€.SULLAIR. PORTABLE AIR COMPRESSOR 600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, 1050 Caterpillar OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE Ri NCE P 34AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 2-day courses that provide hands —on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Portable compressors are presented at regular intervals throughout the year at a dedicated training facility at the Sullair corporate headquarters in Michigan City, Indiana. Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for rental house and Contractor jaintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Matas Training Department 1—888-SULLAIR or 219-879-5451 (ext. 5363) wwwsullai.com = Or Write — Sullair Corporation 3700 E. Michigan Bivd. Michigan City, IN 46360 Attn; ‘Service Training DepartmentSection 1 SAFETY Section 2 DESCRIPTION Section 3 SPECIFICATIONS TABLE OF CONTENTS OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL, Nooounnses © eae 4 4 7 18 24 23 23 23 1.4 GENERAL 1.2TOWING 1.SPRESSURE RELEASE 44 FIRE AND EXPLOSION 1S MOVING PARTS 1g HOT SURFACES, SHARP EDGES AND SHARP CORNERS, 1.7 TOXIC AND IRRITATING SUBSTANCES “8 ELECTRICAL SHOCK 1.9UFTING 1.10 ENTRAPMENT 1.41 JUMP STARTING 21 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS. 2.3 SULLAIR COMPRESSOR UNTT, FUNCTIONAL DESCRIPTION 24 COMPRESSOR COOLING AND LUBRICATION "SYSTEM, FUNCTIONAL DESCRIPTION 25 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 25 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 27 AR INLET SYSTEM, FUNCTIONAL DESCRIPTION ‘2.8INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION. ‘2.9 ENGINE CONTROL MODULE. FUNCTIONAL DESCRIPTION 2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION 3.4 TABLE OF SPECIFICATIONS ‘32 LUBRICATION GUIDE - COMPRESSOR. 23 APPLICATION GUIDE 34 LUBRICATION GUIDE ~ ENGINESection 4 OPERATION Section 5 MAINTENANCE Section 6 NOISE CONTROL Section 7 ILLUSTRATIONS AND PARTS LIST 24 25 25 26 27 27 27 27 27 27 27 27 27 37 37 4a 42 SSsaRS 49 50 TABLE OF CONTENTS. (CONTINUED) 4. GENERAL 4 PURPOSE OF CONTROLS ‘43 INTIAL START-UP PROCEDURE 4444 SUBSEQUENT START-UP PROCEDURE 4 SHUTDOWN PROCEDURE 5.1 GENERAL ‘52 DALY OPERATION ‘5 MAINTENANCE AFTER INITIAL 50 HOURS ‘OF OPERATION ‘54 MAINTENANCE EVERY 100 HOURS 55 MAINTENANCE EVERY 250 HOURS 536 MAINTENANCE EVERY 300 HOURS 57 MAINTENANCE EVERY 600 HOURS 58 MAINTENANCE EVERY 1000 HOURS. ‘59 MAINTENANCE EVERY 1200 HOURS. ‘5:0 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES 5.1 TROUBLESHOOTING 6.1 NOISE EMISSIONS WARRANTY (62 TAMPERING WITH NOISE CONTROL ‘SYSTEM PROHIBITED {6 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG. 774 PROCEDURE FOR ORDERING PARTS 72 RECOMMENDED SPARE PARTS LIST 73 ENGINE AND COMPRESSOR ASSEMBLY ~ ALL MODELS 77K ENGINE ASSEMBLY & MOUNTING ~ ALL MODELS. 74 AIR INLET SYSTEM ~ ALL MODELS 77S EXHAUST SYSTEM ~ ALL MODELS 773 ENGINE COOLING SYSTEM ~ ALL MODELS. ‘7.7 RADIATOR FLUID COOLING SYSTEM-ALL MODELS EXCEPT 1050 ‘77A RADIATOR & FLUID COOLING SYSTEM ~ ALL 1050 MODELS 17718 THERMAL VALVE ASSEMBLY ALL MODELS ‘78 CONTROL SYSTEM MANIFOLD ~ ALL MODELSSection 7 ILLUSTRATIONS AND PARTS LIST (CONT.) 51 Sees 56 57 58 59 60 SSass 69 70 ” 72 73 74 76 85 86 87 TABLE OF CONTENTS (CONTINUED) ‘7 CONTROL SYSTEM COMPONENTS & PARTS ~ ALL MODELS ‘TAOINLET VALVE ~ ALL MODELS EXCEPT 1050, ‘TAOA INLET VALVE ~ ALL 1050 MODELS 1741 DISCHARGE SYSTEM ~ ALL MODELS EXCEPT 1050 AIA DISCHARGE SYSTEM ~ ALL 1050 MODELS. 7.42 RECEIVER SUB~ASSEMBLY — ALL MODELS EXCEPT 1050 7.494 RECEIVER SUB- ASSEMBLY ~ ALL 1050 MODELS 7428 RECEIVER FLUID FILL - ALL MODELS 743 FUEL SYSTEM ~ 600H, 600HH, 750, 750H, 625, 600 MODELS. ‘749A FUEL SYSTEM ~ 750HH, 900H, 1050 MODELS ‘74 FRAME, RUNNING GEAR AND PARTS, TRI-AXLE ~ ALL MODELS ‘71S FRAME, RUNNING GEAR AND PARTS, 4—WHEEL ~ ALL MODELS. ‘718 FRAME AND PARTS, LESS RUNNING GEAR ~ ALL MODELS 7.17 CANOPY AND PARTS ~ ALL MODELS 7.:TA CANOPY PANEL ASSEMBLY ~ ALL MODELS “TR CANOPY PANEL ASSEMBLY ~ ALL MODELS. “TG CANOPY PANEL ASSEMBLY ~ ALL MODELS -7D CANOPY PANEL ASSEMBLY ~ ALL MODELS ‘8 ACOUSTIC INSULATION AND PARTS ~ ALL MODELS 7@ ELECTRICAL PARTS ~ ALL MODELS 7720 INSTRUMENT PANEL AND PARTS ~ ALL MODELS 1721 DECALS ~ ALL MODELS 17.22DECAL LOCATION TRI-AXLE MODELS 722A DECAL LOCATION 4-WHEEL MODELS 7228 DECAL LOCATION LESS RUNNING GEAR MODELS 7.28 WIRING DIAGRAM ~ ALL MODELS.4.1 GENERAL Sullair Corporation designs and manufactures all of its products so they can be operated safely, However, the responsibilty for safe operation rests, with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will mini- mize the possibility of accidents throughout the Useful life ofthis equipment. Read the CIMA Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do 50, and who have read and understood this Opera- tor's Manual. Faure to follow the instructions, pro- Cedures and safety precautions in this manual can result in accidents and injuries. NEVER start the air compressor unless its safe to doo. DO NOT attemptto operate the air compres ‘sor with a known unsafe condition. Tag he air com- pressor and render it inoperative by disconnecting the battery so others who may not know of the un- safe condition will not attempt to operate it untilthe condition is corrected. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements. DO NOT modify the compressor except with writ- ten factory approval. Each day walk around the air compressor and in- spect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recom- mended daily maintenance. Inspect for torn, frayed, blistered or otherwise dete- riorated and degraded hoses. Replace as re- Estimated hose life based on a 5-day 8—hour work Wook yeas hone condions ed ot fan 8-hour shit only. Any other operation 2—hour shite would short- 1.2 TOWING (1) A. PREPARING TO TOW POG DO NOT tow the compressor should ts weightex- ‘ceed the rated limit of the tow vehicle, as the ve ficle may not brake safely with excess weight. ‘See rated mit in tow vehicle Operators Manual, land review its instructions and other require: ‘ments for sate towing. 1. Prior to hitching the air compressor to the tow vehicle, inspect al atachment parts and equip- ment, checking for () signs of excessive wear or corrosion, (i) parts that are cracked, bent, Section 1 SAFETY dented or otherwise deformed or degraded, and (ii) loose nuts, bots or other fasteners. Should any such condition be present, DO NOT TOW Until the problem is corrected 2, Back the tow vehicle to the compressor and Position it in preparation for coupling the com- pressor. 3. I the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the cou- pling device. If not, raise drawbar to engage coupling device or otherwise couple the com- pressorto the towing vehicle. ETS ‘opment ra ny, 90101 essen rye ry Poa the weight is Use the screw jack provided or a chain fall you cannot lft or lower it without avoiding injury to yourself orothers. Keep hands and fingers clear (ofthe coupiing device and all other pinch points. Keep feet clear of drawbar to avoid injury incase it should slip from your hands. 4, Make sure the coupling device is fully en- gaged, closed and locked, 5. If chains are provided, pass each chain through its point of attachment on the towing ve~ hicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under front of drawbar before passing them through points of attachment on towing vehicle to support front of drawbar in case it should accidentally become uncoupled. 6. Make sure that the coupling device and adja- centstructures on the towing Vehicle (and also, it utilized, chain adjustment, brake and/or electri- ‘al interconnections) DO NOT interfere with or restrict motion of any part of the compressor, in- cluding its coupling device, with respect to the towing vehicle when maneuvering over any an- ticipated terrain. 7. If provided, make sure chain length, brake and electrical interconnections provide suffi. cient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or tub on road, terrain or towing vehicle sur- faces which might cause wear that could render them inoperative. POG {is eecured in place prior fotowing. Ma caster wheels provided on the screw jackitis avo he serew Jack and can not be removed. allow the same procedure for stowing away tlSection 1 SAFETY heslelackasyouwouldforthe standardesrow (ck: Pull the pin connectingthe jacktothe draw: ‘aid alge the serew jackto Its full up position. PENNS This equipment may be tengue hea, 00 NOT attempt to raise or lower the drawba ‘the weight Te more than you can safely handle. 8, On two-wheeled models, fully retract front ‘screw jack and any rear stabiizer legs, Ifacast- ‘er wheel s provided on the screw jack itis 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 tots full up position. Rotate the screw jack to its stowed posttion, parallel to the drawbar, and reinsertthe pin. Make sure the jacks secured in place prior to towing. 9. Make sure tires are in good condition and are the size (load range) specified and are inflated to the specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques. 410. If provided, make sure all dualstop,talldirec- tional and clearance lights are operating proper- ly and that their lenses are clean and functional. Iso, make sure all reflectors and reflecting sur- faces, including the slow moving vehicle em- blem’on compressors provided with same, are clean and functional 11. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, it provider 12. Make sure all access doors and tool box cov- ers are closed and latched. Ifthe compressor is large enough to hold a man, make sure all per- sonnel are out before closing and latching ac- cess doors. 18. Make sure parking brakes in towing vehicle are set, or that its wheel are chocked orblocked, or that itis otherwise restrained from moving, Then, release the compressor parking brakes, it provided. 14, Make sure the compressor wheels are not chocked or blocked, and that all tie—downs, if any, are free. 1. Test running brake operation, inoluding breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail 16, DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor. 17. DO NOT load this equipment with accesso- ries or tools such that itis unbalanced from side 10 side or front to back, Such unbalance will re- duce the towabilty of this equipment and may increase the possibilty of tipping, rolling over, Jackknifing, etc. Loss of control ofthe towing ve- hicle may result B. TOWING 1, Observe all Federal, State, and Local laws winile towing this equipment (including those specifying minimum speed). 2. DO NOT exceed the towing speeds listed be- ow under ideal conditions. Reduce your speed according to posted speed limits, weather, traf- fic, road or terrain conditions. a, Two. axle four-wheel steerable models: 15MPH (24KMPH), b. Allother models: 55 MPH (88KMPH) 3, Remember that the portable air compressor Tay approach or exceed the weight of the tow- ing vehicle. Maintain increased stopping dis- tances accordingly. DO NOT make sudden lane changes, U-turns, or other maneuvers. Such maneuvers can cause the compressor to tip, rol over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without waming. U-turns especially should be made slowly and carefully. 4. Avoid grades in excess of 15° (27%). 5, Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain. 6, Maneuver in a manner that will not exceed the freedom of motion of the compressor's drawbar and/or coupling device, in or on the towing ve- hicle’s coupling device and/or adjacent struc- ture whether towing forward or backing up, re- gardless of the terrain being traversed. 7. DO NOT permit personnel to ride in or on the ‘compressor. 8, Make sure the area behind, in frontof, and un- der the compressor is clear of all personnel and obstructions prior to towing in any direction 9, DO NOT permit personnel to stand or ride on. the drawbar, or to stand or walk between the ‘compressor and the towing vehicle. C. PARKING OR LOCATING COMPRESSOR 4. Park or locate compressor on a level surface, if possible. if not, park or locate compressor across grade so the compressor does not tend to roll downhill, DO NOT park or locate com- pressor on grades exceeding 18° (27%). 2, Make sure compressor is parked or located ‘on a firm surface than can support its weight. 3, Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet open- ings, and also where the compressor will not be exposed to excessive dust from the work ste4. (On four-wheel models, park, compressor with front wheels in straight ahead position. 5. Set parking brakes and disconnect break- ‘away switch cable and all other interconnectin. ‘electrical and/or brake connections, if providec 6. Block or chock both sides of all wheels. 7. If provided, unhook chains and remove them from the points of chain attachment on the tow= ing vehicle, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting. 8. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has sufficient load bearing capability to Support the weight of the compressor. EGS Retract the front serew jack only after attaching the compressor to the tow alse the screw ast fl up potion and pl the in connecting the jack tothe drawbar. ‘Rotate ihe ‘Serew jack to ts stowed position, parallel to the ‘drawbar, and reinsert the pin. Make sure the ack Is secured In place prior to towing. lta caster wheelie provided on the screwlackitis of the screw jack and ean not be removed. allow the game procedure for stow wheeledjack as ouwouldfor the: jack. Pull the pin connecting the ack tothe draw- rand alse the screwjackto ts ullup postion, Rotate the serew jack to it stowed positio Sie to the drawbar, and reineer Ue pin. Sure the jack fe secured In place prior to towing. PG) squipment may be tongue heavy. DO NOT mp to ralee or tower tne drawbar by hand it ‘weight Is more than you can safely Ra th 9. Ifa caster wheels provided on the screw jack itis part of the screw jack and can not be re- moved. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack tots stowed position, parallel to the drawbar, and re- insert the pin. Make sure the jack is secured in place prior to towing. 10. Disconnect coupling device, keeping hands and fingers clear of all pinch points. ifthe com- pressor is provided with a drawbar, DO NOT at- temptto lit the drawbar or if hinged, to raise itto the upright position, by hand, if the weight is more than you can safely handle, Use a screw- jack or chain fall if you cannot lift or raise the rawioar without avoiding injury to yourset or others. 11. When possible, stow hinged drawbar in the vertical upright position. Make certain itis se- curely latched in the vertical upright position. Section 1 SAFETY Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from your hands or otherwise fall to the ground. 12. Move the towing vehicle well clear of the parked compressor and erect hazard indica- tors, baricades andor flares (fat night) itcom- pressor parked on of adjacent io public roads Park so as not to interfere with traffic. ( While not towed in the usual sense of the word, many of these instructions are directly applic bye to skid-—mounted portable air compressors as wel 1.3 PRESSURE RELEASE ‘A. Open the pressure relief valve at least weekly to make sure itis not blocked, closed, obstructed or otherwise disabled. B. Install an appropriate flow-limiting valve be- tween the compressor service air outlet and the shutoff, (throttle) vaive, when an air hose exceed- ing 1/2" (13mm) inside diameter is to be connected to shut-off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302 (b) (7) or any applicable Federal, State and Local codes, standards and regulations. C. When the hose is to be used to supply a man- ifold, install an additional appropriate flow—limiting valve between the manifold and each air hose ex- ceeding 1/2" (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. D. Provide an appropriate flow—limiting valve for each additional 75 feet (23 meters) of hose in runs of a hose exceeding 1/2" (i3mm) inside alameter to reduce pressure in case of hose failure. E. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve accordingly. FDO NOT use to's that are rated below the maxi- mum rating of this compressor. Select tools, ait hoses, pipes, valves, fiters and other fittings ac- cordingly. DO NOT exceed manufacturer's rated safe operating pressures for these items. G, Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled, H. Open fluid filer cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. |. Vent all internal pressure prior to opening any line, fting, hose, valve, drain plug, connection or ‘other component, such as filters and line oilers, and before attempting to refill optional airline anti- icer systems with anfireeze compound.Section 1 SAFETY J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge. K. DO NOT use air at pressures higher than 30 psig 2.1 bar) for cleaning purposes, and then only With effective chip guarding and personal protec- tive equipment per OSHA Standard 29 CFR 910.242 (b) or any applicable Federal, State and Local codes, standards and regulations. L. DO NOT engage in horseplay with air hoses as death or serious injury may resut. M. This equipment is supplied with an ASME de- signed pressure vessel protected by an ASME rated relief vaive. Lift the handle once a week to make sure the valve is functional. DO NOT iif the handle while machine is under pressure. NV. Ifthe machine is installed in an enclosed area itis, necessary to vent the relief vaive to the outside of the structure or to an area of non—exposure. ©. DONOT remove radiator filler cap until the cool- ant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling be- fore removing cap completely. Remove radiator fill fr cap only when cool enough to touch with a bare an P.The ethyl ether in the replaceable cylinders used in diesel ether starting ald systems (optional) is un- der pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty. . Ita manual blowdown valve is provided on the receiver, open the valve to insure all internal pres- Sure has been vented prior to servicing any pres- surized component of the compressor airiflid sys- tem, 1.4 FIRE AND EXPLOSION ‘A. Fefuel at a service station or from a fuel tank de- ined for its intended purpose. If this is not pos- sible, ground the compressor to the dispenser prior to refueling. B. Clean up spills of fuel, fluid, battery electrolyte or Coolant immediately i such spills occur. C. Shut off air compressor and allow it to cool, Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, or when checking or add- ing slectrojyte to batteries, or when checking or adding fluid, or when checking diesel engine ether starting aid systems or replacing oylinders, or when fefiling airline anti—icer systems antifreeze ‘compound. D. DO NOT permit liquids, including air line anti— icer system antitreeze compound or fluid film to ac- cumulate on bottom covers or on, under or around acoustical material, or on any external or internal surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as re- quired. If necessary remove acoustical material, clean all surfaces and then replace acoustical ma- terial. Any acoustical material with a protective cov- ering that has been tom or punctured should be re- placed immediately to prevent accumulation of liq- Uids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes. E, Disconnect the grounded (negative) battery ‘connection priorto attempting any repairs or clean- ing inside the enclosure. Tag the battery connec- tions so others will not unexpectedly reconnect it F. Keep electrical wiring, including the battery ter- minals and other terminals, in good condition. Re- place any wiring that has cracked, cut abraded or otherwise degraded insulation or terminals that are worn, discolored or corroded. Keep all terminals. clean and tight. G. Tum off battery charger before making or break ing connections to the battery. H. Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. |. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the ‘compressor with any known leaks in the fuel sys- tem. Tag the compressor and render it inoperative until repair can be made. J. Remove any acoustical material or other material that may be damaged by heat or that may support ‘combustion prior to attempting weld repairs. Re- move diesel engine ether starting aid cylinders and air line antiicer system components containing antitreeze compound, prior to attempting weld re- pais in any place other than the fuel system. DO NOT weld on or near the fuel system. K. Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when ser- vicing and operating the compressor. LL. Keep oily rags, trash, leaves, ltter or other com- bustibles out of and away from the compressor. M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine. N. DO NOT operate compressor under low over- hanging leaves or permit such leaves to contacthot exhaust system surfaces when operating the com- pressor in forested areas. ©. Ethyl ether used in diesel engine ether starting aid systems is extremely fiammable. Change cylin-ders, or maintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame or sparks. DO NOT instal, store or otherwise expose ether oylinders to temperatures above 160°F (71°C), Remove ether cylinder from the ‘compressor wien operating in ambient tempera- tures above 60°F (16°C). P.DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs. 5 serious personnel injury or property damage may result Q. DO NOT spray ether into compressor airfiter or into an air fitter that serves both the engine and the ‘compressor as serious damage to the compressor or personal injury may result R. Antifreeze compound used in airline anti—icer systems contains methanol which is flammable. Use systems and refill with compound only in well- ventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compoundto temperatures above 150°F (66°C). Vapors from the antifreeze com- pound are heavier than ait. DO NOT store com- pound or discharge treated air in confined or un- ventilated areas, DO NOT store containers or ant freeze compound in direct sunlight. S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression systems and detectors if so equipped. 1.5 MOVING PARTS ‘A. Keep hands, arms and other parts of the body and also clothing away from belts, pulleys and oth- er moving parts. B. DO NOT attempt to operate the compressor with the fan or other guards removed. C. Wear snug-ftting clothing and confine long hair when working around this compressor, especially ‘when exposed to hot or moving parts inside the en- closure. D. Keep access doors closed except when making repairs or adjustments, performing service orwhen starting or stopping the compressor. E. Make sure all personnel are out of and clear of the compressor prior to attempting to start or oper- ate it. F. Shut off engine before adding fue, fluid, coolant lubricants, airline antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders. G. Disconnect the grounded negative battery con- ection to prevent accidental engine operation prior to attempting repairs or adjustments. Tag the Section 1 SAFETY battery connection so others will not unexpectedly reconnect it. H. When adjusting the controls, it may require op- eration of the equipment during adjustment. Di NOT come in contact with any moving parts while aiusting the contol regulator an setting the en- gine RPM. Make all other adjustments with the en- Gine shut off. When necessary, make adjustment, ther than setting control regulator and engine RPM, with the engine shut oft. Ifnecessary, start the engine and check adjustment. if adjustment is in- cofrect, shut engine off, readjust, then restart the engine to recheck adjustment. |. Keep hands, feet, floors, controls and walking Surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibilty’ of slips and falls. 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS: ‘A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases. CC, Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assis- tance promptly in case of injury. DO NOT ignore ‘small cuts and burns as they may lead to infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A. DO NOT use air from this compressor for respi- ration (breathing) except in full compliance with OSHA Standards 28 CFR 1920 and any other Fed- eral, State or Local codes or regulations. Death or serious injury may occur trom inhaling ‘compressed air without using ‘proper safely ‘equipment. See OSHA standards, andlor any Federal, State or Local codes of regulations on safety equipment. B. DO NOT use air line anti—icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air ‘rom these systems into unventiated or other con- fined areas C. Operate the compressor only in open or well ventilated areas. D. If the compressor is operated indoors, dis- charge engine exhaust fumes outdoors. E, Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, ar in- takes servicing personnel areas or towards the air intake of any portable or stationary compressor.Section 1 SAFETY F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are typical ofthe industry. Care should be taken to avoid accidental ingestions andjor skin contact. In the event of in- gestion seek medical treatment promptly. DO NOT induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. G. Wear an acid—resistant apron and a face shield ‘or goggles when servicing the battery. Ifelectrolyte is spilled on skin or clothing, immediately flush with large quantities of water. H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with’ the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vorniting, but call a physician immediately. 1. Wear goggles or a full face shield when testi ther starting aid systems or when adding anti freeze compound to air line anti—icer systems. Keep openings of valve or atomizer tube of ether starting 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 iffumes iritate the eyes, they should be washed wih large quant ties of clean water for 15 minutes, A physician, pre- ferably any eye specialist, should be contacted im- mediately, K. DO NOT store ether cylinders or air line anti— icer system antifreeze compound in operator's ‘cabs or in other similar confined areas, LL. The antifreeze compound used in airline anti~ icer systems contains methanol and is toxic, harm- {ul or fatal it swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swal- lowed, induce voriting by administering a table- spoon ofsalt in each glass of clean warm water un- tilvomitis clear, then administer two tablespoons of baking soda in'a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. 1.8 ELECTRICAL SHOCK ‘A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel atleast 10 feet (@ meters} rom power lines and buried cables. D. Stay clear of the compressor during electrical storms! It can attract lightning. 1.9 LIFTING ‘A. If the compressor is provided with a iting bail, then lft by the bail provided. if no bail is provided, ‘then lift by sling. Compressors to be airlifted by he licopter must not be supported by the lifting bail, but by slings instead. In any event, lit only in ful compliance with OSHA Standards’ 29 CFR 1910 subpart N or any other Local, State, Miltary and Federal regulations that may apply. B. Inspect lifting ball and points of attachment for cfacked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts Or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition andhas arated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight of snow, ice, mud or stored tools and equipment. if your are unsure of the weight, then weigh compressor before liting, D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail E. Use guide ropes or equivalentto preventtwisting of swinging of the compressor once it has been lifted clear of the ground. FDO NOT attempt to lift in high winds. G. Keep all personnel out from under and away from the compressor whenever itis suspended. H. Lift compressor no higher than necessary. 1. Keep lift operator in constant attendance when- ever compressor is suspended. J. Set compressor down only on a level surface ca- able of supporting at least its net weight plus an additional 10% allowance for the weight of snow, ice, mud or stored tools and equipment. K. If the compressor is. provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels be- fore disengaging the liting hook B. Keep all parts of the body and any hand—held 1.10 ENTRAPMENT. tools or other conductive objects away from ex- posed lve pats of electrical system. Maintain cry footing, stand on insulating surfaces and DO Ni contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. . Attempt repairs only in clean, dry and well— lighted and vehtlated areas. ‘A. Make sure all personnel are out compressor be- fore closing and latching enclosure doors. B. Ifthe compressor is large enough to hold aman and ifit is necessary to enter it to perform service adjustments, inform other personnel before doin: 80, orelse secure the access door in the open posi- tion to avoid the possibilty of others closing and possibly latching the door with personnel inside.4.11 JUMP STARTING ‘A, Observe all safety precautions mentioned else- where in this manual. B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away. . Batteries contain acid which is corrosive and Poisonous. DO NOT allow battery acid to contact, eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid—resistant apron and face shield when attempting to jump start the compressor. D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells. E. Check fluid level. flow, bring fluid to proper level before attempting to jump start (not applicable to maintenance—frée batteries). F.DONOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60°F (16°C) before attempting to jump start or it may explode. G. Cover open cells ofall compressor batteries with clean dampened cloths before attempting to jump start H. Attemptto jump start only with avehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or bat- teries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start us- ing motor generator sets, welders or other sources of DC power as serious damage may result. |. Bring the starting vehicle alongside the compres- sor, but DO NOT permit metal to metal contact be- tween the compressor and the starting vehicle. J. Set the parking brakes of both the compressor if Proved) and the stating vehicle or otherwise jock both sides of all wheels. K. Place the starting vehicle in neutral or park, turn off all nonessential accessory electrical loads and start its engine. L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current. M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a Source of ignition. Section 1 SAFETY N, Poste battery terminals ae usually identified by a plus (+) sigh on the terminal and the letters POS adjacent to the terminal, Negative battery ter- minals are usually identified by the letters NEG ad- jacent to the terminal or a negative (-) sign. ©. Connect one end of a jumper cable to the posi tive (POS) (+) battery terminal in the starting ve- hicle, When jump starting 24V compressors and it the starting vehicle is provided with two (2) 12V bat- teries connected in series, connect the jumper cable to the positive (POS) (+) terminal of the un- grounded battery. P.Connect the other end of the same jumper cable tothe positive (POS) (+) terminal of the starter mo- tor battery in the compressor, or when jump star Ing 24V compressor, tothe positive (POS) (+) ter- minal ofthe ungrounded battery inthe compressor. Q. Connect one end of the other jumper cable to the grounded negative (NEG) (—) terminal of the battery in the starting vehicle, When jump starting 2aV compressors and ifthe starting vehicles pro vided with two (2) 12V batteries connected in se- fs. connect the jumper cable io the negatve (NEG) (-) terminal of the grounded. battery. R. Check your connections. DO NOT attempt to start a 24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V toone 12V bat- tery in the compressor. S.Connect the other end of this same jumper cable toa clean portion of the compressor engine block away from fuel lines, the crank case breather open- ing and the battery. Start the compressor in accordance with normal procedure. Avoid prolonged cranking, U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the Jumper cable from the engine biock in the compressor, then dis- ‘connect the other end of this same cable from the grounded negative (NEG) (—-) terminal of the bat- tery in the starting vehicle. Then disconnect the otherjumper cable fromthe positive (POS) (+) ter- minal of the battery in the compressor, or if pro- vided with two (2) 12V batteries connected in se- ries, from the ungrounded battery in the compres- sor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the un- grounded battery in the starting vehicle, tit is pro- Vided with two (2) 12V batteries connected in se- ties. \V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps.24 Section 2 DESCRIPTION INTRODUCTION The Sullair 600H, 600HH, 750, 750H, 750HH, 825, 900, 900H, and 1050 Portable Air Compressors offer superior performance and reliability while requiring only minimal maintenance. ‘The compressor is equipped with a Sulla rotary ‘screw compressor unit. Compared to other com: ressors, the Sullairis unique in mechanical reliabil ity and compressor durability. No inspection is re- quired of the working parts within the compressor unit ‘As you continue reading this manual and come to learn how the compressor operates and.is cared for, you will see how surprisingly easy itis to keep a Sul- air compressor in top operating condition Read Section 5 (Maintenance) to keep your com- pressor in top operating condition. Should any problem or question arise which cannot be an- Swered in his tex, contact your nearest Sula rep- resentative or the’ Sullair Corporation Service De- partment, DESCRIPTION OF COMPONENTS Refer to Figure 2—1. The components and assem- blies of the Sullair 60H, 600HH, 750, 750H, 750HH, £825, 900, 80H, and 1050 Portable Ai Compressors are clearly shown. The package includes a com- pressor unit, diesel engine, compressor system, compressor cooling and lubrication system, compressor discharge system, capacity contro! system, instrument panel and electrical system. The machine is also supplied with sound deadening insulation to lower noise emissions to Figure 21 Sullar Rotary Screw Portable Air Compressor ‘MINIMUM PRESSURE) (CHECK YALVE PRESSURE RELIEF VALVE. LOW PRESSURE CONTROL REGULATOR ENGINE SPEED CONTROL CYLINDER HIGH PRESSURE CONTROL REGULATOR ‘SUMP TANK PNEUMATIC AIR INLET VALVE ‘THERMAL VALVE/ FLUID FILTERS, DISCHARGE (CHECK VALVE2.3 24 meet EPA and/or any Federal, State, or Local noise requirement. The Sullair compressor unit is driven byan industrial engine designed to provide enough horsepower for more than adequate reserve at rated conditions. Refer to Engine Operator's Manu- al for a more detailed description of the engine. ‘Ths engine cooling system is comprised ofa ra- diator, high capacity fan and thermostats, The high capacity fan draws air through the radiator, keeping the engine atthe proper operating temper- ature. ‘The same fan also cools the fuid in the compressor cooling and lubrication, system. Prior to passing through the radiator, the fan air also passes through the compressor fluid cooler (which is mounted adja~ Centto the radiator). As air passes through the coot- gr, the heat of compression 1s removed from the uid. The same fan also cools the engines intake air sup- ply. Prior to passing through the radiator and oil cooler, the fan air passes through an air to air after- cooler, As air passes through the airto air aftercool- er heat is removed which was introduced by the en- Gino's turbo charger. The engine is coupled to the ‘compressor unit with a non—lubricated vulcanized rubber disc and drive flange type coupling. All ‘compressor models are supplied with a fuel tank large enough to keep the compressor running at full load through a full shift. ‘SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION Sullair compressors feature the Sullair compressor unit, a single-stage, positive displacement, flood lubricated=type compressor. This unit provides continuous (pulse—free) compression to meet your needs. With a Sullair_ compressor, no maintenance or inspection of the internal parts of the compressor unit is required with the warranty. Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three basic functions: 41. As coolant, it controls the rise of air temperature normally associated with the heat of compres- sion. 2. Seals the leakage paths between the rotors and the stator and also between the rotors them- selves. 8. Acts as a lubricating fim between the rotors allow- ing onerotortodirecty drvethe oer which san idler. Atter the ait/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows to your service line and the fiuid is cooled in preparation for re—injection. COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-2, 2-3 and 2—3A. The com- Section 2 DESCRIPTION pressor cooling and lubrication system is de- Signed to provide adequate lubrication as well as maintain the proper operating temperature of the ‘compressor. In addition to the cooler and fan, the system consists of a main filter and thermal valve. Fluid is used in the system as a coolant and a lubri- cant. The fluid is housed in the receiverisump which from this time on will be referred to as the sump. Upon start—up, the temperature of the fluid is cooi and routing to the fluid cooler is not necessary. The fuid, taking the path of east resistance, flows tothe thermal valve. ‘The thermal valve has two entrance ports and two exit ports. The entrance ports will be referred to as, Port Aand Port B. Port A accepts fluid from the sump and Port B accepts fluid from the cooler. The exit Ports will be referred to as Port C and Port D. Port C routes fluid to the cooler and Port D routes fluid to the compressor. AAs previously stated, upon start—up, the fluid tem- perature is cool, and routing to the cooler is not re- uired, The fluid first enters the thermal valve through Port A and then flows on to the compressor unit through Port D, bypassing the cooler. As the ‘compressor continues to operate, the temperature of the fluid rises and the thermal valve element be- gin to shit. This forces @ portion ofthe fu othe luid cooler through Port C. The cooleris a radiator— type nat works in conjunction with the engine fn. Te fan draws air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve, entering at Port B. Before the temperature of the fluid be- Comes high enough that Port A is completely shifted, cooled fluid entering at Port B is mixed with warmer fluid entering at Port A. When the tempera- {ure of the fluid entering at Port A reaches 170°F (77°C), the thermal element shifts completely caus- ing all fluid to flow to the cooler. The thermal valve incorporates a pressure relief valve, which allows fluid to bypass the cooler, if the cooler becomes plugged or frozen. This helps assure that fluid will Continue to be provided to the compressor for lu- brication. After the fluid passes through the thermal valve itis then directed through the main fluid fier. ‘There the fluid is fitered in preparation for injection into the compression chamber and bearings of the ‘compressor unit. The fitter has a replaceable ele- ment and a built—in bypass valve which allows the fluid to flow even when the fiter element becomes plugged and requires changing or when the viscos- ity ofthe fluid is too high for adequate flow. After the fiuid is properiy filtered, it then flows on to the com- pressor unit where itubricates, seals and cools the compression chamber as well as lubricates the bearings and gears. 2.8 COMPRESSOR DISCHARGE SYSTEM, FUNC- TIONAL DESCRIPTION Refer to Figures 2-2, 2-3, and 2~SA. The SullairSection 2 DESCRIPTION Figure 2-2 Compressor Discharge and Cooling and Lubrication System — All Models MNIMUM PRESSURE! CHECK VALVE ‘separator [1 ELEMENT | SERVICE AIR ourler compressor unit discharges compressed airfuid mixture into the sump. ‘The sump has three functions: 4. Itacts as a primary fluid separator. 2. Serves as the compressor fuid sump. ‘8. Houses the airfluid separator. ‘The compressed airfluid mixture enters the sump dis directed against the side wall. By change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the sump. ‘The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid col- lects on the element's surface, the fluid descends to the bottom of the separator. A return line (or scav- enge tube) leads from the bottom of the separator element to the inlet region of the compressor unit. 10 Fluid collecting on the bottom of the separator ele- ment is retumed to the compressor by the pressure difference between the area surrounding the sey Tator element and the compressor inlet. An ori (protected bya strainer) is included in this return|ine to help assure proper fiow. ‘The sump is ASME code rated at 190 psig (12.1 bar) working ‘pressure. A minimum pressureicheck valve, located downstream from the separator, helps assure a minimum receiver pressure of 55 psig (3.9 bar) during all conditions. This pressure is ecessary for proper air/fluid separation and proper fluid circulation. ‘Aminimum pressure/check valve at the outlet of the receiver is installed to prevent compressed air in the service line from bleeding back into the receiver on shutdown when the compressors being run in par- allel with other compressors ted toa large alr sys- mM.Section 2 DESCRIPTION Figure 2-3 Control System — 600H, 600HH, 750H, 750HH, 900H Models: ows 8 WAY LAD p UNLOAD SRMERESSOR Lee oy xn an REORCULATING } ' VANE ENGINE SPEED MANIFOLD REDUCING Soar Ean re I PRESSURE || HIGH PRESSURE can Soe | econo GAUGE nets ] aa vanaupressuner Crete le Poa A pie ~~ enean v I eg (FS ‘ies d service an PRESSURE GAUGE (ATINSTRUMENT. PANEL) FINAL FLUID. ‘SEPARATOR ELEMENT FLUID LEVEL | Fistor cause ‘COMPRESSOR! NT A INLET VALVE, | 4 LU 4 BLIZZ IL LEZ LILLE) * ‘THERMAL VALVE) FLUID FILTER = 2 ‘ASSEMBLY FLD. COOLER @ For detailed version of control valve, see Figure 2: Instrument Panel Group, in this secti "Section 2 DESCRIPTION Figure 2-3A Control System — 750, 825, 900, 1050 Models 3 — WAY esson (oA 9 UAH ea ees once (CYLINDER REDUCING MANIFOLD REGULATOR scum <] as ere el - eae ee ae oom mies ne, eae poo nga Ste LQ meer ie E a i cruo [aR E> ARFLUID FLD ‘COOLER 12 FLUID FILTER ‘ASSEMBLY THERMAL VALVE26 ‘The compressor unit discharges compressed ait/ fluid mixture through a discharge check valve into the sump. The discharge valve is located on the rear of the compressor unit at the end opposite the drive shaft. The discharge check valve prevents dis- charged air from returning to the compression chamber after shutdown, Fluid is added to the sump via a capped fluid filler. A fluid level gauge glass enables the operator to visu- ally monitor the sump fluid level. PENN) cootrenen Poa remem te iar ie ane Rome ios ELetacni 2 CONTROL SYSTEM, FUNCTIONAL DE- ‘SCRIPTION Refer to Figure 2-9 and 2~SA. The purpose of the control system isto regulate the amount of arintake in accordance with the amount of compressed demand. The control system consists ofan air let valve, a control regulator, a reducing regul tor, blowdown valve, recirculating valve, an er gine speed control cylinder, a start—run sel valve, a high-low pressure selector valve (150 psig machines only), and tubing connecting the var- tous components together. The functional descriptions of the control system are given below in three distinct phases of opera~ tion. These descriptions will apply to all control sys- tems. START ~ 0 TO 65 PSIG (0 to 4.5 BAR) COLD START Refer to Section 4.3 for complete starting instruc- tions. Before the compressor is started the start— run selector valve should be placed in the start posi- tion. The inlet valve is kept in the closed position by the main control springs. This helps assure mit mum load on the engine during starting, After star ing, system pressure wil rise slowly to 25 psig (1.7 bai). The selector valve directs system pressure from the reducing regulator to the control cylinder in the let valve and to tne engine speed conto cyin- der to keep the inlet valve closed and the engine at 1400 RPM idle speed. System pressure will stay at 25 psig (1.7 bar) as long as the selector valve re- Mains in the start position. After sufficient machine warm—up is achieved, turn warm-up valve to run position. This directs regu- lated air pressure behind the ‘inlet valve piston, ‘opening the inlet vaive, and behind the engine speed Control piston to bring the engine to full oper- ating speed. NORMAL OPERATION ~ 65 TO 100PSIG (4.5TO 6.9 BAR) Section 2 DESCRIPTION ‘When the sump pressure rises above 65 psig (4.5 bar) the minimum pressure/check valve opens and delivers compressed air to the service line. The startrun valve is in the run position. On dual pres- Sure (150 psig [10.3 bar]) machines the pressure selector vaive is in the low pressure position. 80 psig (4.1 bar) regulated pressure is maintained behind the inlet valve piston and behind the engine speed control cylinder to keep the inlet valve open and the engine at full rated speed for maximum air output. MODULATION 103 TO 116 ESiG| e317 9 ‘Should less than the rated capacity of air be used, the service line pressure will rise above 100 psig (6.8 bar). The control pressure regulator (labeled “High” in Figure 2-3) gradually opens, applying pressure tothe spring side of the inlet valve piston and speed control cylinder, This causes the inlet alive to partial- ly close and reduces the speed ofthe engine. With the service line closed and no air demand, the con- trol pressure regulator opens fully, closing the inlet valve, reducing engine speed to idle and opening a te-circulation. valve. ‘The re-circulation valve bleeds high pressure air back to the compressor in- let to prevent entrapment of fluid in the rotors. When air demand then increases, the sump pres- sure will fall below 115 psig (7,9 bar). The control pressure regulator vaive will close, which causes the recirculating valve to close, the inlet valve to ‘open and the engine speed to increase to full rated ‘speed. The compressor will hen be operating at full load condition DUAL PRESSURE - 150 PSIG (10.3 BAR) MOD- ELS & 175 PSIG (12.1 BAR) “HH” MODELS The high pressure “H® machines are equipped with a dual pressure system consisting of a second con- trol pressure regulator, a pressure selector valve and connecting lines (Figure 2~3). The standard control regulator is set up to 150 psig (10.3 bar)on “H" machines and up to 175 psig (12.1 bar) on “HH” machines. The second control regulator is set for 100 psig (6.9 bar). The pressure selector valve (lo- cated on the instrument panel) is open allowing a pressure signaltothelow pressure control regulator low pressure operation. Moving the selector valve to the *high’ pressure position closes the se- lector vaive, cutting off the air signal to the low pres- gure regulator, allowing the “high pressure reguia- tor to take over control of the system. ‘SHUTDOWN The blowdown valve is normally closed. When the compressor is shutdown, system pressure backs Up tothe inlet valve causing the check spring in the inlet valve to close the air inlet valve. This sends a pressure signal to the blowdown valve causing ito ‘pen and vent the pressure in the system. After the pressure is vented, the blowdown valve spring re- {furs the blowdown valve to the closed position. 1327 Section 2 DESCRIPTION AIR_ INLET SYSTEM, ‘SCRIPTION Refer to Figure 2—4. The compressor inlet system consists of one air filter, a compressor air inlet valve and interconnecting piping to the engine and compressor. Also, nylon tubing from air fiter restriction indicator gauges on instrument panel are provided. FUNCTIONAL DE- The air fiter is a 2~stage unit with a safety element dry element—type filter. This filter is capable of cleaning extremely dirty air, However, in such cases, {fequent checks ofthe airfiter willbe required. Re- ferring to the instrument panel, the engine air fiter restriction gauge or the compressor al iter restric: tion gauge will indicate when restriction of the air passing through the filter becomes too high. Figure 2—4 Air inlet System At this time, change the air fter element. See Sec- tion $ for Air Filter Maintenance Procedures. These indicators should be checked daily, after start-up under normal conditions. ‘The compressor air inlet valve controls the amount of airintake of the compressor in response to the air demand, 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DE- ‘SCRIPTION Refer to Figure 2-5, The instrument panel group consists of an EMS (Engine Montoring System). On the EMS unit there are ten warning lamps avall- able for system related dianostics. These dignos- tics can be used for system performance monitor- ing. They are located on the main EMS unit in two rows of five: coolant temperature, intake manifold temperature, fuel temperature, baitery voltage, ac- ENGINE AIR Ss INTER-COOLER COMPRESSOR AAR FILTER 14cessory temperature, engine oil pressure, fuel pres- ‘Sure, coolant level, engine derate, and accessory pressure, See Figure 2-5 for functional lamps. Beneath the warning lamps is a digital LCD display to scroll through different engine and machine pa- rameters. Digital readouts are as follows: + engine speed: SPd * engine oil pressure: GA-1 + coolant temperature: GA-2 GA-3 + fuel pressure (not used): GA-4 + engine boost: boosE + intake manifold temperature: LAIRE + fuel temperature: FUELE + accessory pressure (not used): ACCR P + accessory temperature (not used): ACCRE + fuel rate: FUEL Section 2 DESCRIPTION ‘engine running hours: HRS + percent engine load: LOAd Refer to Figure 2—5A for locations of the following indicators and control + The warning lamp is on or flashing when an en- gine operation problem had been detected by the engine electronics. This usually does not indicate an electronic mafunction. This light can be used along with the EMS lights to determine matfunction. Consult Table 1 for engine to warning lamp actions. Time To Shutdown is defined as the time before the engine will shut down following intial activation ofthe diagnostic code, Itis assumed the engine has been running for at least 30 seconds before diag- notic code activation. +Start/Restart Time is defined as the time before a shutdown occurs if conditions causing the diagnos- tic code(s) are present at start up. « ae Gale ne tse mea espe SS 2 eee oo SSeS a 2 ee a a ——— = eee —— Let aa Baie 3 p= ees —— ee = pene = ieee [ee —- te = ee panes te - eee ae we ae eae le * Ee - eee eee | 5 oS Bits oes Z ee : 2 ee oe 19Section 2 DESCRIPTION Figure 2-6 Electrical System3.1 TABLE OF SPECIFICATIONS ‘SPECIFICATIONS Section 3 SPECIFICATIONS M ri th in mm in mm in mm b ka. 60H, 60OHH, 750, 750H & 750HHDTQ (Tandem) 191 «4851872210 89.75 2280 60H, G0OHH, 750, 750H & 7S0HH DPQ (4-Wheel) 204 5182 87 «221097 600H, 600HH, 750, 750H & 2464 2032 10045 4554 10195 4622 9870 4874 750HH DLQ (LRG) 131-3327, «87-2210 80 () Length including drawbar where applicable. (At) Over ting bal COMPRESSOR: Model: 600H, 600HH, 750, 750H, 750HH, Bill of Material: ‘See Compressor Serial Number Plate Rotary Screw Type: Dalvery @ Operating Pressure: 60H Free CFM (283\/s) @ 150 psig (10.3 bar) ~ 150 psig (1 600HH Free CFM (2831/s) @ 175 psig (12 bar) — 175 psig ((1 750 Free CFM (355i/s) @ 125 psig (8.6 bar ‘750H Free CFM (3551/s) @ 150 psig (10.3 bar) — 150 ‘7B0HH Free CFM(355\/s)@ 175 psig (12 bar) ~ 175 psig (1 Cooling: Pressurized Compressor Fluid Lubricating Compressor Fluid: See Lubrication Guide - Compressor ‘Sump Capacity: 21 US. Gallons (80 liters) Track Width ~ (TQ): 77 in, (196mm) ‘Track Width — (OPQ): 7355 in. (2018mm) Tire Size (Load Range) DTQ: 9.50 16.5 LT (E) Tire Size (Load Range) DPQ: -8.75X 16.5 LT Tire Pressure (DTQI) 100 psig (7 bar) Tire Pressure (DPQ): 60 psig (4 bar) Wheel Size (TQ): 165x675 Wheel Size (DPQ) 165x675 Wheel Bolt/Lugnut Torque: 80 ~ 90 ft.—Ibs. (108.5 — 122Nm) Operating Tit (maximum): 15° Electrical System: Engine ~ 24 Vott Instrument System — 24 Vott Battery (2) (4D) 1010 cca. Value at 0°F (-18°C) Alternator: 35 amp Sound Level: 76 dBA at 7 meters ENGINE: Make: Caterpillar Modei: cs Rated speed: 4800 RPM Horsepower, SAE: 275 HP (205kw), SOOHP (224kw) Cylinders: 6 Cycles: 4 Bore x Stroke: 4,41 x 6.00 inches (112 x 149mm) Displacement: 538 cu. in. (8.8 liters) Lubricating System: Full Pressure Oil Type of Motor Oil: Refer to Engine Operator's Manual Fuel Tank Capacity 120 US. gallons (454 liters) Radiator Capacity: 14.75 US. gallons (65.8 liters) Idle Speed: 1400 RPM .3 bar) max. 0. 2 bar) max. be = 149 pag (0.7 ban max psig (10. 8 bar) max. 2 bar) max. 21Section 3 SPECIFICATIONS ‘SPECIFICATIONS M ri ip 825, 900 & 900H 1050 DTQ (Tandem) 191 825, 900 & S00H 1050 DPQ (4—Wheel) 204 825, 900 & 900H 1056 DLQ (LRG) 131 ni Height a mm ib mm in mm b ka 4851 87 = 2210.89.75 2280 10045 4554 5182 87221097 2464 10195 4622 3327 87 «= 2210 8020829870 4474 ) Length including drawbar where applicable. (At) Over iting bal COMPRESSOR: Model: Bill of Material: Type: Delivery @ Operating Pressure’ Cooling: Lubricating Compressor Fluid: Sump Capacity: Track Width ~ (OTQ): Track Width — (OPQ) Tye $28 (Load Range} 079: Tire Size (Load Range) DPQ! Tire Pressure (DTG) Tire Pressure (DPQ): Wheel Size (OTQ): Wheel Size (DPQ): Wheel Bolt/Lugnut Torque: Operating Tit (maximum): Electrical System: Battery (2): Alternator: Sound Level: ENGINE: Make: Model: Rated speed: Horsepower, SAE: Cylinders: Cycles: Bore x Strok Displacement: Lubricating System: Type of Motor Oi Fuel Tank Capacity: Radiator Capacity: Idle Speed: '825, 900, 900H, 1050 ‘See Compressor Serial Number Plate Rotary Screw 825 Free CFM (389 l/s) @ 100 psig (6.9 bar) — 140 psig ( 9.7 bar) max. 900 Free CFM (425 l/s) @ 100 psig (6.9 bar) — 125 psig ((8.6 bar) max. SODH Free CFM (42518) @ 100 pag (6.9ar) ~ 190 pig (10.8 bar) max. 1050 Free CFM (496 l/s) @ 100 psig (6.9 bar) — 128 psig (6.6 bar) max. Pressurized Compressor Fluid ‘See Lubrication Guide — Compressor 21 US. Gallons (80 liters) 77 in, (1956mm) 78.5 in, (2019mm) 9.50 x 16.5 LT (©) 8.75 X 16.5 LT 100 psig (7 bar) 60 psig (4 bar) 165x675 165x675 80 - 90 Ibs. (108.5 - 122Nm) Engine ~ 24 Volt Instrument System — 24 Vott (4D) 1010 cca. Value at 0°F (-18°C) 35 amp 76 dBA at 7 meters Caterpillar ce 1800 APM. 275 HP (197kw), S00HP (224kw) 6 4 4.41 x 6,00 inches (112 x 149mm) 538 cu. in. (8.8 liters) Full Pressure Oil Refer to Engine Operator's Manual 420 US. gallons (454 liters) 14.75 US. gallons (55.8 liters) 4400 RPM 223.2 LUBRICATION GUIDE - COMPRESSOR FLUID TYPE. CHANGE PERIOD, HOURS. Sullair AWF 1200 D-A Torque Fluid 300 SAE10W SE, SF SG, CD 300 MIL-L-2104E 10W 300 Section 3 SPECIFICATIONS ‘AMBIENT TEMPERATURE RANGE “F (°C) =20 to 120 (-29 to 49) 10 to 110 (-12to 43) Oto 100 (—18 to 38) 0 to 100 (-18 to 38) (© Sulit part numbers for multi-viscosty lubricants are 250000-757 (6 gallons/18.9 liter) 250080-758 (65 gallon/208 liter drum). 3.3 APPLICATION GUIDE Sullair Air Compressors are supplied with Sullair AWF which is heavy duty multi—viscosity, all~ ‘weather fluid. Sullair AWF also allows an extended change interval. Detergent motor oils (SAE 10W Class SE,SF, SG or CD). Any can also be used. Any of these olls are suitable under conditions where se- ‘vere oil oxidations can occur. ‘Water must be drained from the receiver periodical- ly. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a “milky” color. ATF or SAE 10Wises- ‘lly pone to his condition, The fué should be changed if this condition develops. DO NOT mix types of fiuids. Combinations of dffer- ent fluids may lead to operational problems such as foaming, fiter plugging, orifice or line plugging. When ambient conditions exceed those noted or if conditions warrant use of other extended life lubri- ants, contact Sullair for recommendations, Sullair encourages the user to participate in a fluid analysis program. This could result in a fluid change interval differing from that stated in the manual. Sull- ait Corporation offers a fluid analysis program for Sullair AWE, Contact your local Sullair representa- tive for details. D-A Lubricant? Company Inc. offers an analysis program for users of DA products and Sullair AWF. Contact your DA lubricant supplier or Sullairrep- resentative for details. 3.4 LUBRICATION GUIDE ~ ENGINE For engine oil specifications, refer to the Engine Op- erator’s Manual. 23Section 4 OPERATION 4.1 GENERAL While Sulla has built into this compressor a com- prehensive array of controls and indicators to as- Sure you that itis operating properly, you will wantto for service or indicate the beginning of a malfunc- tion. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators — their purpose, location recognize and interpret the readings which will call and use. 4.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR PURPOSE 24 ENGINE SWITCH VOLTMETER AIR PRESSURE GAUGE ENGINE WATER TEMPERATURE GAUGE EMS (ENGINE MONITORING SYSTEM) COMPRESSOR DISCHARGE TEMPERATURE. GAUGE ‘SYSTEM PRESSURE SWITCH FLUID LEVEL SIGHT GLASS COMPRESSOR DISCHARGE TEMPERATURE ‘SWITCH REDUCING REGULATOR VALVE CONTROL REGULATING VALVE The engine switch is used to both energize the compres sor's electrical system and engage the engine/starter. The rotary type switch works similar to an automotive key switch; itturns in a clockwise direction with “off” being the first position, “ignition® the second and “start” being the third position It also has a built-in antirestart device that protects the starter from engaging while the engine is tunning. The switch mustbe turned back tothe “off pos tion betore the engine can be re-started. ‘When ro~starting the compressor, make sure recelv- ‘er tank pressure has blown down to 10 pelg (07 bar) ‘Floss, More than 10 psig (0.7 bar) can putetra load ‘on the starter. Monitors the condition of the batteries and the charging Circuit. The normal reading is 24 to 28 volts. Continually monitors the pressure inside the receiver tank at various load and unload conditions. Monitors the temperature of the engine water. The normal operating temperature should read approximately 160°F to 210°F (71°C to 99°C) Depicts system related diagnostics. Can be used for sys- tem performance monitoring, Monitors the temperature of the aiifiuid mixture leaving the compressor unit. The normal reading should be approximately 180°F to 210°F (82°C to 89°C). Prevents starter engagement when the air system is pres- surized. ‘Monitors the fluid level in the sump. Proper level is always visible in the sight glass. Check the level when the com- pressor is shutdown. Opens the electrical circuit to shut down the compressor when the discharge temperature reaches 250°F (121°C) Provides regulated air pressure to the inlet valve and en- gine speed control to open the inlet valve and move en- ine speed cylinder to full speed with warm—up valve in the “run” posttion.. Provides an air signal to the inlet valve and engine speed cylinder to close the inlet valve and reduce engine speed to control air delivery according to demand.4.2 PURPOSE OF CONTROLS (continued) CONTROL OR INDICATOR MINIMUM PRESSURE/CHECK VALVE HI/LO SELECTOR VALVE PRESSURE RELIEF VALVE PRESSURE REGULATOR AIR INLET VALVE BLOWDOWN VALVE ‘THERMAL VALVE START/RUN CONTROL VALVE RUNNING BLOWDOWN VALVE COOLANT LEVEL DETECTOR RE—CIRCULATION VALVE 4.3 INITIAL START-UP PROCEDURE ‘The following procedure should be used to make the intial start—up of your compressor: 1. Position the compressor on a level surface so that proper amounts of liquid can be added if neces- sary. (I) .Ifneeded, add a water and ethylene glycol solu- tion to the engine radiator. Engine cooling sys- tem capacity is 21 gallons (80 liters). Fill compressor fluid sump with fluid as recom- mended in Section 8, Specifications. System ca- pacity is 45 gallons (171 iiters), Check engine oil level and add if necessary. Fill the fuel tank Fill the battery with electrolyte, f necessary. Glose and latch all doors except instrument panel joor. Close all service vaives and turn arrow on start— Tun valve handle down to “start” position. Below 40°F (4°C) use starting aid (per instruc- tions printed on starting aid device). 10. Turn engine switch to the “ignition” position. 4 5. 6. 7. 8. 9. Section 4 OPERATION PURPOSE Maintains a minimum of 65 psig (4.5 bar) in the compres- sor sump. This valve restricts receiver air discharge from receiver/sump when pressure falls to 65 psig (4.5 bar).. Also prevents back fiow into the sump during unload con- ditions and after shutdown, Select high pressure (150 psig) or low pressure (100 psig) at instrument panel to correspond to operator's needs. Opens sump pressure to the atmosphere should pres- sure inside the sump exceed pressure relief valve setting. (Opens a pressure line between the sump and inlet valve allowing inlet valve to regulate air delivery according to air demand. Regulates the amount of air allowed to enter the air inlet valve. This regulation is determined by the amount of air being used at the service line. Vents sump pressure to the atmosphere at shutdown Regulates flow of fluid to and around the fluid cooler. De- signed to maintain a minimum operating temperature: Used for fast warm—up at start—up and to eliminate con densation during operation. Allows the engine to run at unload speed (lower pressure) until properly warmed up. Vents surplus sump pressure to the atmosphere during operation. ‘Shuts the compressor down and/or will preventit from be- ing started if the engine coolant level drops too low. Normally closed. Open when pressure in the spring ‘chamber exceeds spring. 11. Turn engine switch to “start” position and hold un- til engine starts (maximum 15 seconds). 12. When engine coolant temperature reaches 190°F (64°C), turn arrow on start—run valve handle to RUN’ position. Compressor is now ready for ful load operation. 18. After the intialrun, shutthe compressor downand refill the radiator ‘and compressor fluid sump as feguited Tighten any loose tings and check an belt tension (D The radiator is filed with a 50/50 mixture of ethy!- ene glycol and water at the factory before shipment. 4,4 SUBSEQUENT START-UP PROCEDURE ‘On subsequent starts, follow the procedure ex- plained below: 1. Position compressor on level ground so fluid level ‘can be read accurately. Check fluid level and add as needed. 2. Close and latch alldoors except instrument pane! joor. 2526 Section 4 OPERATION 3. Close all service valves and turn arrow on start— run valve handle down to “start” position. 4, Below 40°F (4°C) use starting aid (per instruc- tions printed on starting aid device). 5, Turn engine switch to the “ignition” position. 6. Tum engine switch to “start” position and hold un- til engine starts (maximum 15 seconds). 7.When engine coolant temperature reaches 10°F (54°C), turn arrow on start—run valve han- dle upward to “RUN” position. 45 8. Compressor is now ready for full load operation. ‘SHUTDOWN PROCEDURE To shut the compressor down, close the service valves and tur the start/run control valve to the “stat” poston. Run compressor for approximately '5 minutes; then turn the “on/off” switch to the “ position. In case of emergency where immediate Shutdown is required, this procedure Is not neces- sary, The “on/off” switch should be put in the “off” Position immediately.5.1 GENERAL ‘A good maintenance program is the key to long ‘compressor fe. Below is a program that when ad- heredto, should keep the compressor in top operat- ing condition. For engine maintenance require- ments, refer to the Engine Operator's Manual for a detailed description of service instructions. See Parts Replacement and Adjustment Procedures for a detalled description of specific compressor sys- ‘tem components. Prior to performing maintenance, read the CIMA Safety Manual, if applicable. TEN) DO NOT remove caps, plugs andior other com- onents when compressor fs running oF pres Cursed. Stop compressor and relieve al internal pres- Sure betore doing eo. 5.2 DAILY OPERATION Prior to starting the compressor, itis necessary to ccheck the fluid Ievelin the sump. Should the level be low, simply add the necessary amount. If the addi- tion offiuid becomes too frequent, a simple problem has developed which is causing this excessive loss. See the Troubleshooting Section (5.11) under Ex: cessive Fd Congumption fora probable cause and remedy. Also check the engine oil level and the radiator coolant level prior to starting Baaettamueerncote mente Blacethe coolatwiths solution of 9s eye ‘After a routine start has been made, observe the in- strument panel gauges and be sure they monitor the correct readings for their particular phase of op- eration. After the compressor has warmed up, itis recommended that a general check on the overall compressor and instrument panel be made to as- ‘ure that the compressor is running propery, Also check the air iter restriction gauges. Should they indicate restriction, replace the elements immedi- ately (see Air Filter Maintenance in Section 5.10) 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation, a few simple ‘maintenance routines can rid the system of any pos- sible foreign materials, if any. Perform the following maintenance operations to prevent unnecessary problems. 4. Clean the return line orifice and strainer. 2, Change compressor fluid fier Section 5 MAINTENANCE 3. Check Engine Operator's Manual for required service. 5.4 MAINTENANCE EVERY 100 HOURS After 100 hours of operation, i will be necessary to perform the following: 4. Check the battery level and fil with water itneces- sary. 2. Chick Engine Operator's Manual for required sence. 5.5 MAINTENANCE EVERY 250 HOURS Perform the following after every 250 hours of opera- tion: 1. Check fan belt tension. 2. Clean the radiator and cooler exterior. Depending ‘on how contaminated the atmosphere may be, more frequent cooler and radiator cleaning may be necessary. To clean between fluid cooler and radiator, the three (3) bolts securing the top of the fluid cooler to the top mounting bracket should be removed, allowing the fluid cooler to swing down on its lower hinge. This will allow easier ac- ess to clean between the fluid cooler and radia- tor cores. 3. Check Engine Operator's Manual for required service. 5.6 MAINTENANCE EVERY 300 HOURS ‘When using fiuids other than Sullair AWF, change the compressor fluid and replace the fluid filter ele- ment (See maintenance procedure in Section 5.10). 5.7 MAINTENANCE EVERY 600 HOURS When using Sular AWE, replace the id fiter ele ‘ment only (See maintenance procedures in Section 5.10). 5.8 MAINTENANCE EVERY 1000 HOURS Perform the following after every 1000 hours of op- eration: 1. Clean the return line orifice and strainer. 2. Repack the wheel bearings on wheel-mounted units, 5.9 MAINTENANCE EVERY 1200 HOURS ‘When using Sullair AWF, change the compressor fluid and replace the fluidfiter element (See mainte- nance procedures in Section 5.10). 5.10 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES COMPRESSOR FLUID CHANGE PROCEDURE Warm-up the compressor for 5 to 19 minutes to warm the fluid. Shut the compressor off and relieve all intemal pressure before proceeding. Drain the fluid sump by removing the piug at the bottom of the sump tank. Change the compressor fiuid and re- place the fiuidfiter element. For element replace- ment see progedure for servicing the fd itr in this section. Fill the sump with fluid according to specifications in Section 3. RUNNING GEAR LUBRICATION Refer to Figure 51. An inspection of the running gear should be made on a routine basis. On four orSection 5 MAINTENANCE Figure §—1 Running Gear Lubrication Figure 5-2 Typical E~Z Lube Axle INNER BEARING RUBBER PLUG GREASE FLOW GREASE FITTING j [METAL END CAP ‘SPRING LOADED DOUALE LIP SEALFigure 5-3 Main Filter (PIN 02250049-934) Section 5 MAINTENANCE Lower HOUSING O-RING? 5S ‘THERMOSTAT ELEMENT? ———_ FILTER ELEMENTS + Repair ki for thermostat element ~02250087-682 ‘Replacement element part number (2 required) -250025—525, ———— carscrew WASHER wheel steerable running gear models, front axle piv- ot joints and rod ends are fitted with grease zerks which should be lubricated every six months. WHEEL BEARING LUBRICATION Refer to Figure 5-1 and 5~2. Proper lubrication is essential to the proper functioning and reliabilty of your portable compressor axle. Wheel bearings should be lubricated at least once every 12 months, for more frequently to help insure proper perfor: mance. Use wheel bearing grease that conforms to military specification MIL=G~ 10924 or a high tem- erate wheel bearing grease such as lithium com- plex NLGI Consistency #2. Iyour axle is equipped with the E-Z Lube feature, ‘the bearings can be periodically lubricated without removing the hubs from the axle. This feature con- sists of axle spindles that have been specially diilled and fitted with a grease zerk in their ends. When grease is pumped into the zerk, it is chan- neled to the inner bearing and then flows back to the outer bearing and eventually back out of the grease cap hole (see Figure 51). The procedure i as follows: 1. Remove the rubber plug from the end of the grease cap. 2. With a standard grease gun filed with a quality wheel bearing grease, place the gun onto the ease zerk located in the end of the spindle. lake sure the grease gun nozzle is fully en- gaged onthe fting 3, Pump grease into the zerk, The old, displaced {grease will begin to flow back out the cap around the grease gun nozzle. 4, When the new, clean grease is observed, remove the grease gun, wipe off any excess, and replace the rubber plug in the cap. SERVICING THE MAIN FLUID FILTER Refer to Figure 5~3. The main fluid fiters (P/N 02250049934) are iocated schematically in the coolant line between the receiver/sump and the compressor unit. The main fiter elements are re- \laceable. For installation of the fier elements (P/N. 250025520), folow the procedure explained be- Ww. 1. The compressor MUST be shut off and system ressure MUST be relieved. 2. Position a suitable container beneath the ele- ments to catch fluid drainage, 20Section 5 MAINTENANCE Figure 5: Air Filter ~ Engine and Compressor HOUSING COLLECTOR 7 Brimary Fier Element Pn o4eaea, ** Secondary Filter Element P/N 048463 ‘SECONDARY ELEMENT ‘SEALING WASHER: Remove elements using a suitable tool. Rotate each element counterclockwise to re- move. Remove element and discard. These elements are NOT cleanable. Make certain that the: mounting surfaces of the filter heads are clean, . Apply a light film of clean fluid to each element gasket surface, . Center the new elements on fiter housing heads and tighten until the fiter gaskets make contact, to the fiter housing. After gaskets makes con- tact, tighten 1/2 to 2/3 turn, 8, Run compressor and check for leaks. AIR FILTER MAINTENANCE Refer to Figure 5~4. Airfiter (PIN 048456 for engine and compressor) maintenance should be per formed when indicated on instrument panel by the engine air fiter restriction gauge. The air fiters are both equipped with a primary element and secon- dary element each. 30 1DONOT strike eloments against any hard surface to dislodge dust. This wll damage the sealing sur- {aces and possibly rupture the elements. The secondary element must be replaced after ev- ery third primary element change. DO NOT recon- ect the secondary element once itis removed ELEMENT REMOVAL 4. Clean the exterior of the air fier housing, 2, Remove the cover/element assembly by ioosen- ing the wingnut securing the cover/element as- sembly. 8, Remove the cover/element assembly from the housing by unscrewing the wingnut. 4. Clean the interior of the housing by using a damp cloth. DO NOT biow out dirt with compressed air this may introduce dust downstream ofthe fir ,Section 5 Figure 55 Control System Components — 750, 825, 900, 1050 Models RECIRCULATING VANE PNEUMATIC ono INLET VALVE VALVE ENGINE SPEED ‘CONTROL CYLINDER PRESSURE Gauge REDUCING. REGULATOR PRESSURE \ CONTROL REGULATOR WaRi-uP VALVE, 5, When it becomes necessary to remove the sec- ondary element, pulthe elementoutofthenous- ing 6. Install the new secondary element over the rod. 7. With the secondary element in place, replace the primary element. ELEMENT INSPECTION 1. Place a bright light inside the element to inspect for damage or leak holes. Concentrated light will shine through the element and disclose any holes. 2. Inspect all gaskets and gasket contact surfaces ofthe housing, Should faulty gaskets be evident, correct the condition immediately. 8. Ifthe clean element is to be stored for later use, it ‘must be stored in a clean container. 4. After the element has been installed, inspect and tighten all air inlet connections prior to resuming operation. PRIMARY ELEMENT REPLACEMENT 1. Place the element in position over the threaded tod and tighten the wingnut. 2. Install the cover, replace the clamp and tighten the wingscrew. CONTROL SYSTEM ADJUSTMENT Ree to Figure 6-5 or S—SA, of contol schematic (Figure 2-3). Prior to adjusting the control system, i is necessary to determine the desired operating pressure range as wellas the maximum pressure at ‘which the machine is to operate. This pressure must not exceed the maximum operating pressure which is stamped on the machine serial number plate. The following explanation applies to a typical machine with a desired operating range of 100 to 110 psig (6.90 7.6 bar). This information will apply to a ma- Chine with any other operating range except for the stated operating pressure. For high pressure ma- 31Section 5 MAINTENANCE Figure 5-5A Conrol System Components 600H, 600HH, 750H, 750HH, 900H Models ENGINE SPEED ‘CONTROL CYLINDER LOW PRESSURE CONTROL REGULATOR HyLOW, PRESSURE ‘SELECTOR chines, adjustment pressures are shown in paren- thesis. 1. Startthe machine and letitwarm —up with warm= Up valve in “start” position. On high pressure ma chines place pressure selector valve in the "high” ition. Check for leaks around connections. 2.0pen service valve slightly and turn the warm—up valve to “run” position. Slowly close the service valve, watching the pressure gauge to insure the unload pressure does not exceed 125 psig (8.6 bar) (170 psig [11.7 bar] for “H” machines) (185 sig [12.8 bar] for“ HH” machines .Ifitdoes, the Control regulator set screw must be backed out until the compressor will unload. With service valve closed, check and adjust the pressure at the reducing regulator for a 60 psig (4.1 bar) set ting. With service valve stil closed, adjust the control regulator (high pressure regulator on 150 psig [10.8 bar] machines) to maintain a dis- charge pressure of 115 psig. (79 Bar) on low pressure machines (100 psig 6 9bar), (180 ps9 32 RECIRCULATING PNEUMATIC. INLET VALVE onICE [11,0 bar] on “H" machines) (185 psig [12.8 bar] for “HH” machines. Check the idle speed setting and adjust the threaded rod in the speed control cylinder to maintain 1400 RPM. Open the service valve to load the compressor to maintain 100 psig (6.9 ba (150 poi [10,3] on “H’ machines) (185 psig [12.8 bar] for “HH” machines dis- charge pressure. Check to see that the engine throttle lever is against the high speed stop ‘screw. Ifitis not, the control regulator setting may have to be raised. Set ull oad operating speedto 4800 RPM by adjusting the high speed stop screw. 3, For 150 psig (10.3 bar) and 175 psig (12.1 bar) machines turn the pressure selector valve to “low” position. Close the service valve and set the low pressure control regulator to maintain 145 psig (7.9 bar) discharge pressure. Open the service valve to maintain 100 psig (6.9 bar) and check for 1800 RPM full load speed. If lower speed is observed, raise the setting of the lowFigure 5~6 Separator Element recone — | vane + Repair Kit P/N 250034—086 pressure control regulator until rated speed is achieved, ‘SEPARATOR ELEMENT REPLACEMENT Refer to Figure 5-6. When fluid carry-over is evi- dent after the fluid return ine strainer and orifice, as well as the blowdown valve diaphragm, have been inspected and found to be in satisfactory condition, or ifthe separator restriction gauge reads in excess of 10 psig (0.7 bar), separator element replacement (PIN 250034 086) is necessary. Follow the proce- dure explained below. 1. Remove all piping connected to the sump cover to allow removal (return line, service ine, etc.) 2. Remove the fluid return line from the fitting in the cover. TROUBLESHOOTING Section 5 MAINTENANCE 3. Remove the twelve (12) 5/8" x 2.25” cover bolts ‘and washers and ifthe cover fromthe sump with the minimum pressure/check valve in place. 4, Remove the separator element. 5. Scrape the old gasket material om the cover and the flange on the sump. Be sure tokeep all scrap- ings from falling inside tank. 6. Install the gaskets. 7. Make sure grounding staples are attached to sep- arator gasket. DO EMOVE STAPLES. 8, Replace the sump cover and bolts. Run the cover, bolts in finger tight, then graduaily tighten in a crisscross pattem in 4 to 5 steps. Always tighten the bolts alterately at opposite sides of the cov- ef. Never tighten bolts adjacent to each other. ue bolts to 112 to 127 ft.—Ibs. (151 to 172Nm). 9, Reconnect all piping. The fluid return line should extend to the bottom of the separator element or ‘no more than 1/16" (1.6mm) up from the bottom, This will assure the proper fluid return flow. 10. Cleanthe fluid retum line strainer and clear the ori- fice prior to restarting the compressor. 5.11 TROUBLESHOOTING The following Troubleshooting Chart is based on both the data obtained from actual tests conducted at our factory and real applied situations. itcontains symptoms and usual causes for the described problems. However, DO NOT assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or compo- nent replacement procedures. ‘A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the compressor. Always re- member to: ‘+ Check for loose wiring. + Sheck for damaged piping, = Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem peri ater making the rec: ‘ommended check, consult your nearest Sullair rep- resentative or the Sullair Corporation. ‘SYMPTOM PROBABLE CAUSE REMEDY ‘COMPRESSOR WILL NOT START No Fuel (Check tuol level and add fuel necessary Plugged Fuel Fiter Replace the element. Low Battery Voltage Check electrolyte lel and add distiled wator and recharge tinecessary. Loose battery cables; tighten cables. Dirty battery cables; clean thoroughly. Plugged Air Fiter Replace the element 33Section 5 MAINTENANCE ‘TROUBLESHOOTING (continued) SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR WILLNOT START Engine Problems May Have (continued) Developed Refer to Engine Operator's Manual. Tripped Circuit Breaker on Inatrument Pane! (Check and reset necessary. COMPRESSOR SHUTS DOWN No Fuel (Check fuel gauge and ad fuel necessary WITH AIR DEMAND PRESENT ‘Gompresor Discharge Temperature ‘Swatch Opon Ps Tipped Circuit Breaker on instument Panel Cooling air ow sinsuficient; clean cooler land check for proper ventlation. Low uid sump level; ad hi Dirty compressor fui fiter; change element ‘Thormostatc element isnot functioning property change the thermostatic elrent Defective discharge temperature switch; ‘hock for shor or open eu tothe. engine fuel solenoid. Should this chock ut normal, could be possible that tho Temperature switch tse is defective. (Check and reset i necessary. COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE IMPROPER UNLOADING WITH AN EXCESSIVE PRESSURE BUILD-UP (CAUSING PRESSURE RELIEF VALVE TO OPEN ‘Ar Demand is Too Great Diy Ai Fiter Pressure Regulator Out of Adjustment Defective Pressure Regulator Defective Air nat Cylinder Fuld Charge Lost trom Spring Chamber oniietVabe mms Pressure Regulating Vato Set ‘eorigh Running Blowdown Valve Pressure Fogulatng Vale Set Too High Leak in Control System Causing {ss of Pressure Signal (Check service ines fr leaks oF open valves Chock the titer gauges on instument panel and Shange loment if rogue. " ‘Adjust regulator according to control {ajustmentinstuctions nthe Maintenance sector. ‘Chock diaphragm and replace Hf necessa thtavalabi) 9" °F * Replace cylinder. ‘Addi lt vale spring chamber by remain bigs htop often caroer 0 nating wit Sompressor fas. Some fuid may ieak rom the cont regulator a rst but wi stp ating when fl lvl sping haber equalize Readjust Readjust (Check contol ines. 34TROUBLESHOOTING (continued) SYMPTOM IMPROPER UNLOADING WITH AN. EXCESSIVE PRESSURE BUILD-UP ‘CAUSING PRESSURE RELIEF VALVE TO OPEN (continued) ‘PROBABLE CAUSE. Leak in Control Systom Causing Loss of Pressure Signal Int Valve Jammed Restriction in the Control Systm Detective Prossure lit Valve Section 5 MAINTENANCE REMEDY Wor geisn int va, Replace sole (t available). vet . Dsecve pressure gusting vahes; ope vhs (a avatabiay =NsP Free o replace vate, CCheck all contol ines and components lee and other contaminants could cause reetrtons, Replace pressure rei valve. INSUFFICIENT AIR DELIVERY Plugged Air Fiter Plugged AirFuid Separator Defective Pressure Rogulator Replace. Replace soparater element and also change ompressor fd and ha for at sto. [Adjust o repair Engine Speed Too Low Readjust engine speed. Control ir Cynder Detective Replace cylinder. EXCESSIVE COMPRESSOR. ‘Clogged Return Line tear ore FLUID CONSUMPTION. Leak inthe Lubrication Systom Check all pipes, connections and components ‘Separator Elament Damaged or Not Punetioning Proper ‘Change separator eloment. Defect Minimum Pressure} Check Valve Repair o replace. Fluld Sump Overiled Drain to proper level COMPRESSOR OVERHEATING Loose or Broken Fan Bett, Tighten or change bet Dirty Fld Cooler Core Dirty Atorcooler ity Raclator Core Fauly Thermostat Element Plugged Fluid Cooler Tube (Intrna) Low Sump Fluid Level Plugged Compressor FuidFiter Clean core thorough Clean core thorough. Ciean cor thoroughly. Change thermostat element ‘Clean tube thoroughly. Fa ‘Change element 35Section 5 MAINTENANCE ‘TROUBLESHOOTING (continued) ‘SYMPTOM ENGINE OVERHEATING ‘SHUTDOWN ANNUNCIATOR PANEL LIGHTS ON. PROBABLE CAUSE Loose of Broken Fan Belt Diy Radiator Core Dirty Git Cooler Low Water Level Dirty Afercooler Low Fluid Level Fauity Water Pump Plugged Radiator Defective Engine Thermostat Faulty Switch Indicated by Light Individual Bulb Not Glowing in Fist 10-20 Seconds ‘All Lights Are Glowing After ital 20 Seconds and Att Machine has been Running REMEDY Tighten or change bot (Clean thoroughly. (Clean thoroughly. Refi (Clean thoroughly Refi Change pump. Clean and fush thoroughly. place engine thermostat, Replace the switch, Remove lens and replace bulb fenton nan pg np Seniemaraecessgkurgrene eee ERS SE oe circuit board. * 366.1 NOISE EMISSION WARRANTY Sullair Corporation warrants to the ultimate pur- chaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchas- er, withall applicable U.S. E.PA. and/or any Federal, State, or Local noise control regulations. This warranty is not limited to any particular part, ‘component or system of the air compressor. De- fects in the design, assembly, orin any part, compo- nent, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise ‘emissions to exceed Federal standards are covered by this warranty forthe life of the air compressor. 6.2 TAMPERING WITH NOISE CONTROL SYSTEM. PROHIBITED Federal Law prohibits the following acts or the caus- ing thereof: 1. The removal or rendering inoperative by any per- sons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while itis in use. Section 6 NOISE CONTROL 2. The use of the compressor after such device or element of design has been removed or ren- dered inoperative by any person. ‘Among those acts included in the prohibition against tampering are the acts listed below: 1. Removal or rendering inoperative any of the fol- lowing: a, Engine’s exhaust system or parts thereof. b. Compressor air intake system or part thereof. ©. Enclosure or part thereat. 2. Removal of any of the following: 2. Vibration isolators. bi. Control silencer. «. Floor panel, di Fan shroud. . Acoustical materials including fiberglass foam or foam tape. 3. Operation with canopy doors open for any pur- pose other than starting, stopping, adjustment, repair, replacement of parts or maintenance. 6.3 NOISE EMISSIONS MAINTENANCE AND MAIN- TENANCE RECORD LOG The following instructions and maintenance record og book, for the proper maintenance, use and re- pair of this compressor, is intended to prevent noise emission degradation (refer to Figure 61). Figure 6-1 Noise Emission Maintenance and Maintenance Record Log 1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION At least annually inspect mutfler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints and connections are tight, and that the mufflers in good condition. DO NOT operate compressor with defective exhaust system. Remove and replace any detectve parts by ordering with pert numbers ind- cated in the Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date 7Section 6 NOISE CONTROL 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 at 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 fiter element(s) are intact. DO NOT operate compressor with defective air inlet system. Remiove and replace defective paris by ordering with part numbers indicated in the Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date 3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION Atleast 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 defec- tive parts by ordering with part numbers indicated in Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date 38Section 6 NOISE CONTROL 4, ANNUAL FRAME, CANOPY, AND PARTS INSPECTION A‘least annually inspect tame, canopy and pars, for secunty of attachment to make sure there are no missin members, and to make sure there are no deformed members, including all hinged doors and covers and their fastening devices. DO NOT operate compressor with defective frame, canopy and parts. Remove and replace defective parts by ordering with part numbers indicated in Parts List. Maintenance Performed Maintenance Performed 5. ANNUAL ACOUSTICAL MATERIALS INSPECTION Atleast annually inspect all acoustical materials, ifany, for security of attachment and to make sure no material is 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 partnumbers indicated in Parts List Maintenance Performed Maintenance Performed By Location Date 39Section 6 NOISE CONTROL 6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS. In addition to other instructions in the Operator's Manual, atleast annually, operate compressor and inspectto make sure all systems are operating properly and that engine runs at rated speed and pressure. DO NOT Operate maflunctoning or improperly adjusted compressor. Repair or adjust, per Instuctions In Operators Manual, as required, Maintenance Performed Maintenance Performed By Location Date 40Section 7 ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor Was purchased. Iffor any reason parts cannot be obtained in this manner, contact the factory directly tthe address or phone numbers below. When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill ofLad- ing for the compressor or from the Serial Number Plate located on the compressor. SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-800-SULLAIR (U.S.A. Only) or 1-219-879-5451 SULLAIR ASIA, LTD. ore 210) Peete) SULLAIR EUROPE, S.A. Sullair Road, No. 1 www.sullair.com Zone Des Granges BP'82 ‘Chiwan, Shekou ee 42602 Montbrison Cedex, France Shenzhen, Guangdong PRV. arts Deparimst Telephone: 33—477968470 PRC POST CODE 518068 Fax: (219) 874—1835 "ax: 33-477968499 Telephone: 86-755~26851686 ‘woww.sullair.com/parts.shtm www.sullaireurope.com Service Department Fax: (219) 874-1205 www.suliaircompressors.com 7.2 RECOMMENDED SPARE PARTS LIST DESCRIPTION KIT NUMBER, QUANTITY replacement element for air fiter (primary) o4s462 2 replacement element for air fiter (Secondary) 048463 2 repair kit for air cylinder 022501 12-029 02250112030 4 replacement element for thermal valve 02250073-035 02250087-682 1 replacement for shutdown blowdown valve 02250100—042 02250100-042 1 repair kit for minimum pressure/check valve 242405, 250018~262 1 replacement for recirculating valve 02250100-041, 02250100-041 1 replacement element for separator 250034-086 1 repair kit for main fluid fiter element 250025-526 2 repair kit for inlet valve (1050 Models) 02250112532 1 repair kit for inlet valve (600H thru 900H Models)02250054-763 02250112-534 4 repair kit for reducing regulator 02250046-568 02250055-911 1 repair kit for control regulator 02250052—358 048409 1 repair kit for shaft seal 600893-001 1 lubricant, multi-vis (55 gallons/208 liter) 250030-758 1 lubricant, mutti—vis (5 gallons/18.9 Iter) 250030-757 1 manual, CIMA Safety 250023— 146 i PLEASE NOTE: WHEN ORDERING PARTS, ALWAYS INDICATE SERIAL NUMBER OF COMPRESSOR. aSection 7 ILLUSTRATIONS AND PARTS LIST 7.3 ENGINE AND COMPRESSOR ASSEMBLY ~ ALL MODELS [ae Item no. Part no. Description _Qi 1] wavwa= ues] CAPSCR ER GHB 172-13 XZ whe 20 [ere TSOLATOR, VIBRATION S00-L8._ PACT WASHER, SHUBBING T™-BOLT ‘See Engine & Congest Rasen Tbe soe rt nprestr Aston TB SS SUPPORT. NTT SPACER, COUP [NG CARBON STEEL BUSHING, TAPERLUCK-2°80RE¥-\Z™EEY COUPLING; ASSY-900 CAT7.3A ENGINE ASSEMBLY AND MOUNTING — ALL MODELS. ltem no. OF ENGINE Section 7 ILLUSTRATIONS AND PARTS LIST ENGINE ASSEMBLY AND MOUNTING. Description aty 7 HOSE, HEATER $76-(FTT z 3 12 [ WASHER, PL-6-REG_PLTO_177 é 1. WASHER, SPR LOCK AEG PLTOT 2 a CAPSCR.HEX-GRS T=8 XS 172 10 CAPSCR HEX _GRS_378—16-% 1-374 % 7 25 | CAPSCR,_HEXGRB_172=13-X 3 174 é z WASHER... 375 HARDENED. 6 7 TSOLATOR,- VIGRATION S00 18CAPACITY | & cr 2 = * s r 2 esol Merny ite tore + SPCR, FAN CAI 3804 44" WIDE rSection 7 ILLUSTRATIONS AND PARTS LIST 7.4 AIR INLET SYSTEM ~ ALL MODELSSection 7 ILLUSTRATIONS AND PARTS LIST 7.5 EXHAUST SYSTEM ~ ALL MODELS 335906-071 | WASHER, PL-8 REG PLTO_378 TS [8379p 4-094 | WASHER. SPR LOCK REG PL1D 378 $4_[s29705=100 | SCREW, HEX SER WASHER 5712-16 ¥ 1 T3[e29106=200 | CAPSCR, HEX GRS 378-12 2 1 [s29i06~100 | CAPSCR,_HEX_GRS_3/8—16 x1 =00-| CAPSCR__HEX_GRS 5716-18 ¥ 5 Item no. Part no. Description ‘9 [2s206=387 [ NUT, HEX PLTD 378-16 41415 CLAMP, SEAL 4" OD TUBING 47559 —| RAINCAB, “5 (044748 BAND, MOUNTING 15 [CLAMP EXHAUST CAT 3306 ‘sze00 7 19” [gvms=00 | SOREN, HEX SER WASHER 172157 ra z EADTATOR, CHT C7 200~ 1050, r 18” fsvms-075 | SCREW HEX SER WASHER 710-18 FSET 5 COOLER, OTL CAT CF. r 17 fav e= 95 [ CAPS, HER GRE 172=13 FE -17E = # PANEL, “RADIATOR CAT CF Ta favs 80 | CAPSCR.HEX CRS 6712-18 FT o “Terre | COOLER ALRZATR-FOR-CAT + 15-foppoe-005] CADSCR HO Ges 14-70 XE # [27ers oe | SHROUD.VENTURI Se" OU FAR He lessnespea NUT, HY LOBKING 122-13, z Terese [ELBOW, SWIVEL” S0DEG_1=172" NET zSection 7 ILLUSTRATIONS AND PARTS LIST 7.7 RADIATOR AND FLUID COOLING SYSTEM — ALL MODELS EXCEPT 1050 < ~ sana tem no. Part no, Description ay. Item no._ Part no. Description Qty 7 [essary [ COAVE HOSE CONST TOROUE_1O=¥E = 35 PLE. PIR TH ELT 1 [oasis HOSE, BELLOW -CHRG_ATR- 3° 10-7 z 37 Cows STAT Taiz XT t 1S orsmais PELE, “Ch_AIR-CLR-900-X 3°10 CF 1 3 HOSE HEATER S78CFTY z Ta [ozasrr-is| SA, “COOLER/AAD-CAT CF x WASHER, PL-B-RECPLIO-IZ, a TS ozs arae] HOSE, RADIATOR LOWER CAT-CF 2 ssor- wor] WASHER. GPR COCK REG PLID. 7D « 1 [searh85[ HOSE RADIATOR UPPER CAT CP i 26[exrosos| Sone, Hen SEm WASHER S/16—18 CSE [a GDF AW LR. 50 CAT-CP + 27 saror=vo [caPsce, nex CRS 7716-14 XT ni FAN A H—36™ CAT CF r 26 CAPSER HEX CRS 378-16 KT 17 z EATLE, REAR Se TAT CF 75 WUT HEX LOCKING 378-12 z BAFFLE REAR CS_CAT CY r 3 MOT HEX FPLID- 5716218 ¥ Tose, ATW NOW 3" 65 CATCH r BS ae008-96 [CROWE RUB 2.19 TD ¥- 2B OD z TUBE*ALUMINUMS™CS-CAT CF r Fe | OsS798 | COMMECTOR, WOSE S71GTHOSE KLEE A, OUNL FLTR AMOT”7S0H-TOST r 2r[-oWS1S LCL, ROSE T3716" 101-172 i HOSE, WED PRESS 1.3.x 102" 1 i | “ovo S45 LoL ease 3 t HOSE WED PRESS 1-30 -K 46" TE + ‘fen weil Oar REAR FILLER OS CAT OF t HOSE WED PRESS 180-58" i [espe] GAF-RERE FILLER SS-CAT-OF i HOSE. MED PRESS Tso -KSOTLG r 47Section 7 ILLUSTRATIONS AND PARTS LIST 7.7A RADIATOR AND FLUID COOLING SYSTEM — 1050 MODELS Item no._Part no. Description a ltem no. Part no. Description __Qty 1 [ose [BAF REAR FTCLER SS CAT CF t 34 [seonsam [PLUG, PIPE 72" 1abe ALT 7 Te [snare [CLA ROSE CONST TORQUE T0=P2 = 35 [essem-ae5| NIPPLE, PIPE=AS PLT-1-1e CEE Tr 1S fener [WOSE, BELLOW CHRG-AIR- 3" 10-02 = Sz [esrisaeo| CUe0R, PIPE 90-066 PLT 1-177" 1 i Tee, Com ATR CUR 90K T°1D CF 1 St fsomae- tw] FBR srr ae 17) ET 177 1 1 Sh, COOLER/RAD CAT Co H So serisauy] ROSE HEATER 578 TFT1 % 1 HOSE, RADIATOR LOWER CAT OF 1 By [snare WASHER, PL“ REG PLIO-TZIS t it THOSE RADIATOR UPPER CAT-CP 1 26 WASHER. GPR LOCK REG FLO 7718 * 0 G5, fan tH. So" CATE i zr ScAEN, HEX SeR WASHER 6716-16378 [ie 7 GoS-FANC AEH So" CAT CY 1 ra CAPS, HER CRS 7716-18 XT # z EATFCE,REAE $8 CAT 1 35 EAPSCR EY CRS SrBeTe TTT z H GAFFLE. RATES CAT-CP H a ROT, HOY LOCKING 878-10 z z TUBE ALTHO 3" SS. CAT-CF 1 25 [erssa) WOT HEKP BLID 6716218 7 $ TORE, ALUMINM_S™$-CAT CP i 2 [esonen¥8 | GROE TRUS 2.12 1X 78 z # A, GURL FUIR-AUOT 70H=1050 i 21 [48258 COMECTOR, HOSE S716cHOSE x 1-a5NPT Tr x WoSE,_ WED PRESS x 02" 1G i 20 | v0sis[ CLM, POSE 13716 TO T1727 7 3 [expres [ ROSE WED PRESS 1-0 254" Ce z 1] “040305 CLAP ROSES" = [sent [HOSE WED" PRESS 1-50-20" Le 1 Tose BA REM ICLER CS CAT OF iSection 7 ILLUSTRATIONS AND PARTS LIST 7.7B THERMAL VALVE ASSEMBLY- ALL MODELS. Item no. Part no. Deseription 1 | s07030-940 TELOOW, PIPE 90 DEG_WOW PLT 73" 11 Tesseze-o00[ NIPPLE, PIPES PLT 1 172 X CL 10. ELBOW, “S7FL_90M 1 172-K 1-177 401242150 | CONN, “37_FLZWPT-PLTOT 172 X 1177 seo024=is0 | ELBOW, S7FL_45M 1-1/2 X 1 172 '357806-094 | WASHER, SPR LOCK REG PLTD 378 1579 106~100 | CAPSCR, HEX_GRS 378-16 XT 7260040-097 | WASHER, S00_HARDENED. ‘50025-8246 | ELEMENT, FLUID FILTER (REF 2005-595 TAB) 040292 | ADAPTER, SWIVEL 1 172 aznzeoes-rae] ILTERSTAT, AMOT 1-1/2_NBT fgzs04e-s8e] SUPT, FILTERSTAT MOUNT 49Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 CONTROL SYSTEM MANIFOLD ~ ALL MODELS eR . 4s See ht Item no._ Part no. Description Item no,_Part no. Desorption ty 18 SWI FREES We 7 ot TEE, F BRR Ne 7a Wt t 1s ROSE, ED PRESS OO KOTE™ 1 3 RIPECE, PIPER PUTO VE 17E x ie STLehceR AIR 177" +] [9 [NIPPLE PIPE“BE PLTD 174-317 z 13 onasin-oa REG, REO" PORTS EAL PISTON 1 [ge teerepae| the, Re PUD x ee i 1 [ssa var] GAGE PREGE WEEN B= 100 PSI FELD —[v] | —#r feero-sos| Busing, WD PUTO 173 z 4 fexsstwo NOL, WANTFOCO™] | sr ettasoas tee Fc svi a t 16 HOSE, WES 716 X64 LG W VOTES 1] | “Sa ecoae-os0 [etatw, 76. som 2-372 1 rs HOSE WP-S716X 66" LG S7OEG ST {= Leow S7FL sou S71d 178 t it HOSE WP S716 40" UG S70EE ST z||[—3¢ ELBoW.—S7FL_90N S716 178 z a5 SK, ATR CTC MHELD TADO=1A00H 1 | Ss ens 025] cow, “57 Ftzwer PUD S716 170 i 1 ORE 09-25 FNPT X25 WPT 1 [2st t5 WasneR, SPR LOOK Re PLTON77 z tT Host WeO PRESS 5A" H48 + [3 WASHER, SPR LOCK REG-PLID-FID z 10 Tozssis-st[ WASHER, SPRLOCK HT CUR 37 [= SoHE, SET CUP 174-20 X78 1 2 Terasitessr[ LEVER, SPCC0 CONTROL 00H 00 | SCREW WACH-RO HO FOZ XT z a [sssorsom [CYUIROER, AIR OBL ACTING + [38 SCREW HEX SER WASHER 170-20-K S7E—[t 7 SuBT, SPEED cYL_uTO-3e06E 1 [3 CAPSCH HE CRS 172-15 37 1 z HOSE._WP- $16 X56" 16 SIOEE ST + [2 ‘CRPSCR, HEX ORS 172-1911 370 t 5 HOSE W676 t=51 1-48 | | asl vats eaPEER HOC oe eetasi8 7 € Tupe.5/1¢ 00x00 -WAL | | 26 aaros= iso] CAPER HEE RS S7te=8 TE 1 x Cow S/1sPTUae ETA RT — | =a Psns=tee NUT, WE LOOKIN 57181, z z ELBOW, 900-5716" TURE XIZORET 1] [ge essere R00 SoLc COW CFC SAE AC + 1 $k," TMET VALE ¢ 51Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 INLET VALVE — ALL MODELS EXCEPT 1050 Item no. Part no, Description 30-910 | PLUG PIPE 1a" 30008 STL_PLT 1a ee oao | wasaeR. SPR COCK 1 Tf szeanso7e | CAPSCR: HEX GRS 17470-1374 Te aznsos=i2e | CAPSCR, FERRY HD S/B-16 XT SE 1 ageso9-308 [O-RING._VITON $378 T0-] s36s03-2¢ | O-RING-—VITON 1X 178" pe0042-s84 [ SG, COM Tee" INTER Pen ibd [ORF CTL ,094 178 FRET _X 178 WNPT cessive] SHAFT, 6-80" TNCET VALVE. erasostaut | COVER -AGSEWBLY_ 6.50" TNCET-VALVE tzzsoster] SG, COWPRESION, 1.50 LBS. ezisse7sr | PISTON, 6.50 INLET VALVE eezsoost7ar | Ove, WTER 4-80 VALVE. eaasostyee [ PLATE, ASSY_6.5™ InceT VALVE fezasosi-7e ROUSING, BODY-€.5" INLET VALVE 52Section 7 ILLUSTRATIONS AND PARTS LIST 7.104 INLET VALVE — 1050 MODELS OT om OF SitSection 7 ILLUSTRATIONS AND PARTS LIST 7.11 DISCHARGE SYSTEM ~ ALL MODELS EXCEPT 1050 Qty Item no. Part no. Description aty 2 SoC ETE ee i p ean a Pe z Teco FIP we z Beacktt Aerie SPORT 7 Heo Plet poore woe pete dp Eee pe aso 7 Hibett ribesce rere ra 177 7 faa ub reece gs -ae te 7 (pete Pipes t ‘gurenntone ie 750086 F z eee Pine t Seneca “oe avo one 7 nats t t tiaras z : titi 5 7 mae ¢ 7 eave s tara tSection 7 ILLUSTRATIONS AND PARTS LIST 7.114 DISCHARGE SYSTEM ~ ALL 1050 MODELSSection 7 ILLUSTRATIONS AND PARTS LIST 7.12 RECEIVER SUB-ASSEMBLY ~ ALL MODELS EXCEPT 1050 & Item no. Partno. Description MODEL NUMBER TANK P78 2 POTS 3900 99-809 1 zasu,sssfigssin 300,355,425 02380031-280 1 Gah: 750,730H.808, 960,900" O22500e4-526 A\02250083-221 (EUROPEAN) ASSEUBLIES ONLY Qty _ttem no. Part no. Description a 35000 | UNTO PIPECBRS SEAT" 2 ONL —SOOT EO, V7 z esas ELBOW, “S7FL F170 178 Tr Pawsios-8s| ELSOH SEL FOU SPa 7 Tp [eataesteo [owns 3 FLAT PID TERE 15 Tesstae-so0 [NIPPLE PISE=Xe-PLT-TSection 7 ILLUSTRATIONS AND PARTS LIST 7.124 RECEIVER SUB-ASSEMBLY ~ ALL 1050 MODELS AS 3B 98227 500 {CuROPE! —_0725005)-225 83250055388 05 2500 26°855 Ax 02250 108-227 (500 EUROPEAN? ASSEMBLIES ONLY tem no. Part no. Description Qty Itemno. Partno. Description ay 97Section 7 ILLUSTRATIONS AND PARTS LIST 7.12B RECEIVER FLUID FILL - ALL MODELS ie Item no._Part no. Description ary 4 | 866515-060 | TEE, PIPE _150# PLT 1172 1 S| 040029 | PLUG, O-RING 8OSS SAE 1 178 i 2 [osesoosi-777 | GL, SIGHT OIL LEVEL 1-172" PLTD 1 1 To2ssoose-se5 | ADPT, RECEIVER OIt FILL 1850P0 7 58Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 FUEL SYSTEM — 600H, 600HH, 750, 750H, 825, 900 MODELS os SRE BAe ] Ne ep até BEER " r 4 na, ae eereese SESE tem no. Part no. Description Qty Item no. Part no. Description Q Te [ 907-05 | WEATHERSTRID, 3716 X 328 #1 Si [reasons | COW, FOO STR aC 374K 97IE 15 [4ep004-752[ GASKET, TUEL CAUCE NEOPRENE $0-[sessecons| ELBOW, S/F FOU 3/8 X74 Te] 245738- | NEATHERSTRIB, 1/2" X 1" EET 3p [sexnisons | TUBING, STEEL 97%6- 200A CTT TE] oa 57S SENDER, FUEL-TEVEL IDF 26 [ase05-015 STUD, TERD-S/TEM1EX 1172 12 oasis. [TEIN TURE 57167 x 17a WOT SEL 27 [esewe-07+[ WASHER, PLE WIDE. PLTD S710 Tr [essrintee | HOSE, FUEL RETURN 378 96% SHZSH CF 72 [anor | WASHER. SPR LOCK 771 1 [sass] HOSE FUEL 172 X74" ROO/SH CP Ts [sar@rart WASHER, PLB REG-UNE OT TZE 7 Torsiricse[ VALvE, CHECR FUEL 172" NPT ‘2a [core |CAPSCR: HEX CRS T7161 TE exam oir] TAME, FUEL 128 GAL PLSTC OORT 3S [aseos-1 [ WUT, HEX LOCKING 57 1E=T8 FLANGE, FUEL TANK 2 [eness-205| NUT HEL UNF 716-18 PANEL, TNSL-FUEL TaN BORD 21 [eisos-o2s| CON, TUBE=F $716 3120 SCREW, Fa=19 X-578 PHIL TRUSS. HD 20 [sesn-o:6 [t.6oH Tuas 90 06cm S787 GASKET, FUEL FILU_RECK T™ Weck, #UEL-FTLL Gab, FUEL FILt VENTED ers35[ SW, Lo CEVEL VERT FUEL_TA fe -BEEE ER belle ae [aeoseete | TUSE, FUEL PICK-UP e005 1 [asoas-494 | SCREW, WAGH PAICLPID=24 X17 59Section 7 ILLUSTRATIONS AND PARTS LIST 7.13A FUEL SYSTEM ~ 750HH, 900H & 1050 MODELS TRI IEE om QY Ne “y fs _" Item no. Part no. Description Qty _ Item no. Part no. Description ty 15 ‘Gann L_ FUEL Tae +] [29 [omens [con OOSTR Te 974 97, i is CONNECT MALE 14 OSES CL [28 BUSHING, RED FEY PLTO 1178-597 TS aso022-45e| WEATHERSTRIP, 3718 F-37071 in| [37 12] tpoos-a | DISCONNECT, FEMALE 12-14 TZET Tt [489008 521 CASKET, FUEL GAUGE TEOPRENE TO] 245738 [ WEATRERSTRUD, 172°x 1" ETT | OaTS7S- SENDER, FUEL TEVEL TH BUSHING, AED HEX ALTO 17e T BUSHING RLD-HEX PLIO-T¥ 74 r PLUG, PIPE_IZ7* 3000" STL_PLT z Ss LELBOH 37FL WOW 378- 174 +] [2s feeriscos | TUBING, STEEL 716. 20CK TTT amiss] PUTTING, TUBE S767 X78 HPTSPEL [1 22-[ sonar [ WASHER. PLB REC PLID. 1716 HOSE, FUEL RETURN 978 X96 SHZSH CFL 71 [697-1 [ WASHER. SPR LOCKREG PUTO. TAS r HOSE FUEL 172 X74" ROD/GW CF TI [35003350 | SOREN, Te-F RDG 10-28 7-72 WALVE, CHECK FUEL 172" WOT “er wavoy=ti [eaPsC, VER ORS 17 TeeTe FT sxpesees9] PANEL. INSL FUEL TAN OHO. Te fersas-o38 cone, fURE=F STEW Tt 17 aresm-o0 [ELOOW, TURE DEG SET WZE re Tasssecsie| TURE, FUEL PICK-UP 60-1050 senoeetar] TAWE, FUEL 125 GAL SIEEL poaP, Fuel FILL veNTED «™ sw, "Tro LEVEL VERT FUEL 7Section 7 ILLUSTRATIONS AND PARTS LIST NOTES 6Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 FRAME, RUNNING GEAR AND PARTS, TRI-AXLE MODELS tem no. _Partno. Description 45 | 4400-037 | WRAP__TTE-NYLON T¥_ 270 2 [asso0-195 | WASHER, SPR LOCK 172 ‘1 [asrooa-ave | WASHER SPR LOCK 378 0_[asva16=195 | WASHER PLB REG_UNF IN S7E. ‘39 [as7a08-115 | WASHER PU=@_REG-UNFIN_172, 'S5-[asvane-37" | WASHER.PL=8_REG-UNFIN 376, 7 Tasrzo5-a 7] WASHER, PLB REG _UNFIN 5718 35 [asasoe-iz6 | SCREW, “SECF=ORTUL7 X17 Sa [as0s4-075 | SCREW, SELF-DRILL 178 X-W7 ‘S5-[ 29705-150 | SCREW, HEX SER WASHER 5/1618 11172 m93= 700 | SCREW, HEX SER WASHER S712 18 XT 4250 [CAPSCH, HEX GRS 378-16 1-7 177 49-[ 26210700 | CAPSCR HEX GRB_878=11-X_7, 4B [easa0 8-5) | CAPSCR HEX CRS 172=15-K-1-17E 47 [a35si0=399[ NUT, PEK LOCKING S78-11 45 [a2sso5=265 [ NUT._HEX F-PLTO 5/1618. a [e20;08= 196 | NUT-—JANCRH UNF IN-97 76-20 45 [198590-004 | CLAMP, HOSE 7781-0 ag [a080 11 -[ HOSE, vO. ERAKE 178-XTET Er [“aOS0 SS" [LINES BRAKE SIZ STE LS 4-[ “405032 [LINE BRAKE 3716 x70" LG 39-|Faroae-est| SPACER, OREAK LEVER 250° $8_[sero98-a9 [ROD TARY $716-24-% 9 37 [sano st=iar [| SX, ACTUATOR GRAKE SURGE FD. ‘Se_[sa0000=s0s [BSHC, REO_S/T6_X_ 174 INVERT SEAT 35-[2soor-ses [Tee BhaxE CINE 1/0 INVERT FLR 34[" gavees[CouAL Zee, RUNNING GEAR. 35[fa9071 tine, BRAKE Ve xO" UT 33 [ 247258 [UNTOH,-IRVRT_45-FCR 124" TORE ‘St [-251968-[ PLATE. SPACER 150/175 ‘So-[-G4a52e—[ CABLE BREAK 29046264 | SPacem, Leven ASSEMBLY 046267 | YOKE, -$716=74 THRD. ‘Oae761 | EOUILIZER, 5X I-17 7 946260 [PIN YOKE. 046259 _[ CLANP, BRAKE CABLE (045567 | AGAPTER, WEATHERHEAD 7627 45357_[ CLAN, SPEED TUBE 174 141795 LEVER HANDBRAKE aot [NUr, KEEPER (OEXTER OS-OT-OOT Dao Bolt, KEEPER (OFXTER-07-007-001 49 [osmiesat | AXLE, HYD BRAKE 771K X67 SC. Te [ossmiricase]| TIRE ASSEMBLY 7.90 X12. 50 17 [osssiare-ta¥ COUPLING CINK, SAFETY CHAIN Te [ossstore-tse CHAIN, ASSY 3B X48" W/HOOK NUT,“ SHACKLE (OEKTER 6°71 NUT-~EQUALIZER (DEXTER 6=1107 Tr [osssteroie PARED, TOL BOX §.6, 7507 1 -fossswnes-sis | PLATE OLL Pan ACCESS 7500. 3 [ossspse-ov+ | JACK - SCREW 750-1050, 7 [estsnse om | DRAWEAR, -A-FRAWE 790=105T @[estsones-soo | SUPT, S{DEWEWSER 750 z 2 saoes-sie | FENDER, TANDEW- LH 750 ‘iesds | BRACKET, SPRING HANGER WIG SS 16604] BRACKET.-SPRING HANGER TGCSSection 7 ILLUSTRATIONS AND PARTS LIST 7.15 FRAME, RUNNING GEAR AND PARTS, 4-WHEEL MODELS Item no. Part no. Description Qty __Itemno._Partno. Description ty. 9 |_24is76 | witel, Ta5 X 6.75 1 ]aS7nH= 135 | WASHER, SPALOOK 172 fe [parser TIRE, 8.78 F163 t UL erakas [SON TEx SER WISE SETS EVE @ z 15 [ssene-1as | CAPSCR, HEX GRO172=15-K 174 rr = z a [esst9-863[ NUT, HE COOKING 37410 Ol z + 15 [s9s5-265| NIT-HEX FBLID 9776-10" re = r t 1 [Ssesseed[ VALVE, RTWCTR Te z SUPT, SIDE NEWER 750 z 1 [asongr-oo9 | HANGER, SPRING ASSYTSD_JD_EW a TL oreT78--[ ORME, HEAVY DUTY ASST Tw Tasumrora LANE, REAR <0 an zSection 7 ILLUSTRATIONS AND PARTS LIST 7.16 FRAME AND PARTS, LESS RUNNING GEAR MODELS Item no._Part no. Description 7_| 637508-125 [WASHER, SPR LOCK 1/2 te [#9705075 | SCREW, HEX SER WASHER 714-18 X 374 [v7 ‘S[-s20208-150 | CAPSCR, HEX GRE 172-13 X 11/2 4 fosstoosimi7a | CHAN, UTILITY MTG 750-1050 3 2 7 o77s0049-018 | PANEL, TOOL BOX S.S. 750XH oz280048-s42 | PLATE, OIL PAN ACCESS 7500 ‘92250005541 | FRAME, @-WHEEL 750-10 500Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 CANOPY AND PARTS ~ ALL MODELSSection 7 ILLUSTRATIONS AND PARTS LIST 7.17 CANOPY AND PARTS ~ ALL MODELS Item no. Part no. Description aty 43 | 361005077 NOT, RETAINER S/16-18 092 36 42 | 843103-050 RIVET, POP 3/16 X_1/2 AD68 “ 41 | soi0s-112 EYEBOLT, 5716-18 X 1 1/8" PLID 1 @[ase07-112 WASHER, PL-B WIDE PLID 7716 4 39 | 838205-071 WASHER, PL-B REG PLTD 5/16 2 38 | 37807112 WASHER, SPR LOCK REG PLTO 7/16 4 37 | 6345042075, SCREW, SELF-DRILL 1/8 X 374 4 36 62975-100 SCREW, HEX SER WASHER 5716-18 X 1 [3 35 | 829705-075 SCREW, HEX SER WASHER 5/16-18 X_3/4 | ws 34 | 829107-125 CAPSCR, HEX GR57/16-14 X11 1/4 4 35 | 627104075, CAPSOR, HEX GRE 1/4-20 X 3/4 ie 32 | 5505-166, NUT, HEX LOCKING 5/1618 3 31 | ssue-5 NUT, HEX LOCKING 174-20 “6 0 | 625305-705, NUT, HEX F PLID 5/16-18 Z 27 | 250035-827 CATCH, DOOR LATCH FEWALE $5 4 765 | 25035-828, HOOK, ‘DOOR CATCH WALE $5 4 27 | aso025-917 HINGE, 0OOR 750/100 4 26 [250027-436 WEATHERSTRIP, 3716 X 378 FT m7 25 | aso016-271 WASHER, SPRING OOOR LATCH 3 24 PIN, COTTER 0008 LATCH 8 25 ‘OD, DOOR _LATCH 8 2 WASHER, NYLON S716" 25 21 | 250008152 HINGE, TNSTR_PNL_ DOOR 75071200 1 | 040125 ‘GROWET, RUBBER z 1 [orzo ase | 250078701 on 3-7 [ontaies ommue7 PLATE, COVER EXH 00-1050 1 18 [orzo [ores s-41s [ora 3-30 [oar us-s1 forasasa [PLT, CVR 4.5" LT HOLES REAR 4 17 [orzsos-ws [ore 25644 ozasous-s7 [orzoves-e [PLT, CVR 4.5° LT HOLES FRONT z 16 | 02250 142-642 [07250078-55 jozas0 138-476 | DOOR, T-LATCH SS & CS EUR 2 15 | o2250 142-641 [02250 124-683 | 02250 142-643 jozzsa138-47 | DOOR, ACS RAD/D-BAR END EUR 2 14 [ozo ve-sno {02750138-40 [02290142621 PANEL, ROOF CUR SIDE_C® 1 15 [ozesover-os [oneos-as [ox -us [orn voay omsoniecas [PNL, ASSY REAR END 600-1050 i 12 ozzsaes-er [orp mse [0220 10-128 fozzoez-ne [PNL, ROOF $8 600-1050 1 11 ors 2-us [ozasou-sse [0729 0-487 [ozs 0-126 [orznus-a75 [PNL, HSG_ASSY $8 600-1050 1 10_]ozzso142-see | ozvso046-195 [02250 140-481 [02250 140-125 |ozzs0138-47¢ |PNL, HSG _ASSY CS 600-1050 1 9 [ 072s0142-363 | 022S0046-191 [02250 140-680 [02280 140-124 [02250138472 |PNL, HSG ASSY 600-1050 1 8 Jozasoisa-s42 | 017526 [022s 0-679 [02250 140-123 [azasarse-a71 | CVR, SEP_ACS PNL_ 600-1050 1 T[oasova-35 [ozo 851 [0225010619 [0220 0-119 [oz29138-478 [OO0R, INSTR PNL FOOXH-1900 1 & Jonason-se CAPSCR, BUTTON HEAD 5716-18 X 378 [a5 5 [ozzsoa7ecree CH, FLUSH FLONG, LOCKABLE 2° 4 + Jonm9-30 SUPT,FRT BAFFLE 750 z 3 Jozasones1 ANL, SUPT FRT BAFFLE 750-1050 z 2 Tozaove-ss BAFFLE, FRONT C.S. 750-1050 + 1 [ores BAFFLE, FRONT $8 750=1050 7 ITEM PART | PART NO. | PART NO. | PART WO. | PART NO, DESCRIPTION F NO.) wo. | Green’ | waite | veruow’ |sratnuess 7Section 7 ILLUSTRATIONS AND PARTS LIST 7.17A CANOPY PANEL ASSEMBLY ~ ALL MODELS L. WARE PL-E REG ALI 371Section 7 ILLUSTRATIONS AND PARTS LIST 7.17B CANOPY PANEL ASSEMBLY ~ ALL MODELS. = hs * This Tage oesionates THe o1rceRENT 1) USE ONLY PLATED HARDWARE IW ABseMALY Ata Bir ASSURE ete Nae 2) Re OF TAG PART WITH SULLAIR P/N Para PRC_ASS FRY CS GO-TO, PHL‘ HsG_S10E TOP 600-1050 PC, HsG-S10E Bor TOM 00-5 PHC HS¢-SIOE FRONT CS. BOUT, BOOr 5716-18 ¥ 378 FLT NUT, PEW S715 ESCRTETTON af FART — THREAT PARE PT PRBT wo | PE Y PRET was ante [Peet Bw [ERsSection 7 ILLUSTRATIONS AND PARTS LIST 7.17C CANOPY PANEL ASSEMBLY ~ ALL MODELS % THIS TABLE DESLONATES THE oIFcERENT 1) USE ONLY PLATED HAROWARE IN ASSEMBLY Pat COLOR ASSEMBLY PART NUMBERS 3h anion Tho Pant itn sutintn ow THER PA [WHITE PA ELD PA STRESS levee] 06 on an 3 z pea [oT Pa Se FAT SSO 1050 z 5 asasvena [ons PL, HSG_FAT 88 a0 1080. t = saab acaeh [on e-tt[evir aan [PNL,HSC_S1OE_TOP_<00— 1057 r 3 esa ecanr [onze evsare-a9t [PC HSG_S10¢ BOTTOM a00- 10SD. 1 ape BOLT, eODY 5716-18 374 PLT e +> NUT, PEM S716. 5. ITEM PART —| PART. WO] PART -NO PRET NO] PART WO. DESCRIPTION m Nos) ‘Wo ‘Gaeen | Pte | Pretudw [stainless 70Section 7 ILLUSTRATIONS AND PARTS LIST 7.17D CANOPY PANEL ASSEMBLY - ALL MODELS FOO OO 2) ui om The PaRT WITH SLLAIR Pr * HERS PRIRAL At QUEER ST arrears AER F=O REE PTS ieee ae ee OEseRTPYION BBR) F Far ae aILLUSTRATIONS AND PARTS LIST Section 7 Description Qty Itemno. Part no. Description 7.18 ACOUSTIC INSULATION AND PARTS ~ ALL MODELS tem no. __Partno. 72Section 7 ILLUSTRATIONS AND PARTS LIST 7.19 ELECTRICAL PARTS — ALL MODELS Hem no._Part no. Description Qty . Description ty [040091 [ 1SOLATOR, VIBRATION 1°00 X 37 ra| ne WASHER, SPALOCK REG PLID-S75 z 7 [Bia-an | SUPPORT. RELAY CF H CAPSCR HEX ORS. 5/6°1 XT z oO ARN, NG/COWPR_SOOH-TOSD_OAT H NUT, HEE F PLID 174-20 3 E> PHL, TNSTR-WABFLOTGDOH CAT WOE [1] [17 [rszoss1 [RUT HEE PLO 378: * z CAGE, BATTERY 270X102 LG BED 1] [16 [oesisane [NOT WING BLIO- 376-12 * CABLE BATTERY 20-285". [ois Teaosecnne CABLE, SaTTERY Se" 3eemT72 EYE BCA CABLE, -BATIERY 270 RED_STYLE A 1] [ie [245738 WeATRERSTREP, 17777 TEETT 5 Jassie SOL, ¢PHO”74VOC-CONT-DUTY 1] [15 ge ser— | Boor, BATTER Tew t 2] O01 [ROD S786 X12 417 [ova er oROWIET,RUBSER-1™ HOI z 11a 1032 10 gun, BATTERY TOIT ZL ator Teatro a0 2 WOOT = WET z 73Section 7 ILLUSTRATIONS AND PARTS LIST 7.20 INSTRUMENT PANEL AND PARTS - ALL MODELS Description tem no. Part no. Description aty iar [HasESS—TweTR PL" 1600n-CATSMEaE——[ + | 38 Towers om 7 z OVER, HST PANEL WIRING TeH0H — i Swi fe, Togece SOF + [35 7 Fast TWSTHCTeb0H EAT SSE 7 = Ties SEL ETT FRET | [ar = Eesow, 900 $/ier Wee e/a — = Eng Feat ior | [3 ; AGRE REST FUT 39 Wea | [3 z puGe oUF PRESS 18 P81 fs + Auee vu 300e-F° OTR | [35 Teta [VALVES SAT BALL PRESS SECT # Gavel. FUEL Levee HI—2 TSocatoR, WTaRAT Tone 100-8 S7a*TaT fey EAUEE TEM WE 7 THOSE F 2 ansencrs | CaM WIATATGRE Be t BIVIOER, VOLTAGE 24V-SySTEW | | —o-Toanmonae | CTREOT, BOMRD- FIRST OUT A. i GAUGE, PRESS 2° 5" CO 900 PST | [iv esnwserae | PuuG, SEALING. PLUG. AND REGED Ea 74Section 7 ILLUSTRATIONS AND PARTS LIST NOTES 75Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS ‘CONPRESSOR NOISE EWISSIN CONTROL INFORMATION es D SULLA CORPORATION ne ey ——___ [REGULATIONS FOR NOISE EMSONS APPLGAGLE TO PORTABLE AR COMPRESSORS. THE FOLLOWING ACTE OR "THE CAUSWNG THERED® BY ANY PERSON AME PROMITED (0) THE REMOVAL OR RENDERING NOPERATWE OTHER THAN FOR The PURPOSE OF UANTENUOSE, REPAR, (GRREPLACEMENT, OF ANY NOISE CONTHOL DEVICE ‘kEvevenT or besten tisTen THe ONNERS iowatnconeoAaTeDIvTO Thus COMPRESSOR (CouPece WT THE HOWE CONTROL ACT © ‘heuseor mis coupnessonarTeRsucHevice (RELEVENT OF DESIGN HAS BEEN REMOVED On DATE OF MANUFACTURE: oss a ool oa asl aro Fes [usr] ave war [ 0 |. [auc [sep [ocr |wov ee SHARMA aT ae eae ae OIL FOR COMPRESSOR - SULLAIR @ AWF - (ALL WEATHER FLUID) z DONOT ATTEMPT TO OPEN FILLER CAP § WHILE UNITISRUNNINGOR PRESSURIZED. APIS SELE.SEALING. NO PIPE DOPE is REQUIRED ON CAP. (lL LEVEL SHOULD BE VISIBLE IN THE SIGHTGLASS. 00 ROT OVERFILL WATER ——> | . DRAIN \ height to lovel Cee reer pore fener evra end coe aT arr neeiy PSL eee Cerone) ae en Cee Saas prior oe LESS THAN 55 m.p.h. TS; rere nen na Cech Ea loi CC aay pinch points. Reduce speed Peace precereien ; dictated by SCE Ls Parris ie feu eeu) ae ea teae ecu eenus aria CEs 76Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS key part number description number quantity 1 decal, ISO 9001 02250057624 1 2 decal, noise emission control 049463 1 (US. compressors only) 3 decal, Sullair AWF 250032902 1 4 decal, Sullair logo — black 02250057 -607 3 5 sign, waming hot surfaces 407408 1 6 In, warming crush/sever 408919 1 7 decal, water drain 040345 2 8 sign, caution towing (tandem 4—wheel) 250003292 1 8 decal, towing speed (4—wheel steerable) 049210 1 (Continued on next page) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 7Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS AWARNING | WARNING | 4) AWARNING " Diesel Power Coo ese roe) Ciao 78Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS (CONTINUED) key part number description number quantity 10 decal, warning 100/1600 ) 250028-258 1 1" sign, warning compressor fluid fill cap o4e685 1 12 reflector, 2" x8" red stripe 040103 4 13, reflector, amber 250084-319 2 14 decal, warning sever fan part 049865 2 18 sign, warning sever belt drive 049964 1 16 decal, rated 1800 idle 1200 RPM 250023 -695 1 7 decal, rating 600H o2as0121-367 1 sdecal, rating 600HH (not shown) ooaso121—368 1 ‘decal, rating 750 (not shown) 02250121-369 st decal, rating 750H (not shown) 2250121371 1 sdecal, rating 750HH (not shown) 02250121-373 decal, rating 825 (not shown) 02050121-375 decal, rating 800 (not shown) 02250121-377 1 ‘decal, rating 800H. (not shown) 02250121-379 1 decal, rating 1050 (not shown) o22s0121-398 18 decal,CAT Diesel Power o22s0109-529 19 decal, warning pressurized cooling system 02250051-826 1 (Continued on next page) (D OSHA guidelines are superceded by any Federal, State or Local regulations whenever applicable. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 79Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS SET REGULATOR TO 60 PSIG CAUTION a | SHUT ENGINE OFF _ INE OFF 20 /- a BEFORE REFUELING A WARNING es carton on tg 28 | puree men eee Sarees SET PARKING BRAKE WHEN jalestnepeetle PARKING MACHINE scopes RELEASE PARKING BRAKE Seer BEFORE MOVING MACHINE. ere nl eee GENERAL MAINTENANCE avons asa reo Pesrasuom.nes pec. owe cour, | "inc seo meus oesing MALS Ses Saeed sera os svene tance Ciuc ers ATEN AO er ea err EAN TE FLU RETURN LE GCE 0 THANE, ‘Nou Taweuriet wen angie ees a eas ah age GROSTMCeD WATER ecsbeny,ET*EYTE | Sense es OED NE HDS OF Te ALE ven a oxve non nate esta ee Sena nares Gunmemoecan means | WHR MRE Ltine Uitte, ‘IWOSPs WAY MOR eaLNT Cnn way a | bape NeSig TC A RERURED Fo cco srr en en ef et cera Segoe ey wie erage at carne ute acon SS Setrneroomimin arc Stan | ABH gaa owatin ce auras EEE room serge ower gm nan oune Saas Fe ets | OE CORE SRT CMS eit WACHNE MODEL) gogy, 750,750, 7504 825 08 Per on ra a oro TC a Sane eo Tw TET a Sat SoeSection 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS (CONTINUED) key part number description number quantity 20 decal, run mode 02250075-087 1 21 decal, diesel fuel o40248 2 22 decal, doors closed 250038-030 4 23 decal, warning parking brake 02250081513 1 24 decal, ct! reg low pressure (02250075-086 1 25 decal, ctl reg high pressure (02250075—085 1 26 decal, Proposition 65 022501 18-638 1 27 decal,fiuid fil 250023-655 1 28 decal, general maintenance (not shown) 02250144—427 1 (Continued on next page) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR atSection 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS 29 NN To START: START - STOP PROCEDURE 1) CHECK ENGINE IL, ENGINE COOLANT, FUEL, ANO 1 SEEK ENGRE OL, ENGINE 6) FULLY TURN THE ENGINE SWITCH TO CRANK THE ENGINE. AS THE ENGNE STARTS TO RUN RELEASE SWITCH. NOTE, THE 2) CLOSE ANO LATCH ALL DOORS EXCEPT INSTRUMENT PANEL WARNING LAMP WILL COME ON FOR 2 SECONDS FOLLOWING oor. ENGINE START-UP INDICATING THE CIRCUIT 1S FUNCTIONAL 3) CLOSE ALL SERVICE VALVES AND TURN WARM-UP CONTROL 7) ALLOW TIME FOR ENGNE COOLANT TEMPERATURE TO pe Sst Gia ate an ee 4) IN COLD WEATHER USE STARTING AID PER INSTRUCTIONS E Renan te ) FRNTED ON STARTING AD DEVICE NGTALLED, SS TU VALVE a Oe LONGI '5) TURN STARTER SWITCH TO “ON* POSITION AND OBSERVE VOLTMETER FOR ADEQUATE BATTERY CONDITION, OBSERVE TO STOP: ENGINE EMS (ENGINE MONITORING SYSTEM) FOR POWER-UP. 1) CLOSE ALL SEAVICE VALVES. ON DUAL PRESSURE Here eee ae a ae ite BBicthe a seater sone erea ote 1 SECONDS. F ENGINE DOES NOT START WAIT 1 MINUTE AND REPEAT STEPS 4 - 6. ENGINE MONITORING SYSTEM (EMS) 1) THE EMS DIGITAL LCD IS FUNCTIONAL TO SCROLL THROUGH VARIOUS ENGINE MONITORED PARAMETERS. MOMENTARILY ‘SWITCHING THE "US-METRIC- SCROLL” SWITCH TO THE SCROLL POSITION WILL SHOW THE FOLLOWING PARAMETERS, SPO=APM},GAIENGNE OU PRESSURE) [GA2-ENGNE COOLANT TEMPERATURE, (GA3-NOT USED), [GAA-NOT USED), GDOST=NtAKE PRESSURE) AML T-NTAKE AR TEMPERATURE) (FUEL TOFUEL TEMPERATURE} (ACCA P-NOT USED), [ACCR T=NOT USED}, (FUELFUEL RATE], [HRS=MACHINE HOURS] AND [LOAD=PERCENT ENGINE LOAD]. 2) ONLY FIVE OF THE EMS DIAGNOSTIC INDICATORS (ANNUNCIATORS) ARE FUNCTIONAL. THEY ARE: FIRST ROW. FIRST ‘SYMBOLCOOLANT TEMPERATURE. SECOND SYMBOL-INTAKE AIR TEMPERATURE, THIRD SYMBOL-FUEL TEMPERA TURE. ‘SECOND ROW, FIRST SYMBOL -ENGINE OIL PRESSURE. THRO SYMBOL COOLANT LEVEL LOW. 3) THE WARNING LAMP INDICATES AN ENGINE OPERATIONAL PROBLEM. USEO IN CONJUNCTION WITH THE EMS LIGHTS TO SHOW ‘A FAILER SUCH AS HIGH COOLANT TEMPERATURE SHUTDOWN. 4) THE CHECK ENGINE LAMP FLASHES GENERALLY INDICATING AN ENGINE ELECTRONIC PROBLEM WHICH MAY OR MAY NOT EFFECT ENGINE PERFORMANCE, CONSULT ENGINE AND COMPRESSOR MANUALS FOR FURTHER DETAILS, xzs0004-002 Av. 00 82Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECALS (CONTINUED) key part number description number quantity 29 decal, start—stop EMS functions o2esooe4—602 1 30 decal, wiring diagram (not shown) 02250124-826 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 83Section 7 ILLUSTRATIONS AND PARTS LIST 7.22 DECAL LOCATION ~ TRI-AXLE MODELS ei em bE HRA Biter co ea é z 7a, [our] paar no, DECAL, GAO 08000 ‘eearon leer ee isms wesc my RHE co © NR ST ee msn oO eae Item no._ Part no. Description Qty _Item no. Part no. Description. Qty 12 ozzso TF -SeAOECAL-SULTATR 5.751 36.50 BOOK x [on eed STRIP,_CHGPCTY wate 2 OULCETH z i ISIGN, WARNING CRUSHZSEVER n aes oof ETT MEE LOW PRESSURE 1 wo DECAL, AWLE LOB 7 || aif ennsors oof DECAL, REG_60 STG RUN-WODE” 1 o REFLECTOR, A@te Too x 4.25 el 2I| fel Pes Lf DECAL RATED TOLE TH RP i [25000 S-zPa[DECAL, CAUTION TOWING TANG OT x 9] 345 107-03q RIVET, POP 478 x 378 t T]_cavees DECAL, NOISE EMISSION CONTROL r Taf oawoss-std CAL WARN, PARKING BARE i 1 [ovrsnsr=ee[OEEAC~(S0 9001 (BLACRY + [9 e-40q DECAL LEAD WARN, PROPEL TON ZS r 5 fozasose-re]OECAL, GENERAL UATNT HODOM1IHD i Tal 250071854 occa GRP WHITE Wo0/00 | ovo103 REFLECTOR, REO-1.08 X 4.25, 4 15| as0023-a5q0ecALO1L FILL CEvEL r ‘3 [ozzstnse-ro]OCCAL, OPER INSTR 750—1000 i Ta| 0279 06-074 NMVEPLATE,SULLAIR-WAERTAL T Z| fa ars UA DECAL, WODEL_W/SUCLATR x T3f23051-woq DECAL WO 7SD_CAT WCAUEES r [SIGN, "WARNING- se VER-FAN-PORTSection 7 ILLUSTRATIONS AND PARTS LIST 7.22A DECAL LOCATION ~ 4—-WHEEL MODELS a) a fa) ie ar te] ts ‘en wrasse ; rit os 5 a fe a ERPS Bier A ae nk O — — = — — — — — —| eet SSH. a SS at =I | . — }.. ori LT t } es += ciak tim & ft. wl AG war ag 8 a ear rare EO, OUP 60-60 me [out scarnOn or a ee —— Se Tapio Sea cron BONS aR —s Tae — | een OTT SER TR Face TREE TTT arses farmer wa om — tae © tage moe —— See Oat et ee eae | ea aiscs rea Item no. Part no. Description Item no._Partno. Description at Ti [are [sien, WARNING CRUBHSEVER onsite HTP GUPETE wit Te WOL-TTT 2 TO gee pefOEOR RATED TOE 1] | 2 foemsareand occa: weC-tow PRESSURE i 4 pees sifeerceeTon, eR Tce OS 1} |“ forraron| oc nee PETER WOE 1 Toes. focoat, Tonne SCC (RG! PORT + | =p forest Oren Leno wa, REPOST TONS i 1 [aaveas [occa Nanse EMISSION CONTROL +] | a feeswrose ever ror ve e378" r Epovaosr-cnforent [20 900) THAT 1] | oi easait- [cet stor wor ne Venere t 5 BHn05-3e]DFOACCENERAL WANT HDD=T2O | | Ve soon asf occa eu were e007 oo i 4] 000105 REFLECTOR, FEO 166 14.25 2] | ssa saesf cet OL FIL LEVEL 1 TF pansose-THfSECAL OnE ETE 7S) 1] | foes esd eae, sua WERT i TT traf OEOKL ODE WUT +] | ——iSfozzsestf occa, Woon = 750 ext5300 i Tb 968 S,WARNING-SEVERCE CROAT +] | Tafoatarasob erent succate screw se 3 acs ——T 85Section 7 ILLUSTRATIONS AND PARTS LIST 7.22B DECAL LOCATION ~ LESS RUNNING GEAR O ——— = ai * — a Is =—| ie = = —S = rn nase —- SS @ eh © — —| + = lus — = ws -_ == — I ao Has 4 s = rl, [i ter i @ Woe az i +38 bi ae ae fo Haat Mie sete ol — a = — — — — — sera Ke) Oo] ‘OECAL, GROUP 80018000, Y/Y tae ——— ot a TE co Httgtgon eve cereal oO ta Hox mee sey Ee 2p SRA wees on Item no._Part no. Description Qty Item no._Part no. Description. Qty 1 fore oe-ard MAUEPLATE,SULLATR W/SERIAL # 1 perso w ee] STRIP CRSPOTY WHITE 2" ROL PTT z 5 [on2s0s1-oHf DECAL, wOGOOH ~ 75 CATO“ T Te] 0 03 [REFLeCTOR, REO_1.68 X4.25 « B fozeoizt-iaf DECAL, GULLATH 5-75 36.50 GLACE S| [ir so se-sialaerecTOnaveeR 1a 04.25 x TT tut pai} DECAL RATED 10LE_1W Pw 1 1g prtsors-oudoecaL, CTL REG LOW PRESSURE t E]bavtes [DECAL NOISE EMISSION CONTROL T 15 pezoors ou DECAL, REG 6) PS(G RUN UODE T 5 [ozacos?-

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