressor unit. The filter has a replaceableelement and a built-in bypass valve which allows thefluid to flow even when the filter element becomesplugged and requires changing or when the viscosityof the fluid is too high for adequate flow. After thefluid is properly filtered, it then flows on to thecompressor unit where it lubricates, seals and coolsthe compression chamber as well as lubricates thebearings and gears.

NOTEWith 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 war-ranty.


23

1. Receiver Tank

2. Thermal Valve

3. Fluid Filters


5. Compressor

Figure 2-2: Compressor Oil, Cooling and Lubrication - All Models


24

2.5 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-3, Figure 2-4 and Figure 2-5. Thepurpose of the control system is to regulate theamount of air intake in accordance with the amountof compressed air demanded. The control systemconsists of an inlet valve, the high and low pressureregulators, the pressure reducing regulator, theblowdown/ running blowdown valve, the controller, a<ON> switch, and the <PRESSURE> selectorswitch.

START—0 TO 65 PSIG (0 TO 4.5 BAR)

Keep the <ON> switch to the “ON” position toinitialize the controller. Once the controller says“READY” on LCD, press <ON> switch to the“START” position. In the “START” position, the inletvalve is held closed by the springs in the inlet valve.The valve is cracked open by a vacuum in thecompressor and is allowed to build up to 65 psig (4.5bar). The reason for keeping the valve closed duringstart is to allow the engine to warm up without beingloaded by the compressor. Air pressure is containedin the receiver tank by the minimum pressure valvewhich has a set point of 65 psig (4.5 bar). At thispoint the valve opens allowing the air to pass to theservice valve. After the engine has warmed up themachine automatically transitions to “RUN” mode.

LOW PRESSURE/SINGLE PRESSURE—80 TO 100 PSIG (5.5 TO 6.9 BAR)

With the <PRESSURE> switch in the "LOW"position, and the controller in "RUN" mode, theservice valve can now be opened. Pressure from the60 psig (4.1 bar) reducing regulator opens up theinlet valve and the controller increases the engine

speed to full load (1800 rpm). As the demand for airdecreases, the controller commands the engine toreduce speed to idle (1400 rpm) and the inlet valvecloses, where it stabilizes until the air demand isrequired again. If left in the idle state (>1400 rpm) forperiods exceeding 10 minutes the engine rpm willdrop down further to a low idle state (1000rpm) untila demand for air is seen, in order to reduce fuelconsumption when not needed. If the machine is notmarked with an "H" or "HH", it is a single pressuremachine and will not have a <PRESSURE> switch.The machine will run as if it is in the "low" mode.

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

With the <PRESSURE> switch in the “HIGH”position, the low pressure regulator is blocked off bythe high/low solenoid valve allowing the highpressure regulator to take over control of themachine. The 60 psig (4.1 bar) reducing regulatorfully opens the inlet valve and the controllercommands maximum speed (1800 rpm) from theengine. As the pressure reaches the set point of thesystem the high pressure regulator cracks open andcloses the inlet valve and the controller returns theengine back to idle, until a demand for air is seen.

SHUTDOWN

The blowdown valve is normally closed. When thecompressor is shutdown, system pressure backs upto the inlet valve causing the check spring in the inletvalve to close the air inlet valve. This sends apressure signal to the blowdown valve causing it toopen and vent the pressure in the system. After thepressure is vented, the blowdown valve springreturns the blowdown valve to the closed position.


25

1. Run/Start Solenoid

2. Reducing Regulator

3. Pressure Transducer P2 (Control Pressure)

4. Control Regulator

5. Pressure Transducer P1 (Service Pressure)

6. Shutdown Blowdown Valve

7. Orifice

Figure 2-3: Control Manifold - Single Pressure


26

1. Run/Start Solenoid

2. Reducing Regulator

3. Shuttle Valve

4. Control Regulator (Low)

5. Hi/Low Solenoid Valve

6. Pressure Transducer P2 (Control Pressure)

7. Control Regulator (High)

8. Pressure Transducer P1 (Service Pressure)

9. Shutdown/Blowdown Valve

10. Orifice

Figure 2-4: Control Manifold - Dual Pressure


27

1. Compressor Air FIlter

2. Engine Air FIlter

3. Engine

4. Compressor Unit

5. Service Air (Aftercooled)

6. Discharge Air Filters

7. Compressor Inlet Valve

8. Moisture Separator

9. Aftercooler

10. Relief Valve

11. Fluid Cooler

12. Thermal Valve/Fluid Filter Assembly

13. Receiver Tank

14. Fluid Level Sight Gauge

15. Final Fluid Separator Element

16. Ball Valve

17. P3 Pressure Transducer (Wet Pressure)

18. Service Air (Non-Aftercooled)

19. Minimum Pressure Check Valve

20. Temperature Shutdown Switch

Figure 2-5: Compressor Flow Diagram - All Models


28

2.6 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-6. The Sullair compressor unitdischarges a compressed air/fluid mixture into thereceiver tank.

The receiver tank has three functions:

1. It acts as a primary fluid separator.

2. Serves as the compressor fluid storage sump.

3. Houses the final fluid separator.

The compressed air/fluid mixture enters the receivertank and is directed against the tank side wall. Bychange of direction and reduction of velocity, largedroplets of fluid separate and fall to the bottom of thereceiver tank. The fractional percentage of fluidremaining in the compressed air collects on thesurface of the final separator element as thecompressed air flows through the separator. As moreand more fluid collects on the element’s surface, thefluid descends to the bottom of the separator. Areturn line (or scavenge tube) leads from the bottomof the separator element to the inlet region of thecompressor unit. Fluid collecting on the bottom of theseparator element is returned to the compressor bythe pressure difference between the areasurrounding the separator element and thecompressor inlet. An orifice (protected by a strainer)is included in this return line to help assure properflow.

The receiver tank is code rated. A minimumpressure/ check valve, located downstream from theseparator, helps assure a minimum receiver tankpressure during all conditions. This pressure isnecessary for proper air/fluid separation and properfluid circulation.

A minimum pressure/check valve at the outlet of thereceiver is installed to prevent compressed air in theservice line from bleeding back into the receiver onshutdown when the compressor is being run inparallel with other compressors tied to a large airsystem.

Fluid is added to the receiver tank via a capped fluidfiller. A fluid level gauge glass enables the operatorto visually monitor the receiver tank fluid level.

2.7 AFTERCOOLED AIR SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-4. The purpose of the aftercooledair system is to operate the air compressor inconditions when compressed air temperatures arerequired to be 10 to 25 ̊F (5 to 13 ̊C) over ambienttemperature. The aftercooled feature of thecompressor is controlled by a system of two ballvalves which are standard on all large tier IVaftercooled compressor models. By shifting both ballvalves to the aftercooled position the air flow from thereceiver tank is forced through the aftercoolerproducing aftercooled air. Moving the ball valves tothe standard position blocks air flow through thecooler producing standard air. The ambient air, whichis forced through the aftercooler by the hydraulic fan,cools the compressed air as it passes through theaftercooler core. Cooled air enters the moistureseparator where condensation is removed from thecooler air and discharged. This condensation doescarry some oil and it should be disposed of properlyin accordance with local regulations. A condensationdrain port is located in the frame on the curbside ofthe machine for convenience of condensate removal.This drain port should never be plugged or closed offin any way. From the moisture separator thecompressed air goes through the discharge filters (ifequipped) and on to the service valve.

WARNINGDO NOT remove caps, plugs and/or other components when compressor is running or pressurized.Stop compressor and relieve all internal pressure before doing so.

NOTEAftercooled system should not be oper-ated 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 require-ment.To operate in the non-aftercooled mode, position both aftercooler bypass valves in the aftercooled position.


29

1. Receiver Tank

2. Minimum Pressure Check Valve

3. Service Valve

4. Moisture Separator

5. Air Filter

6. Standard Air

7. Aftercooled Air

A1 To Aftercooler

A2 From Aftercooler

A3 Aftercooled On/Off Valve

Figure 2-6: Aftercooled Air System


30

2.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-7. The compressor inlet systemconsists of two air filters, a compressor air inlet valveand interconnecting piping to the engine andcompressor. Also, air filter restriction indicatorgauges are located next to the air filter housings.

The air filter is a 2-stage unit with a safety elementand dry element-type filter. This filter is capable ofcleaning extremely dirty air. However, in such cases,frequent checks of the air filter will be required.

Referring to the controller, the engine air filterrestriction sensor or the compressor air filterrestriction sensor will indicate when restriction of theair passing through the filter becomes too high.

At this time, change the air filter element. Theseindicators should be checked daily, after start-upunder normal conditions.

The compressor air inlet valve controls the amount ofair intake of the compressor in response to the airdemand.

1. Engine Air FIlter

2. Compressor Air Filter

3. Air Inlet Valve

4. Compressor

Figure 2-7: Air Inlet System

31

NOTES

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

LSEC

TION

2

32 2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP SINGLE)

02250201-316 R00

SECTIO

N 2

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

L

33

2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP SINGLE)

KEY NO.

QTY

DESCRIPTION

1 1 FILTER, AIR

2 1 GAUGE, AIR FILTER RESTRICTION

3 1 INLET VALVE

4 1 COMPRESSOR

5 1 VALVE, RELIEF

6 1 SWITCH, TEMPERATURE

7 1 SENSOR, TEMPERATURE

8 3 SENSOR, PRESSURE

9 1 VALVE, DISCHARGE CHECK

10 1 RECEIVER, AIR/OIL

11 1 GLASS, SIGHT OIL LEVEL

12 1 VALVE, MINIMUM PRESSURE

13 3 VALVE, BALL

14 1 COOLER, AIR

15 1 SEPARATOR, MOISTURE

16 1 TRAP, DRAIN

17 2 ORIFICE

18 1 VALVE, RUNNING BLOWDOWN N.C.

19 1 SIGHTGLASS, ORIFICE BLOCK

20 1 VALVE, THERMAL BYPASS

21 1 COOLER, OIL

22 1 FILTER, OIL

23 1 VALVE, OIL STOP

24 1 VALVE, CONTROL PRESSURE REGULATOR

25 1 GAUGE, PRESSURE

26 1 VALVE, CHECK

27 1 VALVE, SOLENOID 3-WAY RUN/START

28 1 SEPERATOR, ELEMENT

29 1 VAVLE, REDUCING PRESSURE REGULATOR

30 2 VALVE, PRESSURE DIFF. BYPASS

31 1 STRAINER

32

33 1 SEPARATOR, CONTROL MOISTURE

COMPONENT DESCRIPTION

P1 DRY SIDE PRESSURE

P2 CONTROL PRESSURE

P3 WET SIDE PRESSURE

T1 COMPRESSOR DISCHARGE TEMPERATURE SENSOR

T3 RECEIVER TANK TEMPERATURE SWITCH (RTT)

KEY NO.

QTY

DESCRIPTION

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

LSEC

TION

2

34 2.10 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP DUAL)

02250201-316 R00

SECTIO

N 2

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

L

35

2.10 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR (LP DUAL)

KEY NO.

QTY

DESCRIPTION

1 1 FILTER, AIR

2 1 GAUGE, AIR FILTER RESTRICTION

3 1 INLET VALVE

4 1 COMPRESSOR

5 1 VALVE, RELIEF

6 1 SWITCH, TEMPERATURE

7 1 SENSOR, TEMPERATURE

8 3 SENSOR, PRESSURE

9 1 VALVE, DISCHARGE CHECK

10 1 RECEIVER, AIR/OIL

11 1 GLASS, SIGHT OIL LEVEL

12 1 VALVE, MINIMUM PRESSURE

13 3 VALVE, BALL

14 1 COOLER, AIR

15 1 SEPARATOR, MOISTURE

16 1 TRAP, DRAIN

17 2 ORIFICE

18 1 VALVE, RUNNING BLOWDOWN N.C.

19 1 SIGHTGLASS, ORIFICE BLOCK

20 1 VALVE, THERMAL BYPASS

21 1 COOLER, OIL

22 1 FILTER, OIL

23 1 VALVE, OIL STOP

24 2 VALVE, CONTROL PRESSURE REGULATOR

25 1 GAUGE, PRESSURE

26 1 VALVE, SHUTTLE

27 1 VALVE, CHECK

28 1 VALVE, SOLENOID 3-WAY RUN/START

29 1 VALVE, SOLENOID 2-WAY ELECT

30 1 SEPERATOR, ELEMENT

31 1 VAVLE, REDUCING PRESSURE REGULATOR

32 2 VALVE, PRESSURE DIFF. BYPASS

33 1 STRAINER

34

35 1 SEPARATOR, CONTROL MOISTURE


P1 DRY SIDE PRESSURE

P2 CONTROL PRESSURE

P3 WET SIDE PRESSURE

T1 COMPRESSOR DISCHARGE TEMPERATURE SENSOR

T3 RECEIVER TANK TEMPERATURE SWITCH (RTT)

KEY NO.

QTY

DESCRIPTION

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

LSEC

TION

2

36 2.11 PIPING AND INSTRUMENTATION DIAGRAM—HYDRAULIC FAN DRIVE

02250201-316 R00

SECTIO

N 2

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

L

37

2.11 PIPING AND INSTRUMENTATION DIAGRAM—HYDRAULIC FAN DRIVE

KEY NO.

QTY

DESCRIPTION

NOTE

1 1 PUMP,HYD GEAR

2 1 PUMP,HYD

3 1 COOLER

4 1 MOTOR,HYD MAIN

5 1 FILTER,ASSY

6 1 VALVE,ASSY THERMAL BYPASS

7 1 TANK,ASSY HYD

8 1 MOTOR,HYD AFTERCOOLER

9 1 VALVE,CHK

10 1 CAP,AIR BREATHER

11 1 FILTER,STRAINER

12 1 PLUG,SIGHTGLASS

13 1 SENSOR,TEMPERATURE

14 1 SWITCH,FLOAT


T HYDRAULIC FLUID TEMPERATURE SENSOR

L HYDRAULIC FLUID LEVEL SENSOR, NORMALLY OPEN DRY POSITION

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

LSEC

TION

2

38 2.12 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE

02250201-316 R00

SECTIO

N 2

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

L

39

2.12 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE

KEY NO.

QTY

DESCRIPTION

1 1 TURBOCHARGER, ENGINE

2 1 COOLER, CHARGE AIR

3 1 MUFFLER, ENGINE

4 1 SENDER, FUEL LEVEL

5 1 RAIN CAP, EXHAUST SYSTEM

6 1 FILTER, FUEL W/ WATER SEPARATOR

7 1 PUMP, FUEL (INTERNAL TO ENGINE)

8 1 PUMP, CAT PRIMING/ARD

9 1 FILTER, FUEL

10 1 VENT, FUEL TANK

11 1 CAP, FUEL TANK FILL

12 1 THERMOSTAT, THERMOCORD(OPTIONAL)

13 1 KIT, ETHER ASSEMBLY

14 1 PUMP, OIL (INTEGRAL TO ENGINE)

15 1 BY-PASS VALVE (INTERNAL TO ENGINE)

16 1 COOLER, OIL (INTERNAL TO ENGINE)

17 1 FILTER, OIL

18 1 PUMP, WATER (INTEGRAL TO ENGINE)

19 1 RADIATOR, ENGINE

20 1 ENGINE THERMO (INTEGRAL TO ENGINE)

21 1 SENSOR, INLET AIR PRESS(TURBO BOOST)

22 1 SWITCH, COOLANT LEVEL

23 1 SENSOR, FUEL PRESSURE

24 1 SENSOR, FUEL TEMPERATURE

25 1 SENSOR, COOLANT TEMPERATURE

26 1 SENSOR, ENGINE OIL PRESSURE

27 1 SENSOR, CAM SPEED TIMING

28 1 SENSOR, CRANK SPEED TIMING

29 1 HEATER, WATER JACKET (OPTIONAL)

30 1 OIL LEVEL (DIPSTICK)

31 1 FILTER, AIR

32 1 TANK, FUEL

33 1 PAN, ENGINE OIL

34 1 GAUGE, FILTER RESTRICTION

35 1 SENSOR, INLET AIR TEMPERATURE

36 1 VALVE, RELIEF (INTEGRAL TO ENGINE)

37 1 VALVE, AIR STOP (OPTIONAL)

38 1 PUMP, AUX FUEL

39 1 VALVE, 3-WAY

40 1 EXHAUST, AFTERTREATMENT

41 1 COOLER, FUEL


L1 COOLANT LEVEL

L2 FUEL LEVEL

L3 OIL LEVEL (DIPSTICK)

P5 INLET MANIFOLD AIR PRESSURE

P6 FUEL PRESSURE

P7 OIL PRESSURE

T7 INLET AIR TEMPERATURE

T8 FUEL TEMPERATURE

T9 COOLANT TEMPERATURE

S1 CAM SPEED

S2 CRNAK SPEED

KEY NO.

QTY

DESCRIPTION


40

2.13 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Refer to Controller Manual, Sullair Part No. 02250201-742.

HIGH

REGEN PRESSURE ONMENUTOGGLE

MENUSELECT

CABINLIGHTS

LOW

SELECT

START

OFFEXIT

FORCE

INHIBIT

8

3

2

1

2229-30 23 24 21 20 19

31 31

10 926 7

2528

12 13

14

15

16

18

17

6

5

4

3227

11

1. Compressor OK Lamp

2. Compressor Warning Lamp

3. Compressor Shut Down Lamp

4. Engine OK Lamp

5. Check Engine Lamp

6. Engine Shutdown Lamp

7. Battery Disconnect Lamp

8. Compressor Air Filter Warning Lamp

9. High Compressor Temperature Lamp

10. Cabin Light Lamp

11. Remote Start Lamp

12. Diesel Particulate Filter (PDF) Lamp

13. High Exhaust System Temperature (HEST)Lamp

14. Regeneration Inhibit Lamp

15. Low Fuel Lamp

16. High Coolant Temperature Lamp

17. Engine Air Filter Warning Lamp

18. Wait to Start Lamp

19. Power On/Off Switch

20. Menu Select/Exit Switch

21. Menu Toggle Switch

22. Force/Inhibit Regeneration Switch

23. Cabin Light Switch

24. High/Low Pressure Selector Switch (only ondual pressure models)

25. Service Air Pressure Gauge (P1)

26. Compressor Temperature Gauge

27. Engine Temperature Gauge

28. Fuel Level Gauge

29. Engine Controller Diagnostics Service Port

30. Engine Controller Port Cover

31. Key Port

32. Contrast Buttons

Lamp Indicators Switches/Gauges/Features

Figure 2-8: Instrument Panel Group


41

2.14 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION

Diagnostic Fault Codes are provided to indicate anelectrical or electronic problem has been detected bythe ECM (Engine Control Module). In some cases,the engine performance can be affected when thecondition causing the code exists. More frequently,however, the operator cannot detect any differencein the engine performance.

The controller indicates an engine performanceproblem has occurred whenever the Engine WarningLamp is flashing. The diagnostic code may indicatethe cause of the problem, and should be corrected.

If the controller does not indicate a problem with theengine performance, but a diagnostic code is loggedby the ECM, an abnormal condition was detectedthat did not affect performance.

If this is the case, unless there are severaloccurrences of the code in a very short period oftime, or, the ECM is indicating an Active Code at thepresent time, there is most likely nothing wrong withthe system.

If there is an error the controller should display a briefmessage containing the Failure Mode Indicator (FMI)and Suspect Parameter Number (SPN) in the LCD ofthe master gauge. This message helps to pinpointthe source of the problem and aid in troubleshootingthe compressor.

Refer to Table 2-1 on page 42 for possibleperformance of active diagnostic codes.

NOTEOnly active diagnostic codes can be read in this manner. Logged diagnostic codes must be retrieved with an Electronic Ser-vice Tool.


42

Table 2-1: Cross Reference for Diagnostic Codes and Event Codes from CAT trouble shoot guide (KENR 6848)

Flash Code SPN (1)/FMI Code

Diagnostic Code or Event Code

Description of Code

111/139

651-5 1-5 Engine Injector Cylinder #1 : Current Below Normal

651-6 1-6 Engine Injector Cylinder #1 : Current Above Normal

3959-5 2602-5 Engine Injector Cylinder #1 Actuator #2: Current Below Normal

3959-6 2602-6 Engine Injector Cylinder #1 Actuator #2: Current Above Normal

111/179

2950-5 1901-5 Engine Intake Valve Actuator #1: Current Below Normal

2950-6 1901-6 Engine Intake Valve Actuator #1: Current Above Normal

2950-7 1901-7 Engine Intake Valve Actuator #1: Not Responding Properly

112/139





112-179




113/139





113-179




114/139





114-179





43

115/139





115-179




116/139





116-179




133

105-15 539 (1) Engine Intake Manifold #1 Temperature : High - least severe (1)

105-16 539 (2) Engine Intake Manifold #1 Temperature : High - moderate severity (2)

110-3 110-3 Engine Coolant Temperature : Voltage Above Normal

110-4 110-4 Engine Coolant Temperature : Voltage Below Normal

172-3 2526-3 Engine Air Inlet Temperature : Voltage Above Normal

172-4 2526-4 Engine Air Inlet Temperature : Voltage Below Normal

135 102-18 1045 (2) Engine Intake Manifold #1 Pressure : Low - moderate severity (2)

141

190-8 190-8 Engine Speed : Abnormal Frequency, Pulse Width, or Period

190-0 362 (3) Engine Speed : High - most severe (3)

190-15 362 (1) Engine Speed : High - least severe (1)

142 723-8 342-8 Engine Speed Sensor #2 : Abnormal Frequency, Pulse Width, orPeriod

143 637-11 261-11 Engine Timing Sensor : Other Failure Mode

637-13 261-13 Engine Timing Sensor : Calibration Required




Description of Code


44

152

100-3 100-3 Engine Oil Pressure : Voltage Above Normal

100-4 100-4 Engine Oil Pressure : Voltage Below Normal

108-3 274-3 Barometric Pressure : Voltage Above Normal

108-4 274-4 Barometric Pressure : Voltage Below Normal

157

100-1 360 (3) Engine Oil Pressure : Low - most severe (3)

100-17 360 (1) Engine Oil Pressure : Low - least severe (1)

100-18 360 (2) Engine Oil Pressure : Low - moderate severity (2)

165

174-3 174-3 Engine Fuel Temperature 1 : Voltage Above Normal

174-4 174-4 Engine Fuel Temperature 1 : Voltage Below Normal

174-15 363 (1) Engine Fuel Temperature 1 : High - least severe (1)

168 110-15 361 (1) Engine Coolant Temperature : High - least severe (1)

110-16 361 (2) Engine Coolant Temperature : High - moderate severity (2)

181

2949-5 1922-5 Engine Intake Valve Actuation System Oil Pressure Control Valve:Current Below Normal

2949-6 1922-6 Engine Intake Valve Actuation System Oil Pressure Control Valve- Current Above Normal

2949-7 1922-7 Engine Intake Valve Actuation System Oil Pressure Control Valve- Not Responding Properly

182

2948-3 1924-3 Engine Intake Valve Actuation System Oil Pressure: VoltageAbove Normal

2948-4 1924-4 Engine Intake Valve Actuation System Oil Pressure: VoltageBelow Normal

2948-7 1101 (1) Engine Intake Valve Actuation System Oil Pressure: NotResponding Properly

2948-17 488 (1) Engine Intake Valve Actuation System Oil Pressure:Low - leastsevere (1)

186 3241-4 3485-4 Exhaust Gas Temperature 1 : Voltage Below Normal

3241-3 3485-3 Exhaust Gas Temperature 1 : Voltage Above Normal




Description of Code


45

197

100-13 100-13 Engine Oil Pressure : Calibration Required

108-13 274-13 Barometric Pressure : Calibration Required

3358-13 3385-13 Engine Exhaust Gas Recirculation Inlet Pressure : CalibrationRequired

3563-3 1785-3 Engine Intake Manifold #1 Absolute Pressure : Voltage AboveNormal

3563-4 1785-4 Engine Intake Manifold #1 Absolute Pressure : Voltage BelowNormal

3563-13 1785-13 Engine Intake Manifold #1 Absolute Pressure : CalibrationRequired

422

168-2 168-2 Battery Potential / Power Input 1 : Erratic, Intermittent, or Incorrect

168-3 168-3 Battery Potential / Power Input 1 : Voltage Above Normal

168-4 168-4 Battery Potential / Power Input 1 : Voltage Below Normal

439 158-2 1834-2 Keyswitch Battery Potential : Erratic, Intermittent, or Incorrect

516

3509-3 262-3 Sensor Supply Voltage 1 : Voltage Above Normal

3509-4 262-4 Sensor Supply Voltage 1 : Voltage Below Normal

3510-3 2131-3 Sensor Supply Voltage 2 : Voltage Above Normal

3510-4 2131-4 Sensor Supply Voltage 2 : Voltage Below Normal

527 630-2 268-2 Calibration Memory : Erratic, Intermittent, or Incorrect




Description of Code


46

2.15 HYDRAULIC FAN DRIVE SYSTEM

Refer to Figure 2-9. The compressor is equipped witha hydraulically driven fan to provide cooling airflowfor the compressor fluid, engine coolant, charge air,fuel, and hydraulic fluid. If equipped, cooling airflow isalso available to provide aftercooled discharge air.

The system includes a fan and vane motorpositioned in front of the main cooler pack andprovides the cooling airflow for the main coolerassembly. This fan also acts as the cooling airflowmechanism for aftercooled service air as well.

The fan motor is driven by dual pumps which arecoupled together and driven by the engine's auxiliary

gear drive. A variable displacement piston pumpdrives the fan motor while a fixed displacement gearpump pulls all the fluid from the reservoir and helpsto maintain a positive pressure at the inlet of thepiston pump. This arrangement allows a smaller fluidreservoir as well as more favorable inlet conditions tothe piston pump.

The fan is automatically varied depending on theambient, compressor, engine coolant, charge air,and package discharge temperature. This providesfuel savings by only running the fan as much asneeded to maintain proper operating temperatures.Additionally, load on the engine at startup is reducedassisting in cold starts and thermal cycling/shock iseliminated.

1. Piston Pump

2. Gear Pump

3. Cooler

4. Fan Motor

5. Hydraulic Fluid Filter

6. Thermal Valve

7. Hydraulic Reservoir

Figure 2-9: Hydraulic Fan Drive System


47

2.16 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-10. The electrical system iscomprised of not only the necessary equipmentrequired to operate the compressor, but also asystem to shut it down in the event of a malfunction.The components of the electrical system are anengine starter (with an integral solenoid), battery, abreaker protected alternator with a built-in voltageregulator, a breaker protected engine air inlet heater(for cold weather starting), a compressor dischargetemperature sensor and receiver tank temperatureswitch (both will shut down the compressor shouldthe compressor temperature exceed 250°F [121°C]),an ambient temperature sensor, and a fuel levelsensor. This compressor also incorporates an enginecoolant level sensor. This device is located in thebottom of the aeration tank. It will shut the

compressor down or prevent it from being started ifthe engine coolant level drops too low. In addition,there is a starter protection relay which preventsaccidental starter engagement after the engine isrunning or whenever there is pressure in the receivertank. Also, should fuel supply level drop near thebottom of the fuel tank, the controller will shut downthe machine before the engine runs out of fuel. Thereare also several connectors in the main harness thatare designed to receive wiring for factory optionssuch as remote start, engine air stop valve, and etherstart system. The electrical system also incorporatesa lockable battery disconnect to be utilized forextended periods of non use and during machinemaintenance. In case of emergency, an emergencystop switch is located adjacent to the controller onthe canopy of the machine. Figure 2-11, and Figure2-12 show the wiring diagrams for the controller andCEM unit.


48


Figure 2-10: Main Wire Harness Diagram (02250192-509 R05)


49



50

2.16 WIRING DIAGRAM, ELECTRONIC CONTROLLER

Figure 2-11: Controller Wire Harness Diagram (02250200-843 R00)


51

2.16 WIRING DIAGRAM, ELECTRONIC CONTROLLER


52

2.16 WIRING DIAGRAM, CEM INTERFACE

Figure 2-12: CEM Interface (02250192-546 R01)


53

2.16 WIRING DIAGRAM, CEM INTERFACE


54

2.17 ENGINE EXHAUST AFTERTREATMENT, FUNCTIONAL DESCRIPTION

Refer to Figure 2-13. The Clean Emissions Module(CEM) or aftertreatment serves as the means ofachieving the Tier IV emissions requirements set forthby the EPA/ EU (69 FR 38957-39273, 29 Jun 2004) tobe phased in from 2008-2015. The module itselfconsists of a Diesel Particulate Filter (DPF), Muffler,Exhaust Outlet, DOC/Inlet Cap, Absolute pressuresensor, CEM Connector to ECM, Combustion AirValve, Exhaust inlet, Outlet cap, and a Caterpillar RShead. The basic function of the aftertreatment is toremove soot and other solid particulates from theexhaust via the DPF. The level of soot is monitored bythe engine and, when needed, the system willautomatically regenerate the DPF by raising thetemperature in the DPF through active combustion andreducing the soot to ash. This system allows the unit tokeep the particulate concentrations of the exhaust atlevels that comply with EPA/EU regulations.

Regeneration can be engaged by two methods:

1. Regeneration Switch (manual force/ inhibition)

2. ECU controlled (automatically managed)

Instead of expelling exhaust gases to the atmosphere astypical exhaust systems do, exhaust exits the engineturbocharger and enters the inlet of the CEM, where thelevel of soot loading in the DPF is measured by thepressure differential across the DPF. This information inconjunction with engine speed is used to determine ifconditions are correct to initiate an automaticregeneration cycle. During regeneration the CAT RSmodule adds diesel fuel and air from the turbocharger toburn the exhaust fumes and reduce the accumulatedsoot to ash. The table in Figure 4-1 describes thereaction of the system at various stages of the sootloading profile. For detailed CEM component informationplease see the Engine Operator's Manual.

WARNINGRegenerated exhaust gases can reach tem-peratures of up to 1400ºF. DO NOT come into direct contact with these gases.

Figure 2-13: Exhaust System

1. MUFFLER/SPARK ARRESTOR2. CEM MODULE3. EXHAUST PIPE4. CEM FAN

A1. FUEL LINE INA2. COOLANT INA3. COOLANT OUTA4. FROM ENGINE TURBOCHARGER

Section 3

55


SPECIFICATIONS3.1 TABLE OF SPECIFICATIONS—600H, 600HH, 750, 750H

Table 3-1: Overall Dimensional Specifications—600H, 600HH, 750, 750H

Model SeriesLength (I) Width Height (II) Weight (wet)

in mm in mm in mm lb kgDTQ (Tandem) 241 6121 88 2235 103 2616 16810 7625

DLQ (LRG) 189 4801 88 2235 70 1778 15230 6908

(l) Length including drawbar where applicable(II) Over lifting bail

Table 3-2: Compressor Specifications

Compressor 600H 600HH 750 750HType Rotary Screw Rotary Screw Rotary Screw Rotary Screw

Delivery @ Operating Pressure

600 600 750 750

Maximum Operating Pressure

150 psig (10.3 bar) 175 psig (12.1 bar) 125 psig (8.6 bar) 150 psig (10.3 bar)

Rated Pressure 150 psig (10.3 bar) 175 psig (12.1 bar) 100 psig (6.9 bar) 150 psig (10.3 bar)

CoolingPressurized Compressor Fluid

Pressurized Compressor Fluid



Lubricating Compressor Fluid

See Lubrication Guide, Engine on page 59




Hydraulic Tank Capacity 13 gal 13 gal 13 gal 13 gal

Receiver Tank Capacity 20 gal 20 gal 20 gal 20 gal

Operating Tilt (maximum) 15° 15° 15° 15°

Electrical SystemEngine – 24 Volt Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt

Instrument System – 24 Volt




Battery (2)1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

Alternator 95A 95A 95A 95A

Sound Level (US EPA)1 76dBA 76dBA 76dBA 76dBA

Sound Level (CE)2 72dBA 72dBA 72dBA 72dBA

1 Sound level measured per U.S. 40 CFR Ch. 1 Part 2042 Sound level measured per 2000/14/EC Outdoor Noise Directive


56

Table 3-3: Engine Specifications

Engine 600H 600HH 750 750HMake Caterpillar Caterpillar Caterpillar Caterpillar

Type C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB

Rated Speed 1800 rpm 1800 rpm 1800 rpm 1800 rpm

Horsepower, SAE 300 hp (224 kW) 300 hp (224 kW) 300 hp (224 kW) 300 hp (224 kW)

Cylinders 6 6 6 6

Cycles 4 4 4 4

Bore x Stroke4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

Displacement567.5 cu. in (9.3 liters)

567.5 cu. in (9.3 liters)



Lubricating System Full Pressure Fluid Full Pressure Fluid Full Pressure Fluid Full Pressure Fluid

Exhaust SystemSee Engine Operator’s Manual

See Engine Operator’s Manual



Type of Motor OilSee Engine Operator’s Manual




Fuel Tank Capacity 200 gal 200 gal 200 gal 200 gal

Engine Cooling System Capacity

14.7 U.S. gallons (55.6 liters)




Idle Speed 1400 rpm 1400 rpm 1400 rpm 1400 rpm

Low Idle Speed 1000 rpm 1000 rpm 1000 rpm 1000 rpm

Table 3-4: Trailer Specifications

Trailer: DTQ

Track Width 101

Tire Size (Load Range) 215/75R17.5 (H)

Tire Pressure 125 psig (8.6 bar)

Wheel Size 17.5 x 6.75HC

Wheel Bolt/Lugnut Torque 275 – 325 ft lbs


57

3.2 TABLE OF SPECIFICATIONS—750HH, 825, 900H, 1050

Table 3-5: Overall Dimensional Specifications—750HH, 825, 900H, 1050

Model SeriesLength (I) Width Height (II) Weight (wet)

in mm in mm in mm lb kgDTQ (Tandem) 241 6121 88 2235 103 2616 16810 7625

DLQ (LRG) 189 4801 88 2235 70 1778 15230 6908

(l) Length including drawbar where applicable(II) Over lifting bail

Table 3-6: Compressor Specifications

Compressor 750HH 825 900/1050 900HType Rotary Screw Rotary Screw Rotary Screw Rotary Screw

Delivery @ Operating Pressure

750 825 900/1050 900H

Maximum Operating Pressure

175 psig (12.1 bar) 125 psig (8.6 bar) 125 psig (8.6 bar) 150 psig (10.3 bar)

Rated Pressure 175 psig (12.1 bar) 125 psig (8.6 bar) 100 psig (6.9 bar) 150 psig (10.3 bar)

CoolingPressurized Compressor Fluid




Lubricating Compressor Fluid





Hydraulic Tank Capacity 13 gal 13 gal 13 gal 13 gal

Receiver Tank Capacity 20 gal 20 gal 20 gal 20 gal

Operating Tilt (maximum) 15° 15° 15° 15°

Electrical SystemEngine – 24 Volt Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt





Battery (2)1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

1150 CCA @ 0°F (-18°C)

Alternator 95A 95A 95A 95A

Sound Level (US EPA)1 76dBA 76dBA 76dBA 76dBA

Sound Level (CE)2 72dBA 72dBA 72dBA 72dBA

1 Sound level measured per U.S. 40 CFR Ch. 1 Part 2042 Sound level measured per 2000/14/EC Outdoor Noise Directive


58

3.3 LUBRICATION GUIDE—COMPRESSOR

Table 3-7: Engine Specifications

Engine 750HH 825 900/1050 900HMake Caterpillar Caterpillar Caterpillar Caterpillar

Type C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB C9.3 iT4/Stage IIIB

Rated Speed 1800 rpm 1800 rpm 1800 rpm 1800 rpm

Horsepower, SAE 300 hp (224 kW) 300 hp (224 kW) 300 hp (224 kW) 300 hp (224 kW)

Cylinders 6 6 6 6

Cycles 4 4 4 4

Bore x Stroke4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

4.53 x 5.87in (115 x 149mm)

Displacement567.5 cu. In (9.3 liters)

567.5 cu. In (9.3 liters)



Lubricating System Full Pressure Fluid Full Pressure Fluid Full Pressure Fluid Full Pressure Fluid

Exhaust SystemSee Engine Operator’s Manual




Type of Motor OilSee Engine Operator’s Manual




Fuel Tank Capacity 200 gal 200 gal 200 gal 200 gal

Engine Cooling System Capacity





Idle Speed 1400 rpm 1400 rpm 1400 rpm 1400 rpm

Low Idle Speed 1000 rpm 1000 rpm 1000 rpm 1000 rpm

Table 3-8: Trailer Specifications

Trailer: DTQ

Track Width 101

Tire Size (Load Range) 215/75R17.5 (H)

Tire Pressure 125 psig (8.6 bar)

Wheel Size 17.5 x 6.75HC

Wheel Bolt/Lugnut Torque 275-325 ft lbs

Fluid Type Change Period, Hours Ambient Temperature Range °F (°C)Sullair AWF (I) 1500 -20 to 120 (-29 to 49)

D-A Torque Fluid 300 10 to 110 (-12 to 43)

SAE 10W DSE, SF, SG, CD 300 0 to 100 (-18 to 38)

MIL-L-2104E 10W 300 0 to 100 (-18 to 38)

Sullair T4 Hydraulic Fan Fluid (II) Annual -20 to 125 (-29 to 52)

(I) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5 gallons/18.9 liters), 250030-758 (55 gallons, 208 liter drum)(II) Requirements for other fluids:—Must meet Park Hannifan HF-0—Maximum viscosity for cold weather operation: 1600 cSt at minimum ambient temperature—Minimum viscosity at 225°F (107°C) 6cSt


59

3.4 APPLICATION GUIDE

Refer to Figure 3-1. Sullair Air Compressors aresupplied with Sullair AWF which is heavy duty multi-viscosity, all weather fluid. Sullair AWF also allowsan extended change interval. The fluids in Section3.3: Lubrication Guide—Compressor on page 58 canbe used. Any of these oils are suitable underconditions where severe oil oxidations can occur.Water must be drained from the receiver tankperiodically.

In addition to AWF the compressor hydraulic tank isfilled from the factory with Sullair T4 hydraulic fanfluid. This is a specially formulated hydraulic fluidwhich meets all requirements of the hydraulic systemat ambient operating temperatures ranging from -20°F to 125°F.

In high ambient temperature and high humidityconditions, condensed moisture may emulsify withthe oil forming a “milky” color. ATF or SAE 10W isespecially prone to this condition. The fluid should bechanged if this condition develops.

When ambient conditions exceed those noted or ifconditions warrant use of other extended lifelubricants, contact Sullair for recommendations.

Sullair encourages the user to participate in a fluidanalysis program. This could result in a fluid changeinterval differing from that stated in the manual.Sullair offers a fluid analysis program for SullairAWF. Contact your local Sullair representative fordetails.

D-A Lubricant® Company Inc. offers an analysisprogram for users of D-A products and Sullair AWF.Contact your D-A Lubricant® representative fordetails.

3.5 LUBRICATION GUIDE, ENGINE

For engine oil specifications, refer to the EngineOperator’s Manual.

CAUTIONDO 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 Glass (I)

2. Fluid Fill Port

(I) If fluid is seen in the sight glass when the machine is not running, no fluid is needed.

Figure 3-1: Fluid Fill Location

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

LSEC

TION

3

60 3.6 IDENTIFICATION, TANDEM AXLE (DTQ)

02250186-726 R00

SECTIO

N 3

600H, 600H

H, 750, 750H

, 750HH

, 825, 900H, 1050 U

SER M

AN

UA

L

61

3.6 IDENTIFICATION, TANDEM AXLE (DTQ)

KEY NO.

QTY

DESCRIPTION

1 1 TURBOCHARGER, ENGINE

2 1 COOLER, CHARGE AIR

3 1 MUFFLER, ENGINE

4 1 SENDER, FUEL LEVEL

5 1 RAIN CAP, EXHAUST SYSTEM

6 1 FILTER, FUEL W/ WATER SEPARATOR

7 1 PUMP, FUEL (INTERNAL TO ENGINE)

8 1 PUMP, CAT PRIMING/ARD

9 1 FILTER, FUEL

10 1 VENT, FUEL TANK

11 1 CAP, FUEL TANK FILL

12 1 THERMOSTAT, THERMOCORD(OPTIONAL)

13 1 KIT, ETHER ASSEMBLY

14 1 PUMP, OIL (INTEGRAL TO ENGINE)

15 1 BY-PASS VALVE (INTERNAL TO ENGINE)

16 1 COOLER, OIL (INTERNAL TO ENGINE)

17 1 FILTER, OIL

18 1 PUMP, WATER (INTEGRAL TO ENGINE)

19 1 RADIATOR, ENGINE

20 1 ENGINE THERMO (INTEGRAL TO ENGINE)

21 1 SENSOR, INLET AIR PRESS(TURBO BOOST)

22 1 SWITCH, COOLANT LEVEL

23 1 SENSOR, FUEL PRESSURE

24 1 SENSOR, FUEL TEMPERATURE

25 1 SENSOR, COOLANT TEMPERATURE

26 1 SENSOR, ENGINE OIL PRESSURE

27 1 SENSOR, CAM SPEED TIMING

28 1 SENSOR, CRANK SPEED TIMING

29 1 HEATER, WATER JACKET (OPTIONAL)

30 1 OIL LEVEL (DIPSTICK)

31 1 FILTER, AIR

32 1 TANK, FUEL

33 1 PAN, ENGINE OIL

34 1 GAUGE, FILTER RESTRICTION

35 1 SENSOR, INLET AIR TEMPERATURE

36 1 VALVE, RELIEF (INTEGRAL TO ENGINE)

37 1 VALVE, AIR STOP (OPTIONAL)

38 1 PUMP, AUX FUEL

39 1 VALVE, 3-WAY

40 1 EXHAUST, AFTERTREATMENT

41 1 COOLER, FUEL

Overall Specifications—600H, 600HH, 750, 750H, 750HH, 825, 900H and 1050

WEIGHT (WET) WEIGHT (DRY)

LBS. KG. LBS. KG.

16,810 7,625 15,230 6,908

KEY NO.

QTY

DESCRIPTION

62

NOTES

Section 4

63


OPERATION4.1 GENERAL

While Sullair has built into this compressor acomprehensive array of controls and indicators toassure you that it is operating properly, you will wantto recognize and interpret the readings which will call

for service or indicate the beginning of a malfunction.Before starting your Sullair compressor, read thissection thoroughly and familiarize yourself with thecontrols and indicators—their purpose, location anduse.

4.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

Power ON Switch (Start Up) * 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.

Voltmeter * Monitors the condition of the batteries and the charging circuit. The normal reading is 24 to 48 volts.

Service Air Pressure Gauge * Continually monitors the pressure inside the receiver tank at various load and unload conditions.

Engine Temperature Gauge * Monitors the temperature of the engine water. The normal operating temperature should read approximately 160ºF to 210ºF (71ºC to 99ºC).

Controller * Depicts system related diagnostics. Can be used for system performance monitoring.

Compressor 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).

NOTEWhen restarting the compressor, the controller will not allow restart until system pressure falls below 10 psig (0.7 bar) or less. More than 10 psig (0.7 bar) can put extra load on the starter.


64

Reducing Regulator Valve Provides regulated air pressure to the inlet valve.

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.

High/Low Pressure Selector Switch (only on dual pressure models) *

Select high pressure 150 psig (10.3 bar) or low pressure100 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 compressor. This regulation is determined by the amount of air being used at the service line.

Thermal Valve Regulates flow of fluid to and around the fluid cooler. Designed to maintain a minimum operating temperature; used for fast warm-up at start-up and to eliminate condensation during operation.

Blowdown Valve * Vents surplus receiver tank pressure to the atmosphere during operation and shutdown.

Coolant Level Switch Shuts the compressor down and/or prevents it from being started if the engine coolant level drops too low.

Hydraulic Fluid Sight Glass Monitors fluid level of hydraulic fan drive system. Proper level is filled to top of sight glass. Should be checked before every startup.

Hydraulic Fluid Level Switch Triggers a warning message when hydraulic system fluid level is low.

Hydraulic Fluid Temperature Sensor Triggers a warning message when the maximum hydraulic fluid temperature, 225°F (107°C) is exceeded. Normal temperature will depend on ambient temperature and system loading.

Regeneration Switch * To manually control the exhaust aftertreatment is in soot indicator levels of 15 - 105%

DPF Lamp * Indicates DPF is above 80% soot loading. Warns operator that regeneration is required.

Regeneration Inhibited Lamp * Indicates regeneration is inhibited by operator, application, or Cat ET.

High Exhaust System Temperature (HEST) Lamp *

Indicates that the exhaust aftertreatment is in active regeneration.

Cabin Light Switch * Manually turns interior compressor lighting on.

Menu select switch * Allows the user to make selections in the controller menu, and navigate the menu structure

Menu Toggle switch * Allows the user to scroll the menu options

CONTROL OR INDICATOR PURPOSE


65

4.3 COMPRESSOR START-UP PROCEDURE

1. Toggle the <ON> switch, located on the con-troller, to the “on” position. The controller willpower up and a self-diagnostic program willbe initiated. During the initiation process, thegauges will wag (the needles on each gaugewill sweep through its full scale) to verify allrelevant sensors are operational. Also, acommunication link will be established withthe engine ECU. During this time, severalmessages will be displayed on the panel.Some of these messages may not benoticed by the operator because the control-ler steps through the initialization phaserather quickly. However, the operator shouldsee the following messages during this step:

When the system has successfully initial-ized, the following message will be displayedon the LCD Graphic Display:

2. Be sure that the auxiliary fuel pump switch isin the correct position. This depends on yourfuel source if on-board the auxiliary fuelpump switch need to placed in the “on” posi-tion. off-board the auxiliary fuel pump switchneed to placed in the “off” position. Theposition of this switch needs to be estab-lished before starting the unit.

3. Toggle the <ON> switch to the “start” posi-tion. You do not have to hold the switch in the“start” position. The LCD panel will show thefollowing message:

Once the compressor has started, the unitwill enter a warm-up phase. At this point, theunit is not producing usable compressed airand the service valve should still be closed.The following message will be displayed onthe LCD panel:

Once the proper operating conditions aremet, the machine will automatically switchinto run mode and provide pressurized ser-vice air.

WARNINGIf the 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.


66

4.4 EXHAUST REGENERATION PROCEDURE

The aftertreatment constantly monitors the sootlevels of the exhaust gas. If soot levels detected bythe indicator reach above 80% the engine Electronic

Control Module (ECM) lights the DPF lamp , on

the controller screen, and should automaticallytrigger the ARD to ignite diesel fuel passing throughthe DPF until soot levels return to normal (< 10%).

During regeneration the HEST Lamp , on the

controller screen, should be lit. If for some reason theemissions module is not automatically engagedregeneration can be achieved, manually, by pressingand holding the <REGEN> Switch in the "force"

position , on the controller, for 15 seconds. This

will manually force the regeneration process at sootlevels of 15% - 105%. If regeneration is not desiredthe automatic regeneration process can be halted byengaging the <REGEN> Switch in the "inhibit"

position , on the controller. If regeneration is

inhibited the DPF Inhibited Lamp , on the

controller screen, should be lit. Regenerationinhibition should not be a regular practice, asallowing soot load percentages to get above 116%could cause the unit to abnormally shut down andfault the DPF. The Unit will NOT be able to function

until the faulted DPF is replaced. Force regenerationto reengage automatic feature. If for some reason theregeneration methods do not work and soot levelsare close too, at, or above 100% shut the unit downimmediately until this issue is resolved. Fortroubleshooting and next steps please refer toSection 5.17: Troubleshooting Guide on page 81,Engine Operator's Manual, or contact your CATdealer.

DANGERRegenerated exhaust gas can reach temper-atures as high as 1300-1400F. DO NOT come into direct contact with these gases.

WARNINGUnder no circumstances should the soot level reach above 140% as this will fault the DPF and halt unit operation until it is replaced. If for some reason the regenera-tion methods mentioned in this document do not work and soot levels are close to, at, or above 116%, shut the unit down immedi-ately until this issue is resolved.

Soot Level

<80%

80%

100%

116%

116%

116%

120%

140%

NA

NA

NA

NA

+5min

+10min

NA

NA

Timer OperatorIndication

Engine De-Ratebegins at -25%Yellow

Yellow

Yellow Red

** Pre-Emptive Idle Down (Programmable—Enable/Disable)

*** Rolling Shutdown Trigger

REGEN Disabled ServiceLevel Regen Only

Engine ShutdownReplace DPF

30 sec Rolling Shutdowns

Engine De-Rateat -60%

Engine De-Rate Strategy

Engine ShutdownStrategy

EngineProtection

Low Soot Mode

!

! !

!

Figure 4-1: Active Regeneration Operation Sequence


67

4.5 SHUTDOWN PROCEDURE

1. Close the service valve.

2. Place the <ON> switch in the “off” position.The following message will be displayed inthe LCD graphic display:

3. The unit will continue to run, though it will notproduce usable air. At the end of the cooldown cycle, the engine will be shut down.The controller will stay powered up, and anew message will be displayed:

The controller will continue to monitor thesystem pressures and will not power downuntil all pressures drop below 10 PSI (0.7bar). This final process may take 3 to 5 min-utes. Operator interaction is not necessaryduring this time as the controller will auto-matically disconnect power to all systems sothat the battery is not inadvertently drainedafter shutdown.

WARNINGThe E-Stop (emergency stop switch) should be used only in the event of an emergency. Refrain from using the E-Stop to shut the machine down during normal operations. All usage of the E-Stop is logged in perma-nent memory for use by service technicians when troubleshooting a machine. Non-emergency use of E-Stop is considered equipment abuse and could void the manu-facturer’s warranty.

68

NOTES

Section 5

69


MAINTENANCE5.1 GENERAL

A good maintenance program is the key to longcompressor life. Below is a program that whenadhered to, should keep the compressor in topoperating condition. For engine maintenancerequirements, refer to the Engine Operator’sManual for a detailed description of serviceinstructions.

Refer to “Description Of Components” on page 19 fora detailed description of specific compressor systemcomponents. Prior to performing maintenance, readthe CIMA Safety Manual, if applicable.

5.2 DAILY OPERATION

Prior to starting the compressor, it is necessary toperform a daily inspection. Perform the followingmaintenance operations to prevent unnecessaryproblems.

1. Check the fluid level in the compressorreceiver tank. Should the level be low, simplyadd the necessary amount. If the addition offluid becomes too frequent, a simple problemhas developed which is causing this exces-sive loss. Refer to “Troubleshooting Guide”on page 81 under Excessive CompressorFluid Consumption for a probable cause andremedy.

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.

6. Check the hydraulic fluid level

After a routine start has been made, it is necessary toperform an inspection to ensure all operations areperforming correctly. Perform the followinginspections to prevent unnecessary problems.

1. Observe the instrument panel gauges andbe sure they monitor the correct readings fortheir particular phase of operation.

2. After the compressor has warmed up, it isrecommended that a general check on theoverall compressor and instrument panel bemade to assure that the compressor is run-ning properly.

3. Check soot load percent

4. Check the air filter restriction gauges. Shouldthey indicate restriction, replace the ele-ments immediately. Refer to “Air filter assem-bly.” on page 78.

5.3 ENGINE COOLANT

The coolant provided with Sullair portable aircompressors is ethylene glycol based, 50/50 mixture,colored green, and should never be mixed with acoolant of a different color such as yellow, orange, orpink. If radiator coolant is to be added, for anyreason, be sure that the coolant added is the sameas what is in the cooling system, as well as what isrecommended. Refer to the Maintenance Section ofthe Engine Operators Manual for proper enginecoolant specifications and instructions. Ensure thatthe proper coolant is used when adding enginecoolant to the machine and never mix different colorcoolants. An engine originally filled with aconventional green coolant should not be “upgraded”to an extended life coolant unless the cooling systemis completely flushed and filled with water severaltimes to remove all traces of the old coolant. If youare not sure of the coolant that is installed originally itis always best to flush the system using water as abase until flushed water is clear. Then, fill the system

CAUTIONDO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal pressure before doing so.


70

with the recommended coolant using only one brand/type. Cross contamination which is caused by addingdifferent types of engine coolants will result in thecoolant additives to deplete (dropout); thus leavingradiator surfaces unprotected. Corrosion to radiatorsurfaces will occur, thus reducing radiator lifeexpectancy.

5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

After the initial 50 hours of operation, a few simplemaintenance routines can rid the system of anypossible foreign materials, if any. Perform thefollowing maintenance operations to preventunnecessary problems.

1. Clean the return line (scavenge line) orificeand strainer.

2. Change compressor fluid filter.

3. Change the hydraulic system fluid filter ele-ment.

4. Check Engine Operator’s Manual forrequired service.

5.5 MAINTENANCE EVERY 100 HOURS

After 100 hours of operation, it will be necessary toperform the following:

1. Check the battery level and fill with water ifnecessary.

2. Check Engine Operator’s Manual forrequired service.


Perform the following after every 250 hours ofoperation:

1. Check alternator belt tension and adjust ifneeded.

2. Clean the radiator and cooler exterior.Depending on how contaminated the atmo-sphere may be, more frequent cooler and

CAUTIONThe 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 Man-ual 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 nonchromate rust inhibitor must be added.

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

Coolant Service Life

Cooant Type Service Life

Caterpillar ELC Six Years/12,000 Hours

Caterpillar DEAC Three Years/3,000 Hours

Commercial Heavy -Duty Coolant/Anitfreeze that meets “ASTM D5345”

Two Years/3,000 Hours

Commercial Heavy -Duty Coolant/Anitfreeze that meets “ASTM D4985”

One Years/3,000 Hours

NOTECaterpillar DEAC DOES NOT require a treatment with an SCA at the initial fill. Commercial heavy-duty coolant/ anit-freeze that meets “ASTM D4985” or “ASTM D5345” specifications MAY require a treatment with an SCA at the ini-tial fill. Read the label or the instructions that are provided by the OEM of the prod-uct.t


71

radiator cleaning may be necessary.

3. Check Engine Operator’s Manual forrequired service


When not using Sullair AWF, change the compressorfluid and replace the fluid filter element. Refer to“Main Fluid Filter Servicing” on page 74.


When not using Sullair AWF, replace the fluid filterelement only. Refer to “Main Fluid Filter Servicing” onpage 74.


Perform the following after every 1000 hours ofoperation:

1. Clean the return line orifice and strainer.

2. Repack the wheel bearings on wheel-mounted units.


When using Sullair AWF, change the compressorfluid and replace the fluid filter element.

Refer to Section 5.15: Parts Replacement AndAdjustment Procedures on page 72 .

5.11 MAINTENANCE EVERY YEAR OR 1500 HOURS

Change hydraulic system fluid filter element.

5.12 MAINTENANCE EVERY YEAR

1. When using Sullair T4 Hydraulic Fan Fluid,change fluid.

2. Change hydraulic system fluid filter element.

3. Remove and clean suction line strainer inhydraulic fluid reservoir. Refer to Section 5on page 75 for detailed Maintanence Instruc-tions.

4. Test operation of hydraulic fluid level switch.Refer to Refer to Section 5 on page 75 forTest Instructions.

5.13 MAINTENANCE AFTER 4500 HOURS OF OPERATION

1. Replace CEM spark plugs.

2. Check Engine Operator's Manual forrequired service.

5.14 MAINTENANCE AFTER 5000 HOURS OF OPERATION

1. Replace the CEM DPF element.

2. Check Engine Operator's Manual forrequired service.


72

5.15 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

COMPRESSOR FLUID CHANGE PROCEDURE

Warm-up the compressor for 5 to 10 minutes towarm the fluid. Shut the compressor off and relieveall internal pressure before proceeding. Drain thefluid by opening the appropriate drain valve locatedin the frame on the curbside of the machine. Closethe valve when draining is complete. Change thecompressor fluid and replace the fluid filter element.

For element replacement see procedure for servicingthe fluid filter in this section. Fill the receiver tank withfluid according to Section 3.3: Lubrication Guide—Compressor on page 58.

RUNNING GEAR LUBRICATION

Refer to Figure 5-1. An inspection of the running gearshould be made on a routine basis. On four-wheelsteerable running gear models, front-axle pivot jointsand rod ends are fitted with grease zerks whichshould be lubricated every six months.

Figure 5-1: Running Gear Lubrication


73

WHEEL BEARING LUBRICATION

Refer to Figure 5-2. Proper lubrication is essential tothe proper functioning and reliability of your portablecompressor axle. Wheel bearings should belubricated at least once every 12 months, or morefrequently to help insure proper performance. Usewheel bearing grease that conforms to militaryspecification MIL-G-10924 or a high temperaturewheel bearing grease such as lithium complex NLGIConsistency #2.

If your axle is equipped with the E-Z Lube feature,the bearings can be periodically lubricated withoutremoving the hubs from the axle. This featureconsists of axle spindles that have been speciallydrilled and fitted with a grease zerk in their ends.When grease is pumped into the zerk, it is channeledto the inner bearing and then flows back to the outer

bearing and eventually back out of the grease caphole (refer to Figure 5-2). The procedure is asfollows:

1. Remove the rubber plug from the end of thegrease cap.

2. With a standard grease gun filled with a qual-ity wheel bearing grease, place the gun ontothe grease zerk located in the end of thespindle. Make sure the grease gun nozzle isfully engaged on the fitting.

3. Pump grease into the zerk. The old, dis-placed grease will flow back out of the caparound 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.

1. Rubber Plug

2. Outer Bearing

3. Inner Bearing

4. Grease Flow

5. Grease FItting

6. Metal End Cap

7. Spring-Loaded Double Lip Seal

Figure 5-2: Typical E-Z Lube Axle

1

2

3

76

5

4

SU_0000076


74

MAIN FLUID FILTER SERVICING

Refer to Figure 5-3. The main fluid filters are locatedschematically in the lubricant line between thereceiver tank and the compressor unit. The main filterelements are replaceable. For installation of the filterelements, follow the procedure explained below:

1. The compressor MUST be shut off and sys-tem pressure MUST be relieved.

2. Position a suitable container beneath theelements to catch fluid drainage.

3. Remove elements using a suitable tool.

4. Rotate each element counterclockwise toremove.

5. Remove element and discard. These ele-ments are not cleanable.

6. Make certain that the mounting surfaces andfilter heads are clean.

7. Apply a light film of clean fluid to each ele-ment gasket surface.

8. Center the new elements on filter housingheads and tighten until the filter gasketsmake contact with the filter housing. Aftergaskets make contact, tighten 1/2 to 2/3 of aturn.

9. Run compressor and check for leaks.

*Repair kit for thermostat element, part number 250026-561

**Replacement filter element (2 required), part number 250025-526

1. Capscrew

2. Washer

3. Upper Housing

4. O-Ring

5. Thermostat Element*

6. O-Ring

7. Lower Housing

8. Filter Elements **

Figure 5-3: Main Fluid Filter Assembly and Thermostat

1

2

3

4

5

6

7

8


75

5.16 HYDRAULIC SYSTEM MAINTENANCE

FLUID CHANGE PROCEDURE

Refer to Figure 5-4. Warm-up the compressor for 5 to10 minutes to warm the fluid. Shut the compressoroff and relieve all internal pressure beforeproceeding. Drain the fluid by opening both theappropriate drain valve located in the frame as wellas the valve on the bottom of the hydraulic reservoir,refer to Figure 5-4. Remove filler cap during draining.

Close the valves when draining is complete. Fill thereservoir with fluid according to Section 3.3:Lubrication Guide—Compressor on page 58.

HYDRAULIC FILTER ELEMENT MAINTENANCE

The filter is located near the hydraulic fluid reservoirand is a cartridge style filter.

Replace as follows, referring to Figure 5-5.

1. Remove filter canister with a wrench.

2. Remove and dispose of filter element.

3. Clean gasket sealing surface.

4. Apply a light film of fluid to the element seal.

5. Screw the canister to the filter head. Tightento 20 lb-ft (27.1 Nm).

6. Run compressor and check for leaks.

* Replacement filter element part number 02250168-084

HYDRAULIC FLUID LEVEL SWITCH TEST

With hydraulic reservoir empty, power up controllerand confirm that a low hydraulic fluid level warning isdisplayed. If no warning is present, repair switch and/or wiring.

Figure 5-4: Hydraulic Tank

1. Fill Cap

2. Sight Glass

3. Strainer

4. Level Switch

5. Temperature Switch

6. Drain Valve

Figure 5-5: Fluid Filter Assembly

1. Canister

2. Element *

3. Filter Head


76

SUCTION LINE STRAINER MAINTENANCE

Service strainer as follows, referring to Figure 5-6:

1. Disconnect hose and remove fitting.

2. Remove strainer from tank.

3. Clean and dry strainer.

4. Replace strainer and fitting being careful notto damage O-rings. Replace O-rings if theyare damaged or distorted.

5. Reconnect hose, start compressor andcheck for leaks.

Figure 5-6: Suction Line Strainer


77

SEPARATOR ELEMENT REPLACEMENT

Refer to Figure 5-7. When the need for a separatorelement replacement is indicated by the controller,use the following procedure for separatorreplacement.

1. Remove the air receiver tank lid by removingthe hex head capscrews and washers.

2. Remove the elements from the separatorchamber by gently rocking back and forthand pulling upward and discarding.

3. Before installing the new separator ele-ments, make sure to lubricate the sealing O-ring on each element with a lubricating com-pound (i.e. Silglyde). Then install the newseparator elements by firmly pressing down-ward until the element is fully seated on thebaffle plate inside the tank.

4. Next, inspect the tank flange O-ring andreplace if necessary. Before installing the lid,relubricate the O-ring (i.e. Silglyde). Reinstallthe tank lid. Install the capscrews and wash-ers finger tight, then gradually tighten in acrisscross pattern in 4 to 5 steps. Alwaystighten the capscrews alternately at oppositesides of the cover. Torque lubricated cap-screws to 322 ft-lbs. (440 N·m).

5. Clean or replace fluid return line strainer.

6. Clean the fluid return line orifice installed inthe side of the compressor unit air end.

CAUTIONTo assist with the removal of the tank lid, Sul-lair has provided a jack bolt at the bottom of the lid pivot shaft. Simply jack the lid up until it will clear the dowel pin located on the top tank flange underneath the lid. Rotate out of the way.

1. Capscrew

2. Washer

3. Grounding Plate

4. Lockwasher

5. O-ring

6. Separator Elements

7. Receiver Tank

Figure 5-7: Separator Element Assembly


78

AIR FILTER MAINTENANCE

Refer to Figure 5-8. Air filter maintenance should beperformed when indicated on instrument panelcompressor air filter warning lamp. The air filters areboth equipped with a primary element and secondaryelement each.

The secondary element must be replaced after everythird primary element change. DO NOT reconnectthe secondary element once it is removed.

ELEMENT REMOVAL

1. Clean the exterior of the air filter housing.

2. Remove the service cover by unlatching thefour hook latches.

3. Remove the primary filter from the housing.

4. Clean the interior of the housing by using adamp cloth. DO NOT blow out dirt with com-pressed air as this may introduce dust down-stream of the filter.

5. When it becomes necessary to remove thesecondary element, pull the element out ofthe housing.

6. Install the new secondary element over therod.

7. With the secondary element in place, replacethe primary element.

* Primary Filter Element, Part No. 02250175-062

** Secondary Filter Element, Part No. 02250175-063

ELEMENT INSPECTION

1. Place a bright light inside the element toinspect for damage or leak holes. Concen-trated light will shine through the elementand disclose any holes.

2. Inspect all gaskets and gasket contact sur-faces of the housing. Should faulty gasketsbe evident, correct the condition immedi-ately.

3. If the clean element is to be stored for lateruse, it must be stored in a clean container.

4. After the element has been installed, inspectand tighten all air inlet connections prior toresuming operation.

PRIMARY ELEMENT REPLACEMENT

1. Place the element in position over the sec-ondary element.

2. Install the cover with clean-out port pointingdown. Clamp in place using all latcheslocated on canister.

1. Access Cover

2. Vacuator Valve

3. Primary Filter Element

4. Secondary Element

5. Air Cleaner Housing

Figure 5-8: Air Filter Assembly


79

CONTROL SYSTEM ADJUSTMENT—SINGLE PRESSURE

Refer to Figure 5-9. Prior to adjusting the controlsystem, it is necessary to determine the desiredoperating pressure range as well as the maximumpressure at which the machine is to operate. Thispressure must not exceed the maximum operatingpressure which is stamped on the machine serialnumber plate.

1. Start the machine and let it warm-up andenter full "run" mode.

2. Open service valve slightly until engine triesto speed up. Slowly close the service valve.With service valve closed, check and adjustthe pressure at the reducing regulator to a

minimum of 60 psig (4.1 bar) and not toexceed 85 psig (5.2 bar). With service valvestill closed adjust the backpressure regulatorso the service pressure is between 115 to125 psig (7.9 to 8.6 bar) for standardmachines, 165 to 175 psig (11.4 to 12.1 bar)for "H" machines, and 190 to 200 psig (13.1to 13.8 bar) for "HH" machines with theengine at 1400 rpm. Open the service valveto load the compressor to maintain a servicepressure of 100 psig (6.9 bar) for standardmachines, 150 psig (10.3 bar) for "H"machines, and 175 psig (12.1 bar) for "HH"machines. Operating speed should be 1800RPM on the controller panel. If not, repeatstep, or adjust the unload service pressureup or down as needed until desired pressureis maintained and engine speed is 1800 rpm.

1. Pneumatic Inlet Valve

2. Controller

3. HI/LO Solenoid (Dual Only)

4. High Pressure Regulator

5. Low Pressure Regulator (Dual Only)

6. START/RUN Solenoid

7. Reducing Pressure Regulator

8. Dry Pressure (P1)

9. Wet Pressure (P2)

10. Control Pressure (P3)

Figure 5-9: Control System Components


80

CONTROL SYSTEM ADJUSTMENT—DUAL PRESSURE

Refer to Figure 5-8. Prior to adjusting the controlsystem, it is necessary to determine the desiredoperating pressure range as well as the maximumpressure at which the machine is to operate. Thispressure must not exceed the maximum operatingpressure which is stamped on the machine serialnumber plate.

1. Start the machine and let it warm-up andenter full “RUN” mode.

2. Open service valve slightly until engine triesto speed up. Slowly close the service valve.With service valve closed, check and adjustthe pressure at the reducing regulator to aminimum of 60 psig (4.1 bar) and not toexceed 85 psig (5.2 bar). With service valvestill closed, and the <PRESSURE> switch inthe “Low” position, adjust the low-pressureback-pressure regulator so the service pres-sure is between 115 to 125 psig (7.9 to 8.6bar) with the engine at 1400 rpm. Open theservice valve to load the compressor tomaintain 100 psig (6.9 bar) discharge pres-sure. Operating speed should be 1800 RPMon the controller panel. If not, repeat step,but adjust the unload service pressure up ordown as needed until 100 psig (6.9 bar) ismaintained when engine speed is 1800 rpm.

3. For 150 psig (10.3 bar) “H” machines, turnthe <PRESSURE> switch to “HI” position.Close the service valve and set the “HI” pres-sure control regulator to maintain 165 to 175psig (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-loadspeed. If lower speed is observed, raise thesetting of the low pressure control regulatoruntil rated speed is achieved.

4. For 175 psig (12.1 bar) “HH” machines, turnthe <PRESSURE> switch to “High” position.Close the service valve and set the “High”pressure control regulator to maintain 190 to200 psig (13.1 to 13.8 bar) discharge pres-sure. Open the service valve to maintain 175psig (12.1 bar) and check for 1800 RPM full-load speed. If lower speed is observed, raisethe setting of the low pressure control regu-lator until rated speed is achieved.


81

5.17 TROUBLESHOOTING GUIDE

The following Troubleshooting Chart is based onboth the data obtained from actual tests conducted atour factory and real applied situations. It containssymptoms and usual causes for the describedproblems. However, DO NOT assume that these arethe only problems that may occur. All available dataconcerning the trouble should be systematicallyanalyzed before undertaking any repairs orcomponent replacement procedures.

• Check for loose wiring.

• Check for damaged piping.

• Check for parts damaged by heat or an electricalshort circuit, usually apparent by discoloration or aburnt odor.

Should your problem persist after making therecommended check, consult your nearest Sullairrepresentative or the Sullair.

SYMPTOM PROBABLE CAUSE REMEDY

Compressor will not start No fuel Check fuel level and add fuel if necessary.

Plugged fuel filter Replace the fuel filter element.

Battery 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 Controller Manual. Sullair Part No. 02250201-742.

Compressor shuts down with air demand present

No fuel Check fuel gauge and add fuel if necessary.

Compressor discharge temperature switch is open

Cooling air flow is insufficient; clean cooler and check for proper ventilation.

Low fluid sump level; add fluid.

Dirty compressor fluid filter; change element.

Thermostatic element is not functioning properly; change the thermostatic element.

Defective discharge temperature switch; check for a short or open circuit to the engine fuel solenoid. Should this checkout normal, it could be possible that the temperature switch itself is defective.

Instrument panel problems may have developed

Refer to Controller Manual. Sullair Part No. 02250201-742.

Aftertreatment soot load >100%. Force a regeneration cycle to reduce soot loading. If problem persists, contact your local CAT dealer.

Compressor will not build up full discharge pressure

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

Aftertreatment soot load >100%. Force a regeneration cycle to reduce soot loading. If problem persists, contact your local CAT dealer.


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Improper unloading with an excessive pressure build-up causing pressure relief valve to open

Fluid charge lost from spring chamber on inlet valve pressure regulating valve is set too high

Add fluid to inlet valve spring chamber by removing plugs in the top of the spring chamber and filing with compressor fluid.

Some fluid may leak from the control regulator at first but will stop leaking when fluid level in the spring chamber equalizes.

Running blowdown valve pressure regulating valve set too high

Readjust.

Leak in control system causing loss of pressure signal

Check control lines.

Worn seals in inlet valve. Replace seals (kit available).

Defective pressure regulating valves; repair valves (kits available).

Inlet valve jammed Free or replace valve.

Restriction in the control system Check all control lines and components.

Ice and other contaminants could cause restrictions.

Defective pressure relief valve Replace pressure relief valve.

Insufficient air delivery 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.

Excessive compressor fluid consumption

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.

Compressor overheating 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.



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Engine overheating 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.

Regeneration will not automatically engage.

Regeneration Switch in the inhibit position.

Force regeneration, or restart the unit.

Unit derated on its own Soot load >100% Force regeneration, or restart the unit.

Inspect spark plugs.

Compressor shuts down with air demand present

Compressor discharge temperature switch is open

Insufficient cooling airflow due to low hydraulic fluid level; add fluid and check for leaks

Compressor overheating Low cooling airflow due to low hydraulic fluid level

Add fluid and check for leaks

Low cooling airflow due to incorrectly programmed machine.

Verify controller is loaded with correct machine configuration file.

Fan speed higher than expected.

Wiring or connector issue to fan control solenoids.

Verify and correct wiring.

Sensor (compressor, CAC, ambient, coolant, package discharge) malfunction.

Replace sensor.

Hydraulic system overheating

Low fluid level. Add fluid and check for leaks

Faulty thermostat element. Replace thermostat element.

Dirty cooler core. Clean core thoroughly.

Plugged internal cooler passages. Clean passages or replace cooler.


NOTEAdditional troubleshooting tips are avail-able in the Controller Manual. Sullair Part No. 02250201-742.

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NOTES

Section 6

85


NOISE CONTROL6.1 NOISE EMISSIONS

WARRANTY

Sullair warrants to the ultimate purchaser and eachsubsequent purchaser that this air compressor wasdesigned, built and equipped to conform at the timeof sale to the first retail purchaser, with all applicableU.S. E.P.A. and/or any Federal, State or Local noisecontrol regulations.

This warranty is not limited to any particular part,component, or system of the air compressor. Defectsin the design, assembly, or in any part, component,or system of the compressor which, at the time ofsale to the first retail purchaser, caused noiseemissions to exceed Federal standards are coveredby this warranty for the life of the air compressor.

6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED

Federal Law prohibits the following acts or thecausing thereof:

1. The removal or rendering inoperative by anypersons, other than for purposes of mainte-nance, repair, or replacement, of any deviceor element of design incorporated into anynew compressor for the purpose of noise

control prior to its sale or delivery to the ulti-mate purchaser or while it is in use.

2. The use of the compressor after such deviceor element of design has been removed orrendered inoperative by any person.

Among those acts included in the prohibition againsttampering are the acts listed below:

1. Removal or rendering inoperative any of thefollowing:

a. Engine exhaust system or parts thereof

b. Compressor air intake system or part thereof

c. Enclosure of part thereof

2. Removal of any of the following:

a. Vibration isolators

b. Control silencer

c. Floor panel

d. Fan shroud

e. Acoustical materials including fiberglassfoam or foam tape

3. Operation with canopy doors open for anypurpose other than starting, stopping, adjust-ment, repair, replacement of parts or mainte-nance.


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6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

The following instructions and maintenance recordlog book, for the proper maintenance, use and repairof this compressor, is intended to prevent noiseemission degradation.

NOISE EMISSION MAINTENANCE AND MAINTENANCE RECORD LOG1. 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


By

Location

Date

2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION

In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight, that there are no other leaks in the system, and that the filter element(s) are intact. DO NOT operate compressor with defective air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts List.


By

Location

Date


By

Location

Date


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3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. DO NOT operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbers indicated in Parts List.


By

Location

Date


By

Location

Date

4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION

At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any missing or deformed members, including all hinged doors, covers and their fastening devices. DO NOT operate compressor with defective frame, canopy and parts. Remove and replace defective parts by ordering with part numbers indicated in Parts List.


By

Location

Date


By

Location

Date

5. ANNUAL ACOUSTICAL MATERIALS INSPECTION

At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material missing or damaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate compressor with defective acoustical material. Remove and replace defective parts by ordering with part numbers indicated in the Parts List.


By

Location

Date


By

Location

Date


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6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.

In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to make sure all systems are operating properly and that engine runs at rated speed and pressure. DO NOT operate malfunctioning or improperly adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required.


By

Location

Date


By

Location

Date

Printed in the U.S.A.Specifications subject to change

without prior notice.E12EP

Always air. Always there.

SULLAIR3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.

Telephone: 1-219-879-5451

WWW.SULLAIR.COM

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