Assembly and Disassembiy:-

Instruction Manual and Parts Lis

 INDEX
Section 1 Assembly Instruction

Section 2 Disassembly Instruction

Section 3 Parts List, Tooling List,

Kits and Tolerance Chart

SULLAIR CORPORATION
3700 East Michigan Blvd.. Michigan City, Indiana 46360
Phone: (219) 879-5451 Telex: 258318
 INTRODUCTION TO SULLAIR

SERVICE AND REPAIR MANUAL

SULLISCREW® COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

All Sullair air compressors feature the Sulliscrew® compressor unit, a

two-stage, positive displacement, flood-lubricated type compressor. This unit

provides continuous pulse-free air compression to meet your needs. With a

Sullair machine there will be no maintenance or internal inspection of the

compressor unit required.

Oil is injected into the compressor unit in large_ quantities and mixes

directly with the air, as the internal rotors turn compressing the air. The oil

has three primary functiOns:

.As a coolant, it controls the rise of air temperature normally accociated

with the heat of compression.

.Seals leakage paths between the rotors and stator and between the rotors=

themselves.

.Acts as a lubricating film between rotors, allowing one rotor to directly

drive the other, which is an idler rotor.

After the air and oil mixture has been discharged from the compressor, the

oil is separated from the air. At this time, the air flows to your service line

and the oil is cooled in preparation for reinjection.

OPERATING PARAMETERS

COMPRESSOR:

Type 204mm 1st stage/127MM - 2nd stage "C" version

Maximum Operating Pressure 350 PSI
Bearing Type Anti-Friction
Ambient Temperature (Max.) 125°F (52°C)
Section 1 Assembly Instruction
 1
1
1
BB
1
CASTING BEARING ASSEMBLY

1. Inspect all castings and rotors for

burrs and any irregularities, making
sure all dirt is cleaned carefully and
'burrs filed to within tolerance. Break
all sharp edges .015" maximum. Wash
all castings in industrial solvent.
Wipe the stator housing inlet face
with a clean cloth.

2. Attach the stator (8) to the assembly

stand. Apply primer to both inlet
face of stator and mating'surface of
inlet housing (4).

All reference numbers pertain to unit

assembly drawing No. 004350.

3. Apply liquid gasket (color code #515

purple) to the stator inlet mating
surface in a continuous bead.

4. Spread the liquid gasket (color code

#515 purple) in and around bolt holes
by hand.

5. Tap 2 dowel pins (72) into the inlet

housing pin bores. Align dowel pins
to stator housing pin bores and place
inlet housing on stator housing.

- A -
6. Tap dowel pins flush to inlet housing
face.

7. Place 12 ferry head capscrews (83)

into the bolt holes. Apply liquid
gasket under the heads of the two
internal screws.

8. Drive the capscrews in using a criss-'

cross or stagger-torqued pattern with
an approximate torque of 80 ft./lbs.

9. Place the inlet bearing outer races

in the inlet housing bearing bore with
the numbers up. The male bearing is
reference 62 and the female bearing is
reference 61.

10. Install the female race by tapping

with a plastic mallet and make sure
that it is firmly seated.
 83

78
38
/ 37 61

72

H5 89

/ 2
R14 49

64
41
42
94 86 5 1
49 /2 79
4P
64
83 dra
64
50 AiYOr& 42
'1411b
79 '22 15
G12 41 7 5-- ''`..f•-•""•-.A.,

(A,
11. Install the male race in the same
manner as in Step 10.

12. Place both male (33) and female (38)

balance piston outer rings over
bearings and install as in Steps
10 SI 11.

ROTOR REARING ASSEMBLY

13. Place the inner bearing races for

bearings in step 9 and the female
balance piston inner ring (37) in
the oil bath for 10-15 minutes at
approx. 275°F.

JMEMINII

14. Place the male race over the rotor

shaft and tap it until it is firmly
seated.

15. Place the female race over the rotor

shaft and tap it until it is also
firmly seated.
 83
z z
78
80 q 38
37 61
45

72
R12

62
H5 89

R14 49

64
48
41
42
9 86 1456 8 21

83
49 lee
64
64
50
r
42

79 22 15
G12 41 75
;
y` .:' '‘`.1 -•- 4.-•?)
• .7„7// ,
••••••• e' .,•-.N
-. e , ...0:...t•-
__..,

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\ 423,
oi/Zi
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e
r
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►
►
1
16. Place the female balance piston
inner race over the rotor shaft and
tap it until it is firmly seated.

17. Locate the male rotor serial number.

(see arrow) The number is stamped
in the root area of the rotor lobe.

18. Locate the female rotor serial

number. (see arrow) The number is
stamped on the outside diameter of
the rotor lobe.

19. Place the rotors, one at a time, in

the end clearance fixture. Make sure
that the numbers of the rotors are
matched together.

20. Apply a coat of grease to the end

faces of the rotor lobes.

A .... 04 Al
R14

\--,:-.
,/
i 7r
g:l.f ll 7
i'' /;
I / iiir
;* 7.404
'4,:p '(.7:4f:i t:Allt
fi 1
OUTLET ASSEMBLY

21.Place the outlet housing (H5) over

both rotors.

22. Install both inner (15) and outer

(16) spacers in the male bearing bore.

END CLEARANCE ADJUSTMENT

23. Place the end clearance tooling into

both bores as shown.

24. Place .035 shims (49) (see arrow) on

both male and female tooling.

25. Install a bearing (64) in each set

of tooling. NOTE: These bearings
are matched sets and should not be
mixed.
 83
1

78
80 38
414„a,
45 37 61

72

33

H 5 89

49
64
64
48
( 41
42
5 21
49
79
64
64
„*.,
42

79 22 18 ;;-: 4
G12 41 75
. 26. Install the remainder of the tooling
on both bearings as shown.

27. Tighten the screws. If either rotor

hangs up, install additional shims
until rotor turns freely.

28. Check the end clearance by inserting

equal size shim stock strips between
the rotor and outlet face. (see arrow)
Each strip should be placed on opposite
lobes of each motor.

29. Remove the inner races. Do not mix.

Adjust the shims until the proper end
clearance of .002 — .003 is obtained
for each rotor. re-7"—N

30. Place all 4 bearing inner races (64)

and the gear (G9) into the oil bath.
Make sure that the bearing positions
are not mixed, such as male inboard
bearing male outboard bearing, female
inboard bearing, and female outboard
bearing.

A — 6 — 83
 83
1

78
80 38

45
37 el

72
R12 c.

H5 89

R14 49
64

Li 64
rio 48
41
42
94 86 5 / 5 21
49 79
83
6a •e
64 it 41
2
/
79'22 15
G12 41 75
31. Remove the tooling and place the
shims on their respective rotor
shafts.

32. Apply pipe sealant to all plugs

(89 & 94) and to set screws (86).

33. Tighten all plugs and screws. Make

sure that plugs (94) are below the
surface of the casting.

34. Apply pipe sealant to plug (94) and

install in the position shown.
(see arrow) This plug should also be
below the surface.

35. Install the female inboard bearing

outer race in the housing. Use the
end clearance tooling. Make sure
that it is firmly seated.

c 11
 36. Install the male inboard bearing
outer race in the housing. Use the
end clearance tooling. Make sure
that it is also firmly seated.

37. Remove spacers (see arrow) to lower

housing.

38. Install the female inboard inner

race.

39. Install the female outboard inner

race.

40. Install the female bearing retainer

(41) and three screws (75).

— A — R3
 83
1

78
38
37 1
6
/

72
R12

14 5 89

R14 49
64
4 64
11 .
• 48
•
41
42
94 86 L:616 5 21
49 79
83 64
64 for
50
ti 1)•-• 42
79 15
22 .
GI 2 41 7 5
41. Tighten the screws.

42. Install the male inboard bearing

inner race.

43. Install tooling spacers, bearing

retainer and screws. Tighten the
screws.

44. Raise the housing by using the

spacers removed in Step 37. Remove
the tooling spacers, retainer and
screws.

45. Install the male outboard bearing

inner race.

1, _
 83
/1

78
38
/ 3781
as

72
R12
33 /

H 89

x? iVelb. 2
R14 sr 49
64
1 64
48
11" f# 41
42
5 21
94 86
49 79
64
64
5C

79 r 1
46. Replace spacers, retainer and
screws. Tighten the screws.

47. Recheck the end clearances as in

Step 28 to make sure they are within
tolerance. Record the clearances.

48. Remove screws from female side and

install locking plate (42). Retighten-
screws and torque to approximately
35 ft./lbs.

49. Install outer race 0f female

outboard bearing.

50. Tap it gently to seat it firmly.

 83
1

.61
78
38

37

72
R12

H 5 89
1

R14 49
64
1 64
48
41
42
94 86 e; 5 21
49
64 r-
83
64 fit •44,1
50' 'tom' 42

79 22 15 /
G12 41 75

•rrS • • //>/ •f
oi 0
51. Using a depth micrometer, measure
the distance from the housing surface
down to the outer race. Do this on
both sides of the shaft to insure the
same dimension.

52. Install shims (48) to equal the

exact amount of the micrometer
reading.

53. Place the bearing retainer (21)

over the shims.

54. Install the screws (79) and torque

them properly to approximately
35 ft./lbs.

55. Place .040 shims (50) on the

housing around the male rotor.
 St
09
94.
C9
)1
56. Insert the outer race of the male
outboard bearing into the bearing
retainer (22).

57. Tap it to seat it firmly in the

bearing retainer.

58. Place the bearing retainer over

the shims.

59. Install the screws (79) and

tighten them.

60. Remove the spacers as done in

Step 37.

not
 83

78
\ 38
19V
*kik,
/ 37 61
45

72
R12
33

H 5 89 83

'i-firktffif‘a
-No* 49
2
R14
64
64
48
•47
41
42
94 86 Iv; 15
5 21
49
79
64
83
64

79 15 .
z
G12 41 75,
61.Lock the outlet housing down to
the fixture. This will push the
rotors up to the outlet housing.

62. Check the end clearances as in

Step 28. This clearance should be
.0005 - .0015 less than the clearance
recorded in Step 47, but no less than
.002 actual clearance.

63. Adjust the shims (48) on the

female side to obtain the proper
clearance in Step•62. Replace the
retainer (21) and screws (79).

64. Adjust the shims (50) on the male

side to obtain the proper clearance
in Step 62. Replace the retainer (22)
and screws (79).

65. Tighten all the screws and torque

them to approximately 35 ft./ibs.
Install rear spacer (15).

A - 5 - 83
 83
„. /1

78
38
I 37 61

72
R12 K.

H5 89

R14 49

64
48
41
42
94 86 L41> 549 / J521
4/ 79
83 64 r
64
50 f:s 42
7922 i5 /
G12 41 75,
DRIVEN GEAR ASSEMBLY

66. Tap the gear key (G28) lightly in

place. Make sure it sticks above the
shaft approximately 1/8" as shown.

•••=mmuilb•

67. Place the gear (G12) over the shaft

and use the key to help align it.
Tap it down with a plastic mallet.

68. Drive the key below the gear

surface.

69. Install the retainer, locking

plate (42) and screws (75). Torque
the screws to approximately 35 ft./lbs.

70. Bend the tabs of the locking plates

up against each screw for both rotors.

A — 6 — 83
 83
/1

38
37 61

72
R12

H 5 89

R14 49

64 •
48
41
42
94 86 5 21
10..f
di . ...• •
64 r
64 3.-*A1
Sa
'irs--- 1/44 42
,_
79"22 15 2,.
G1 2 41 75,
71. Apply primer and liquid gasket to
the outlet face of the stator.
Spread the liquid gasket by hand.

72. Insert the rotor and outlet

assembly into the stator.

73. Insert the dowel pins (72) into the

pin bores and tap in until they are
flush with the outlet flange.

74. Insert the screws (83) and torque

them properly to approximately
80 ft./lbs.

INLET END ASSEMBLY

75. Turn the unit over to the inlet

end. Apply oil to the rotor faces
and rotate the rotors 3 to 4 turns to
keep the liquid gasket from locking the
rotors.

A-6- 83
76. Insert the male balance piston (32)
into the sleeve. Insert the
screws (76).

77. Place three pieces of .003 shim

stock between the piston and the
sleeve at 120° intervals between
them. Torque the screws to approx-
imately 35 ft./lbs.

78. Using a depth micometer, check the

distance from the inlet housing down
to the piston outer sleeve (33).

79. Install shims (51) with the equiv-

alent dimension or .001 over the
reading on the micrometer.

80. Apply primer and liquid gasket to the

face of the inlet housing. Spread the
liquid gasket by hand. Place 2 screws
(82) (see arrow) into the inlet
cover (1). Using the 2 screws, align
the inlet cover and inlet housing. Do
not disturb the shims (51).

A - 6 - 83
 63

78
so
45 /3837 61

8
R12

H5 89

R14 49
84
64
48
41
/ 42
94 86 5 / / 5 21
49 I, .
79
83 84 e
p>, .0. t
i

1 84 t.:441
50 li)" e. 4.s....
l
, i
)% g 42
79 n 15 `...
irf,
G12 41 75,

. 9- fele at
I .fro 5 -toroo
.66 1 0119
(04 to CO& rIos
81. Install the rest of the screws
(82 & 83) and torque ref. 82 to
approximately 35 ft./lbs. and
ref. 83 to approximately 80 ft./lbs.

82. Install the cover (45) and screws

(78 & 80). Torque the screws to
approximately 35 ft./lbs.

83. Cap all openings with plastic cap

plugs. Set the unit aside.
 47 14
13
/ 810
1 11
811
/.•
5
/ "OF
5 47 -
22 14 /
13
53 e10
11
811
R9
53

G24
32
31
55

R10
S17 53

813
S4 S11 18
67
26
17 / 13935

G14
61
ts/Cczer„, G32 2 27
45
69
ez4,...G26
D14 45
05 01
2 20
\ 4k. 19

D10 /
S2
I
• G10 D6 28
S18

S9 S6
S15 / S8 16
S10 61
S1 S10
816
.01112•1=•

INLET ASSEMBLY

1. Place both male (B12) and female (B13)

bearings in the compressor adapter (17).

All reference numbers pertain to unit

assembly drawing number 004351.

2. Tap both bearings in and make sure

they are firmly seated.

3. Place 0-ring (39) on bearing

retainer (18). Apply oil to 0-ring.

4. Install retainer in adapter with

tapped hole located as shown.
(see arrow)

5. Install male bearings retaining

ring (41).
 47
14
13
B10
51 11
B11
V 5
,
15 47
22' 14 /
13
B10 /
11
B11
R9
53

G24
32
4150/546.--J 43 r-* /'31 55
52
R10
S17 53

B13
S4
S11 18
87
26
17 / 39
35
/

G14
•••""...„..G15
G32 2 27
\
45
69
, ... G26 .N.
014 kti 45 lik,
05 D1
../ 2 \ 20
\\ 4kb ..... 19

S14
010
S2 S13

S12 • G10 06 28
S18

S9
Al S6
S15 / S8 16
Lrf/114J ID /
S10 61—
(..T 4
S1 S10
316
 6. Install female bearing retaining
ring (35) with proper pliers.

7. install studs (52) using stud lock.

8. Apply pipe sealant to plug (61)

and install in adapter.

9. Place 0-ring (S1I) on bearing

cover (S4) and install bearing cover
on adapter. Insert screws (S17) and
torque to approximately 8 ft./lbs.

10. Apply primer and liquid gasket to

the second stage mounting surface of
the adapter. Spread the liquid gasket
by hand. Place second stage unit over
studs and lower until approximately 1/4"
off of adapter. Place lock washers (30)
and nuts (49) over studs, but do not
tighten completely down.

83
22

R9

S9
Si 5
11. Lower unit all the way down and
insert dowel pins (43). Tap down
until flush with flange.

12. Insert screws (53) and torque

properly to approximately 80 ft./lbs.
Tighten nuts (49).

13.-Apply primer and liquid gasket to

the stator mounting surface of the
adapter. Spread the liquid gasket by
hand. Insert the dowel pins (43) into
the stator (9). Tap them in.

14. Lower stator onto the adapter and

align dowel pins with the dowel pin
bores. Install the six short screws (53)
and use liquid gasket around the head
of the internal screw. Torque the
screws to approximately 80 ft./lbs.

15. Install the long screws (55) and

torque them to approximately
80 ft./lbs.
 47 14
13
810
1
B11
7
7
5 47
22 14 /
13
B10 /
11
ell
R9
53

G24
32
49' / O,
50 31
/ / 55

R10
S17 53
I )(
/

813
S4
Sll 18
67
26
17 / 35

G14
Cvitr,,,G32 27
45
69
G26
45
01
2 \ 20

D10
S2

S18

59 _ • 441,4N*0 S6
515 / S8
S10 61
31 SiO
S16
16. Attach the support leg and filter
bracket with screws and torque to
approximately 75 ft./lbs.

17. Place the four radial bearing

inner races in the oil bath for
approximately 10-15 minutes at approx—
imately 275 °F.

18. Place the male outlet bearing (311)

inner race over the rotor shaft.

19. Tap it gently to make sure it is

properly seated.

20. Place the female outlet bearing (B11)

inner race over the rotor shaft and
tap it gently.

C
 47
14
13
B10
51 11
B11
7
5 47 •
22: 14 /
13
B10

B11
R9
53

G24
32
50 31
52 55

R10
S17 53

813
$4
S11 18
67
26
17 / 39
35
z
61
G14
61
G32 27
45
69
tv,...• G26
D14 45
05 01
2 20
\ ak, 19

D10 /
S2
S12 • G10 D6 28
S18
Nab
S9 S6
S15 / S8 16
S10 61
S1 SlO
S16
21. Place the male inlet bearing (B12)
inner race over the rotor shaft and
tap it gently.

22. Place the female inlet bearing (B13)

inner race over the rotor shaft. Make
sure the lip (see arrow) is toward the
rotor lobes as shown. Tap it gently
to make sure it is properly seated.

23. Install the male rotor-(R10) in

its proper bore in the stator. Locate
the serial number (see arrow) and face
it toward the female bore.

24. Locate the serial number on the

female rotor (R9). Place the rotor
in its bore with the serial number
facing the number on the male rotor.
(see arrow)

25. Prime the outlet face of the

stator. Apply a coat of grease
to the outlet face of both rotors.

A .4
 47 14
13
810
11
811
5

22'
13
/ B10 /
11
811
R9
53

!S'G24
32
31
/ 55

R10
S17 53
IX
ct‘

B13
S4
S11 18
67
26
17 / 39
/ 35

2 27
45
69
D14 45
D5
2

514
D10 /
S2
$12 • G10

S9
S15 S8
S10 61—
S1 sip
S16
26. Place both outlet bearings (311)
over the bores of the outlet housing (5)
and tap them in. Make sure they are
seated firmly.

27. Apply liquid gasket to the outlet

face of the stator and spread it by
hand. Lower the outlet housing over
the stator.

28. Install the dowel pins (43) by

tapping them gently.

29. Install the screws (53) and torque

them properly to approximately
80 ft./lbs.

30. Install .035 shims (11) to both

rotor shafts.

- 3 - 83
1
I 1

I
I 22
/

I R9

I
I
I Rio

I
I
I
I
1
I S9
S15

I
I
I
31. Place the "dummy bearings" over
the shims.

32. Place the retainers (13) and screws

(47) over the bearings and tighten.
Make sure both rotors turn.

33. Check the end clearance through the

discharge port by rotating the rotors
until a rotor lobe is in view. Measure
the clearance between the outlet hous-
ing and rotor by inserting shim stock.

34. Adjust the shims to obtain the

proper clearance of .004 - .006.
Repeat Steps 32 thru 34 until the
proper clearance is obtained.

35. Heat the thrust bearings (B10)

over light bulbs for approximately
10-15 minutes. OPTIONAL: The oil
bath may be used instead of the
light bulbs.
 13
B10
11
B11

22 14 /
13
B10
11
B11
R9

32
31
/ 55

R10
53

513
S4
511 18
67
26
17 39
35

G14
61
Ckv,ter,G32 45
2 27

ett ..-- G26

014 45 tt:zt
D5 01
2 \ 20
\qk
514
010 /
S2
S12 G10
518

S9 -10 S6
S15 / 58
61--
Si S10
 36. Install the thrust bearings,
retainers, locking plates (14) and
screws one set at a time and torque
the screws to approximately 80 ft./lbs.
Recheck the end clearance.

37. Apply oil to the rotor faces while

rotating the rotors.

38. Bend the tabs of the locking

plates up against each screw.

39. Place the outlet cover gasket (15)

over the outlet housing.

40. Place the outlet cover (7) over

the gasket.

A — 5 — 83
 47
1
,13,BI 0
1 11 1

7 5
/
5 47
14 /
22 13
B16

R9

G24

Rio

52

S9
515
41. Install the screws (51) and
tighten properly to approximately
35 ft./lbs.

42. Apply pipe sealant to the plugs (61)

and install them.

43. Install the fittings (67 & 69).

Install the tube (26) and tighten
fitting nuts.

44. Place Lhe gear spacer (G13) over

the male rotor.

45. Install the key (G24). Make sure

approximately 1/8" is sticking above
the rotor.
 51

22'
/

32
Y o/ 31 55
4 C

S17 53
keb
/
B13
S4 sil / 18
87

17 26 39
/ 35

G14
61 G18
G32 2 27
45
N
etw" - G26 45
D14
05 D1
2 \1 20
•
19

010 /
52
G1 0 06 28

S9 s6
515 r 58 16
si0 61—
S1 81°
516
46.Place the gear (G11) in the oil
bath for approximately 10-15 minutes.
Remove and place over the shaft using
the key for alignment.

47. Install the retainer (G14), locking

plate (G15), and screws (G32). Torque
the screws to approximately 80 ft./lbs.

48. Bend the tabs of the locking plate

up against each screw.

49. Place the outer race of the inboard

bearing (D14) over its bore.

50. Tap it in until firmly seated.

 22:

1:19

S17 53

B13
S4
S11 / 18
67
26
17 / 39
/ 35

G14
61 -"%„..G15
G32 2 27
as
G 26
D14 45 41k,
D5 ,D1
22 \ 20
~~ __19

D10 /
52
G10 D6 28
S18

S9 S6
S15 / S8 16
S10
Si 310
S16
51. Stack the outboard bearing inner
race (D14), spacer (D6) (see arrow)
and drive gear (G10) under the press.

52. Lubricate the bore of the drive

gear (G10).

53. Insert the key (G26) into the

shaft (D1).

54. Place the shaft into the gear and

align the key.

55. Press the shaft down through the

gear.
 47 14
13
el B10
1 11
W * / B11
". kl
° ,

22 14 / a:
13 '' -•!*
Gzr
1
B10 7" ..1i'
.
11 Kte%
/
811
/ R9
53

}IAA G24
32
49" /-"kb.
• 31
so52/ a/43 r / 55

R10
S17 53

S4 B13
S11 18
67
26
17
35

G14
1 G15
G32 2 27
45
D14 45
D5
2 \ 20
./tt 19

010
S2
S12 • G10 D6 28
S18

S9 : etr.
/
S15 /S6 S8 16
4 „Si() 61
kr
.4
Si S10
S16
56. Make sure the radius of the shaft
is clearly below the gear.
(see arrow)

57. Place the spacer (D5) (see arrow)

and inboard bearing inner race (D14)
over the shaft.

58. Press the bearing down until

firmly seated.

59.Place the input shaft assembly into

the inboard bearing inner race.

60. Rotate the input shaft several

times.
 51

22

R9

Rio

S9
Sis
61. Install tube tee (65)and nipple (63).
Place orifice directional brackets
(19 & 20) on bosses. Install orifices
(2) and tighten. Install screws (45)
and torque to approximately 8 ft./lbs.

62. Install tubes (27 & 28) and

tighten fitting nuts.

63. Prime gear housing surface of

compressor mounting adapter. Apply
liquid gasket and spread by hand.
Install dowel pins (43) and tap with
hammer.

Wiw.e:Ot

64. Place gear housing over dowels and

tap with plastic hammer.

- 65. Install screws (54) and tighten

properly to approximately 80 ft./lbs.

A - 6 - 83
 47 14
13
/ B10
51 11
811
7
*At
5 47 14 /laT
22 Ct. A*.
13
53 B10
11 c
811
R9
53

G 24
32
31
55
R10
S17 53
I X,

B13
S4 S11
/ 18
67
26
17 / 39
/
35

G14
61 G 15
17(v:tr.,. G32
45
2 27

G 26
014 45
05 D1
2 20
19

010 /
S2
G10 06 28
S18
59 - . 4ND S6
l iiiihr
S15 / S8 16
4) "a
'l
/ 61
Si $10 i 4.7,
' /P
66. Apply pipe sealant to plug (61)
and install.

67. Install outboard bearing (D14)

outer race.

68. Install .020 shims (D10) over

bearing outer race.

69. Install bearing retainer (S2).

Make sure that the trapped holes
(see arrow) are aligned horizontal.

70. Install 2 screws (S19) (see arrow)

and tighten. Rotate unit several
times.
 1
B11
5
15 47 14 /
22
13
810
11
B11
R9
53

G24
32
V 31
/ 55

R10
S17 53

qZ(b
B13
S4
S11 / 18
67
26
17 39
35

G14
61 -•""G15
G32 2 27
45 \
69
® ,G26
D14 45 4kb
D5 D1
2 \ 20
4k. 19

D10 /
S2
I
S12 • G10 D6 28
S18

S9 S6
S15 / SE 16
S10 61—
S1 0
S16
71. Install fixture T-525 & T-527 and
dial indicator as shown. Tighten the
screw to 10 ft./lbs. and read the
amount of end play on the dial. Do
this until the same reading is
obtained twice.

72. Remove the tooling and bearing

retainer. Adjust the shims (see arrow)
to obtain an end play of .0020 - .0025.
Repeat Steps 69 thru 71 until proper
end play has been obtained.

73. Remove the retainer. Prime the'

surface of the gear housing. Apply
liquid gasket and spread by hand.
Install the retainer as indicated in
Step 69. Install the screws (S19)
and torque to approximately 80 ft./lbs.

74. Install the spring retainer (S14).

Make sure it is evenly seated.

75. Install the pin (S15) in the seat

retainer (S1).

A - 5 - 83
 47
14
13
B10
11

53

R9

32
31 55
.0'

S17 53
X

B13
S4
Si1 18
67
26
17 39
35

j 14
1
G32 2 27
45 \

014 45
D5
2 \ 20
ezz

S14
010 /
S2 S13

512 • G10 06
S18

1 S9 S6
S15 / S8
/ S10 61—

516
76. Apply grease to seat 0-ring.
Insert seat into seat retainer.
Make sure pin aligns with slot in seat.
(see arrow) Make sure seat is evenly
seated and pin does not bottom out
in seat.

77. Insert 0-ring (S12) into groove

of retainer (see arrow). Insert snap
ring (S13) into retainer.

78. Grease shaft, bore and rubber

bellows of seal.

79. Install the seal. Omit the spring

retainer (see arrow) which comes with
seal.

80. Grease the 0-ring on the seat

retainer.
 47 14
13
B10
1 • 11
/ B11

22
13
53 810
11
B11
R9
53

G24
32
31
52 55

R10
S17 53

B13
S4
S11 / 18
67
26
17 39
/ 35

G14
61 G1532
G 2 27
45
- 69
D14 45 ttzt,
D5 ,D1
2 \ 20
ilkt3 19

D10 /
S2
G10 06 28
S18

S9 S6
S15 / S8 16
S10 61-g
Si S10
516
81. Place the seat retainer over the
shaft with the tapped hole (see arrow)
facing down. Using 2 5 / 16" x 1/1/2"
screws, run the seal retainer down and
parallel to within 1/4" from the
bearing retainer.

82. Install 4 screws (S18) and tighten

properly to approximately 18 ft./lbs.
Install the remaining 2 screws (S18)
properly.

83. Install the inside V-ring (S10)

(see arrow) as shown. Install the
gasket (S6) and V-ring cover (S8).

The V-ring should be installed to

a width dimension of .35.

84. Install the screws (S16) and

torque to approximately 8 ft./lbs.
Install the outside V-ring to a
width of .35.

85. Cap all openings with plastic cap

plugs.

A - 6 - 33
 47
14
13
B10
51 11
/ 811
7 5
7
/
15 47
22 14 /
13
53 B10 11
/ /
B11
R9
53

324
32
31
/." 55

R10
S17 53
,z4:4
<
t
813
S4
S11 18
67
/ 26
17 / 39
35
z

G14
61 •••"..." G15
„.G32 2 27
45

014 45
D5 D1
2 \ 20
4Ittb 19

010
S2
S12 • G10
S18
riot
S9 S6
S15 / S8
S10 61
sio
S16
86. Rotate the unit several times
to allow oil to flow around seals.

87. Attach unit tag (31) and arrow

indicator with drive screws. (32)
Section 2 Disassembly Instruction
 47 14
13
B10
51 11
B11

7 5

15 47 /
22 14 / ,
13 4e; "4?
53 B10 1
11
B11
R9
53

G24
32
It4
31
55

R10
S17 53
I )(

B13
S4
Sll 18
67
/ 26
17 39
/ 35

G14
G15
cid G32 2 27 54
45 \
69
...-G26
etze 45 ditza
01
/ 2 \ 20
19

D10 /
S2
D6 28
S18

S9 S6
S15 / S8 16
S10 61—e
Si S10
S16
General
The Sullair compressor unit is a precision
built product that must be properly handled
and cared for. Repairs or parts replacements
must be made by a knowledgable competant
mechanic trained and experienced in repair of
Sullair compressor units. Any work done
inside the compressor should be performed in
a place where a reasonable degree of cleanli-
ness can be maintained.
SULLAIR
1. Remove ferry capscrews (51) from the
outlet housing cover (7) than remove
cover.

2. With a chisel straighten out the tips

of locking plates (14). Do this to both
the male and female rotors.

3. Remove hex hd screws (47) and retainers

(13).

4. Remove all but two screws (53) from the

outlet housing (5).

D - 6 - 83
 51

22

53

R9

32
31
50/ 52 / 55

Si7
x

B13 'ZI{it 53
18
67
26
/ /39 35

G14
1
G32
2\ 27
45
69
®"*""G26
014 45
05 7D1
2 \ 20
\.,_
--- 19

D10
S2
28
S1 2 S18
06

Ntl
S9 et S6
Si8 S8 16
S 11;) 61-4

SIC
5. Remove drain plug (61) from the bottom
of gear housing (16).

6. Remove screws (S16) that holds the V-ring

cover (S8).

7. Remove screws (S18) that holds the seal

cover.

8. If, the covers don't come off easily it

may be necessary to put a screwdriver
behind them and pry.

9. Remove the seal housing (S1).

D - 6 - 33
 47
1
13
810
/
11
B11
77
15`47
22 14
13
810
53 11
811 R9
53

G24

32
50/ /31 55
52
Rio
53

54 Sii
67
26
17
/39 35

14
-.0P
1 G32 27
2
45
- G26 4 -N
5
014 05 01 \ 20
/
~ 19

010
/
S2 I
G10 06 28
S12
Si8

59 S6
618 / /58 16
510 61
S1 S10
S16
10. Remove the V-ring cover (S8) and
V-ring (S10) from the seal cover (S1).

11. Pull the shaft seal out (S9).

12. Remove ferry cap screws (S19) that

holds the bearing retainer (S2).

13. Remove the bearing retainer (S2).

14. Remove shims (D10) that are against

the bearing (D14). Also, remove seal
spring and the spring holder (S14).
 47
1
13
610
51 11
611

22:

53

R9
53

G24
32
31
55

R10
S17 53

B13
S4
S11 18
67
26
17 / 39
35

G14
61
./ G15
G32 2 27 54
t
45

014 45
D5 D1
2l 20 /
/

S14
010 /
S2

S12 • G10 D6 28
S18

S9 -11D S6
S15 / S8 16
S10 61
S1 S10
S16
15. Remove the 0-ring (S12) on the back-
side of seal cover.

16. Using a screwdriver remove the retain-

ing ring (S13).

17. Punch the shaft seal seat (this is

part of the shaft seal) out of the
cover.

18. Remove screws (54) that hold the gear

housing (16) to the adapter (17).

20. Turn the unit up with the shaft,

straight up. Attach eye bolt to the
gear housing. With an overhead crane
pull the chain tight.

D - 6 - 83
 47
14
13
B10
1 11
C4P 47
I .:,
14.9, A
B11

L ..!..:
5 47 ..„.,
22 14 i /
13
, ."if'
...
53 810 /
11 %
/ ,
B11
R9
53

G24
32
50
31
52 / 55

R10
S17 53

B13
S4
S11 / 18
67
26
17 /3935

G14

Ctizzir„G32 45.
2 27 54
I

G 26
D14 45 4rakt
D5 D1
2 \ 20
.kb „.19

D10 /
S2
S12 • G10 06 28
S18

S9 "rwle
—"i*4 S6
S15 -.'„044 / S8 16
S10 61-0
tr41 4
Si S10
SI G
20. Place long screws into threaded holes
provided. By turning these screws
down it will force the two housing
apart. When housing are apart, Lift
gear housing (16) off.

21. Tap the bearing race (D14) out of the

gear housing (16).

22. Turn the gear housing (16) over and

remove all tubing and fittings.

23. Lift the drive shaft and drive gear

off the unit.

24. Place the long shafted end of drive

shaft assembly downward on the press.
NOTE: It will take approx. 22 ton
to press apart.

D - 6 - 33
 47
14
13
B10
1 11
811
z
/
15 47 /
22 14 /
13
1 /
510 /
11
/
B11
R9
/
53

G24
32 /
ta
31
, 55
R10
S17 53

4(
tt
513
18
67
26
17 39
/
1 35
/

G14
1 -""..........G15
1. , G32 2 27 54
\Se czer
45 \
69 s"...
ttzb,..- G26 45 Ilk)
D14
D5 D1
." 2 \ 20
\ 4kt. __19

/
D10 /
S2 /
• G10 D6 28
S18

S9 S6
S15 / S8 16
/
/ S10
,
61
81 510
S16
25. Press the drive shaft (Dl) thru the
drive gear (G10).

26. Turn the drive shaft over and press

the shaft thru the remaining bearing
(D14) on the shaft.

27. Remove the dowel pin (G26).

28. Remove the tube fitting (67).

29. Straighten out the tips of locking

plates (G15).
 7
14
13
/ B10
51 11
811

22

B10
11
811
R9
53

G24

43

R10
S17 53
I x

B13
S4
S11 18
67
26
17 39
/ 35

G14
61 G15
2 27
45
69
®.- G26
D14 45 15k,
05 01
V 2 20
\ 41k. 19

D10 /
S2
S12 • G10 06 28
S18

S9 .- Illic
1
/ .4 :iii,f1 S6
S15 4k., , / S8 16
'4...1-.-, f,._41) /1
S10
L.. o
Si S10
GIs
30. Remove capscrews (75) on the end of
the 12 Series unit.

31. Remove the locking plate (42) and the

retainer(41).

32. Remove hex hd capscrews (G32) on

20 Series unit.

33. Remove the gear retainer (G14) and

locking plate (G15).

34. Remove snap ring (35) with a snap

ring pliers.
 53
/
R9

..., 32
43 ir 31
/ 55

-S17 53
Ix

/ 813
S4
S11 18
67
26
17 / 39
/ 35
/

G14
1 ••••"./G15
C.,N,....., G32 27
2
45 \
69
® ....-G26 \
D14 45 et,,,
D5 D1
-, 2 \ 20
\ 4k. ..-19

/ 514
010 /
S2 S13
/
S12 G10 D6 28
S18
/
tvisfe
S9 S6
S15 / S8 16
S10 61
Si S10
,
S16

1
35. Remove the outer race of bearing (DI4)
using a gear puller.

36. Remove ferry capscrews (55) on the

inside of the adapter housing (17).

37. Using a dowel pin puller remove

dowel pins (43).

38. Remove ferry capscrews (55).

39. Stand the unit upright.

r
I 40. Using gear pullers remove the driven
gear (G12) from the 12 Series unit.

I
I
I
.

1 41. Remove the spacer (28) that's behind

the gear (G12).

I
I
I
I 42. Using gear pullers, remove the driven
gear (G11) from the 20 Series unit.

I
I
I
43. Remove the gear spacer (G13).
I
I
1
I 44. Remove the smap ring retainer (41).

I
I
I D - 6 - 83
 II / /4"; •
•
'Jo
• 1.
1

/
?if
45. Remove ferry capscrews (79) that
hold the bearing retainers (21).

46. Remove shims (48).

47. Remove set screws (86) and plugs

(89 & 94).

48. Remove ferry capscrews (78). Also,

remove the cover.

49. Remove the ferry capscrews (82 & 83)

that holds the inlet cover (1).
 83
1

78
ov
45

72
R12
62
H5 89

2
49
R14

48
41
42
16 5 21
94 86 (44;5
49 79
64
83
64
50 42

7922 15 /
G12 4 75
50. It may be necessary to tap the back
of the inlet cover because of the
locite.

51. Some models have this plug. If your

unit has this, just pull it out.

52. Remove hex. hd. capscrews (76) that

hold the balance piston (32).

53. Remove shims (51).

54. Rotate the unit so that the gear

box is down.

D - 6 - 83
R12 K.

trOix. H5 89
k
7tffia
, 49
R14

64
48
41
A"- 42
94 86 Loir,6 1 dd
/1
ir4r• • 5 21
4!. 79
64
83 64 t y4!
r=
i

79 22
G 12 41 75,

•:0 4 • it ///
//‘?;

•
55. Remove the last two screws (53)
holding the outlet housing (5).

56. Lift up the outlet housing with the

rotors approx. 5".

57. Between the outlet housing (5) and

stator (9), place a spacer that
will except the weight of the rotors
and outlet housing.

58. Using a press, push each rotor

(R9 & R10) thru the bearings (B10).

59. After the rotors are pushed out,

then you should be able to pull the
outer bearings (B10) out.
 83
/ /1

78
,
ou

45

76 /
32 / 72
R12
33

H5 89 83

2
49
R14

/6 \
5 21
, 1 49
94 86 `1146
16
4 79

.,,,,
oot
64 I
83
64
50
it
s ,. ,„.
, 42

79
-22 15 '..
/
Z..- ..c..
7sh,
G 1 2 41 75

,‘ //fir!

)
 60. Remove bearing spacers (11).

1 61. Lift the outlet housing off (5).

62. From the outlet face side, knock

the bearings (B11) out.

63. Bearings shown out of the

outlet housing

1 64. Lift both the rotors (R9 & R10)

out of the stator (9).

D - 6 - 33
 83
z /1

78
80 38
/ 37 61
45

72
R12
33

H 5 89
28,-* a
2
R14 49
64
64
48
41
42
94 86 clD6 1 5 21
49
41 .0., 79
64
83
64
C -tom ev
.••••• 42
15
79 22 /
G /2 41 75,

V,
r,
65. Punch the two dowel pins (43)
out of the stator.

66. Attach your crane to the stator so

that the weight of unit can be held
for removing the support leg.

67. Remove all screens holding the

support leg.

68. Remove any screws (55) still

holding the stator (9) to the
adapter (17).

69. Using the crane, take the stator (9)-

off the adapter (17).

n- A -
R12

H5 89

61-1
474f; <i
R14 49

64
48
41
42
5 21
94 86 116
49 • 79
83
64
64 ,1
44
50
5ft,
7 9 22 15 / ,,„„
dor
/
G12 41 75,-
,,,-...;-- ...::„... ,... .ie....i
...,.,... ,, ., 7, ... p.,.... ..,
70. Using a dowel pin puller, remove
the dowel pins (72) between the
inlet housing (4) and stator (8).

71. Remove the ferry capscrews (83) that

holds the inlet housing (4) to the
stator (8).
• • ''' ..... ..

72. Lift the inlet housing (4) off.

73. Placing the inlet housing on a

arbor press, press the bearings
(61 & 62) out.

74. Remove the ferry capscrews (53)

holding the outlet housing flange
(H5) to the adapter (17).
 83

78
38
80
37 61
45

72
R12

H5 89
4 /100
,

rat
i % 49
R14 64

48
41
42
1 5 21
94 86 114;6 Ly
49 79
64
83 64
50 42
,c/
79 22 15
G 12 4175.-
75. Punch the two dowel pins (72) out
of stator (8).

76. Lift up the stator (8) slightly and

remove the two nuts (49) and lock-
washers (50) holding the stator to
the adapter.

77. Lift the stator off.

78. Using a stud puller, remove the

two studs (52).

79. Lift the stator and turn it over.

R12

H 5 89

R14 49
-\. ("
r %
e. Ait:
,
er
fa' - ri
,,..!.. ior ci, 64
48
0.4, 41
,...ri_ 42
94 86 LZ6
49
/ ._ ..,. 5 21
- er, / 79
64 /
83
64
50
42
7922 1g / ;Y.
Se:

G12 41 75 '.."--...9-1';;-• ,.
J7.: / "ss. '''.3-- ••-"—:!.... )4:7*-i
;:--Z4,_.,..8,
.. .4 ) / i f / eV4..Az.,
7:--Z56
:l iii tr._ ///7 te / : itr* %
...., ,
4:.(, •:S' :1 (4 i
4̀:. 1
80. Remove ferry capscrew (83) from
the outlet housing (H5).

81. Using two screws, jack the two

housing apart by tightening the
two screws.

82. Using a crane, lift the outlet

housing (H5) and rotors out of the
stator.

83. Place the outlet housing and rotors

on the press with the rotors facing
down. Press the female rotor (R12)
out of the outlet housing (H5).

84. Press the male rotor (R14) out of

the outlet (H5).

n - F -
 47 14
13
/ B10
1 11
B11
41;. /

7
/ln C %.!
15 47~~
14 /
22 13
810
53 11
B11 R9

53

G24

32
31
R10

.. • 53
S17
1 x

B13

I( S4 S11
/ 18
67
/ 26
39
17 35

G14
1 2 27
45

1 014
69
®
"....G26
D1
45
20
05 2
\ ..,19

010
I
S2 • G10 06 28

S9 S8 16
S15
61
S10
S1 S10
S16
85. Stand the adapter up (17).

86. Punch out remaining bearings

(BI2 & B13) from the adapter (17).

87. On all parts removed in this tear-

down make sure that all plugs and
fittings have been removed.
Section 3 Parts List, Tooling List,
Kits and Tolerance Chart
 8
1

17
16 2

15

18 10

e(-016.01101
5.- .- 21 22 8
1

/ 23
19
24
I 24
25
/ 26
/4 \ / 7
CO 29
34 36 .4,e 32 , /_ /
23 30
8 24
24
37 27
-1.
30 33 32/
31 26 28
COMPRESSOR UNIT - DH -12

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REF. # QUANITY

1 cover, inlet housing 230479 1 1

2 ring, spacer 222223 38 1

3 sleeve, female - DH12 224152 37 1

4 bearing, cylindrical roller (5209) 499084-209 61 1

5 housing, inlet 230480 4 1

6 pin, dowel 1/2" x 1 1/2" 499045-043 72 4

7 stator - DH12 230470 8 1

8 capscrew, ferry hd. 1/2"-13 x 1 1/2" 828408-150 83 27

9 bearing, cylindrical roller (5211) 499084-211 62 1

10 sleeve, male - DH12 231956 33 1

11 shim set, piston outer ring 231961 51 1

12 piston, balancing 222222 32 1

13 capscrew, hex hd. 3/8"-16 x 1" GR 8 828206-100 76 2

14 capscrew, ferry hd. 3/8"-16 x 1 1/2" 828406-150 82 15

15 cover, valve 231960 45 1

16 capscrew, ferry hd. 3/8"-16 x 2 1/2" 828406-250 80 2

17 capscrew, ferry hd. 3/8"-16 x 1" 828406-100 78 4

rotor, female 224017 R12 1

18
rotor, male 224016 R14 1
19

20 key, square CL2 3/8" x 2" 821206-200 G28 1

21 housing, outlet - DH12 230481-036 H5 1

22 plug, pipe 1/8" 3000# STL. 807800-005 89 4

23 shim set, outlet bearings 224112 49 2

 8
1

17
2
16
15

13
12
1
10

21 8
e 11.11.•
r0;...
22

23
19
24
24
-1 25 26
27
2829
34 36 c 32 / 30
23 1,
8 24
24
37 27

32
33 /
31 26 28

• .. 01
COMPRESSOR UNIT - DH-12

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REF. # QUANITY

24 bearing, taped roller 499015-008 64 4.

25 shim set, inlet bearings 220301 48 1

26 cap, retainer 231959 41 2

27 plate, locking 28039 42 2

28 capscrew, hex hd. 3/8"-16 x 1 1/4" GR 8 828206-125 75 6

29 retainer, outlet bearing 224687 21 1

30 capscrew, ferry hd. 3/8"-16 x 1 1/4" 828406-125 79 12

31 gear, driven 2.35:1 499060-235 G12 1.

32 spacer, gear 1.75. x 2.25 x .700 227397-002 15 2

33 retainer, male outlet, bearing 227280 22 1

34 plug, pipe - cntrsk, 1/8" 499046-001 94 2

35 ring, male rotor dist. outer 227279 35 1

36 screw, set cup 1/2"-13 x 3/8" 832208-038 86 2

37 shim set, male outlet bearing 227281 50 1

 53

14 5

10

13,

15
68( / 16
/ 17
701

52 14

18
51
50 19
20
/ 21
49 22
23

24
9 / 30

C kt ,.. 31 33
32 \
34
13
37

48 32 Ckz,
47 44
35
36

55
56
42 41 39

59 65
61 / 66 38

Ctir* . 64
63 64 ,4/
67
 COMPRESSOR UNIT - DDH2O

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REP. # QUANITY

1 capscrew, ferry hd. 3/8"-16 x 3" 828406-300 51 12

2 capscrew, hex hd. 1/2"-I3 x 1 1/2" GR 8 828208-150 47 6

3 plate, locking D20 24704 14 2

4 retainer, bearing 24703 13 2

5 bearing, angle cont. 499099-314 B10 2

6 shim set, bearing axial outlet 225102 11 2

7 bearing, cylindrical roller 499014-314 B11 2

8 housing, outlet 249983 5 1

9 stator, D204 24680 9 1

10 rotor, female 223810 R9 • 1

11 key, square CL2 5/8" x 2" 821210-200 G24 1

12 rotor, male 28130 R10 1

13 pin, dowel 1/2" x 11/2" 499045-043 43 8

14 capscrew, ferry hd. 1/2"-13 x 1 1/2" 828408-150 53 36

15 screw, drive type U 8" x 3/8" 40130 32 2

16 plate, serial number - 31 1

17 capscrew, ferry hd. 1/2"-13 x 2 3/4" 828408-275 55 9

1 18 bearing, cylindrical roller 499013-310

27053
B13

18
1

1
19 retainer, inlet bearing

20 elbow, 90° tube 3/8" x 1/4" 810506-025 67 1

21 tube, bearing oil line 28070 26 1

22 0-ring, Buna-N 4 1/8" x 1/8" 826102-243 39 1

23 ring, bevel retainer 46027 35 1

 53

10 .

e;411/44„,
681 /
/ 13
691 701

52
1X

18
51
50 / 19
20
21
49 22
23
z

29
33 34 37
32 r 13 I

32 iik, I

33 \a,. 35
'... "
•1%-- ..... 36

55
56

62

59 - r,65
41% "je
jr
61
/
29-9
,64
63 64
67
COMPRESSOR UNIT - DDH2O

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REF. # QUANITY

24 retainer, bearing 24703 G14 1

25 gear, driven 1.65:1 499060-165 Gil 1

26 ring, male distance 231556 G13 1

27 ring, ret-int SPL 6 114" 836369-625 41 1

28 bearing, cylindrical roller 499014-315 B12 1

29 plug, pipe 3/8" 3000# stl. 807800-015 61 3

30 plate, locking 24704 G15 1

31 capscrew, hex hd. 1/2"-13 x 1 1/2" GR 8 828208-150 G32 3

32 capscrew, ferry hd. 1/4"-20 x 1/2" 828404-050 45 2

33 nozzle 13412 2 2

34 tube, gear R.H. oil line 28071 27 1

35 bracket, gear nozzle - pos. up 27056 20 1

36 bracket, gear nozzle - pos. low 27055 19 1

37 capscrew, ferry hd. 1/2"-13 x 1 3/4" 828408-175 54 36

38 housing, gear 26975 16 1

39 nipple, pipe 1/8" x 2" 822202-020 63 1

40 tee, tube 1/4" x 1/8" 810704-012 65 1

41 tube, gear L.H. oil line 28072 28 1

42 ring, dist. - input shaft rear 27058 D6 1

43 gear, drive 1.65:1 499059-165 G10 1

44 shaft, input 27059 DI 1

45 key, square CL2 7/8" x 2" 821214-200 G26 I

46 elbow, 90 ° tube 3/8" x 3/8" 810506-038 69 1

 53

15
68( / (44z1
, „ 16
691 17
701

52 14

18
51
50 19
20
21
49 / 22
/ 23
/

24
30
..---
-c:tr- 31 33 34 37
1
32 \ 13

<8\ tv,..45
_,44
32 412ka

..." 33, \,._ 35

N. •••••• ..... 36

55 /
56 40
42 41 39

59 65
61 / 66 38
29 —9
64
63 64
67
COMPRESSOR UNIT - DDH2O

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REF. # QUANITY

47 ring, dist. - input shaft front 27057 D5 1

48 bearing, tapered roller 499015-014 D14 2

49 adapter, compressor mounting 26976 17 1

50 0-ring, viton 2 3/8" x 1/16" 826502-036 SIl 1

51 cover, input shaft hole 221556 S4 1

52 capscrew, ferry hd. 1/4"-20 x 3/4" 828404-075 S17 4

53 compressor unit DH12 65077B 22 1

54 capscrew, ferry hd. 1/2"-13 x 1 1/2" 828408-150 S19 8

55 shim set, input shaft bearing 220100 D10 1

56 retainer, input shaft bearing 221938 S2 1

57 holder, oil seal spring 221971 S14 1

ring, retainer - int T spir. RR 315/16 41134 S13 1

58

59 seal, shaft - Viton 3" 240017 S9 1

60 0-ring, viton 4 1/4" x 3/32" 826502-116_ S12 1

,---
61 pin, headed spring 1/8" x 3/8" 499064-806 S15 1

capscrew, ferry hd. 5/16"-18 x 7/8" 828405-088 S18 6

62

retainer, oil seal 221937 S1 1

63

V-ring 499044-075 SlO 2

64
gasket, dust shield 221941 S6 1
65
shield, oil seal dust 221939 S8 1
66
67 capscrew, ferry hd. 1/4"-20 x 1/2" 828404-050 S16 6

nut, hex unfinished 1/2"-13 824208-448 49 2

68
837508-125 50 2
69 washer, springlock - reg. 1/2"
 53

10 .

13

15
68 / qtzk, 16
6.91 17
701

52 14

1141 ) 18
51
50
ere 19

/ 21
20

C -AP
/ 22
/ 23

24
..--- 30
.0'
34
C (czo.... 31 33
32 \ 13
- 37

,...- 45
ti 32 Ilk>
44
33\ ,, 35
N... 'id .„.., 36

/
55 56 40
42 41 39

59
61 38
29
64
63 64
67
COMPRESSOR UNIT - DDH2O

KEY PART ENG.

NUMBER DESCRIPTION NUMBER REF. # QUANITY

70 stud, threaded - unfin. 1/2"-13 x 2" 839408-020 52 2

71 cover, outlet housing 24684 7 1

72 gasket, outlet housing cover 24693 15 1

 A-
En Ina ma um am En um on um a an ant mg an a al a on a
27 G12 G28 2 20 45 G1C G26 G24 G11 19 45

28

32
57
 17 R9
R10
39 1

51
16

54 14
35 47

18 13
813 B11
41 67
610
B12
11
D6
13
D14
14
S19 47
B10
S18

S16
10.-
40AAlaffIrgffirIVAfflr
,"
5z rill:, B11
*Dimas. 53
D1 -7a •
ne105.-:
'6:1:7•4

S11

S10
S
S6 S17
Si
S15 Sd
S12
S2 D14
S13
D5
S9

514 D10

61 63
 TOOLING

KEY PART
NUMBER DESCRIPTION NUMBER QUANITY

1 tool, bearing spacer 735-001 1

2 tool, inner bearing 735-002 2

3 tool, male outer bearing 735-003 1

4 tool, female outer bearing 735-004 1

5 capscrew, ferry head 3/8" x 4 1/2" 828406-450 6

6 spacer - 4

7 spacer - 2

8 cap - 3
 TOOLING

I
I
I
I
I
I
I
I0

I
I
I
KEY PART
DESCRIPTION NUMBER QUANTITY
NUMBER
...-
tool, shaft body 740-001 1
1 ...
740-002 1
2 tool, key
740-003 1
3 tool, strap clamp

dial indicator — 1
4

capscrew, ferry head 1/2" x 2 1/4" 828408-225 1

5
837208-112 1
6 washer, plain type B regular 1/2"
828404-075 2
7 capscrew, ferry head 1/4" x 3/4"
740-009 1
8 tool, bearing press. assembly
726-006 . 1
9 tool, rotor clearance check
821214-200 4
10 key, square CL2 7/8" x 2"
 MISCELLANEOUS TOOLING AND EQUIPMENT

SHOP RAGS

1. Eye Bolts
1) 3/8"-16

2) 1/2"-13

3) 3/4"-10

2. 8 oz. Ball Peen Hammer Large Plastic Mallet

3. Bearing Heater Oil Bath Light Bulb Box (optional)

4. Shim Stock Strip Set .001 thru .010

5. Dial Indicator

1) 0-1" outside micrometer

2) 0-1" depth micrometer

6. Impact Wrench - Torque Wrench

minimum range of 10 ft./lbs. to 200 ft./lbs.

7. Sockets - 12 point
1) 3/8" drive - 1/2"

2) 1/2" drive - 1/4" - 5/16" - 3/8" - 1/2" - 9/16" - 3/4"

3) 1/2" to 3/8" adapter

4) 1/2" drive universal joint

5) 1/2" drive 10" extension

8) Ilex Wrenchess (Allen)

3/16" - 1/4"
9. Open End Wrenches

9/16" - 11/16" - 3/4" - 15/16"

10. Medium Adjustable Pliers (channel locks)

Large Internal Snap Ring Pliers

11. Medium Punch

Medium Chisel

15" Pry Bar

12. Large Standard Screwdriver

13. Two-ton Crane

Fifty-ton Press

MISCELLENEOUS SPECIAL TOOLS

1. Plates - Steel

1) 3 1/4" diameter - 1/2" thick

2) 3 7/8" diameter - 1/2" thick

3) 4 1/4" diameter - 1/2" thick

4) 5 7/8" diameter - 1/2" thick

2. Shaft Rotating Wrench

3. Assembly Stand - #740-011

For Mounting Units to Stand

1) 2 - 3/4"-10 x 3 1/2" hex hd. bolts

2) 2 - 3/4"-10 x 2 1/4" hex hd. bolts
3) 3 - 3/4"-10 nuts
 For Bolting Outlet to End Clearance Stand

2 - 3/8"-16 x 1 1/4" ferry hd. screws

For Assembling Seal Housing

2 - 5/16"-18 x 1 1/2" ferry hd. screws

4. Locite Primer - T

Locite Liquid Gasket #515

Locite Stud Lock #242

Locite Pipe Sealant #567

Grease

Oil

Lubricating Compound

1
REPAIR KITS

KEY PART
NUMBER DESCRIPTION NUMBER

1 shaft seal 300 diameter 001811A

2 filter replacement parts 001847E

3 filter element 001847D

(includes replacement parts)

4 filter bypass valve 001847E

5 filter, window 001847F

 DIMENSIONS

DDH 204
MALE ROTOR Outlet Bearing Journal 2.7569 / 2.7564
Outlet Blocking Journal 3.618 / 3.616

Diameter Over Lobes 8.0315 / 8.0297

Inlet Blocking Journal 3.791 / 3.787

Inlet Bearing Journal 2.9538 / 2.9533

Gear Journal 2.5015 / 2.5008

Length Over Lobes 13.660 / 13.650

DDH 204
FEMALE ROTOR Outlet Bearing Journal 2.7569 / 2.7564

Outlet Blocking Journal 3.618 / 3.616

Diameter Over Lobes 8.0315 / 8.0297

Inlet Blocking Journal 3.754 / 3.750

Inlet Bearing Journal 1.9693 / 1.9689

Length Over Bores 13.660 / 13.650

DDH 204
OUTLET HOUSING Bearing Bores 5.9049 / 5.9063

Blocking Bores 3.625 / 3.626

DDH 204
STATOR Bores 8.0346 / 8.0375

Length 13.693 / 13.683

MOUNTING
ADAPTER Male Inlet Blocking Bore 3.797 / 3.799

Female Inlet Blocking Bore 3.76 / 3.78

Female Inlet Bearing Bore 4.3302 / 4.3314

Male Inlet Bearing Bore 6.2986 / 6.3000

Input Shaft Outboard Bearing Bore 5.9100 / 5.9110

 DIMENSIONS

DXH 12
STATOR Bores 5.0227 / 5.0247

Length 8.556 / 8.551

DXH 12
INLET HOUSING Male Blocking Bore 2.714 / 2.724

Male Bearing Bore 3.9368 / 3.9377

Female Blocking Bore 2.266 / 2.276

Female Bearing Bore 3.3463 / 3.3472

DXH 12
FEMALE PISTON
OUTER RING O.D. 3.3485 / 3.3475

I.D. - 2.1720 / 2.1730

DXH 12
FEMALE PISTON
INNER RING O.D. 2.1646 / 2.1638

I.D. 1.7712 / 1.7720

DXH 12
MALE PISTON
OUTER RING O.D. 3.939 / 3.938

I.D. 3.3500 / 3.3510

DXH 12
MALE BALANCE
PISTON O.D. 3.3420 / 3.3413

ti
 HIGH STRENGTH ANAEROBIC ADHESIVE

For Form-In-Place Gasketing

Viscosity 800K cP/200K cP @ 72 °F on .5/5 RPM Brookfield

Shelf Life 1 Year Minimum at 70° - 80°F

Cure Speed 24 to 48 hours without primer for full cure

1 to 8 hours with primer for full cure

Shear Strength 2000 to 3000 PSI

Tensile Strength 2000 PSI Maximum

Heat Resistance 300°F Maximum

Approved Sources Part Name Part No. Color Code

Loctite Corporation Gasket Eliminator 515 Purple

Broadview Chemical Corp. Sta-Lok

NOTE: Fill all voids between mating flanges to form a flexible, insoluble,
solid. When taking apart, remove bolts, then use a wedge or sharp
• hammer blow to loosen the assembly. To reassemble, clean foreign
matter off parts and reapply gasket eliminator.

PART
DESCRIPTION NUMBER QUANTITY

loctite, 6 ml tube 005910-006 1

loctite, 50 ml tube 005910-050 1
loctite, 300 ml caulking cartridge 005910-300 1
loctite, 850 ml caulking cartridge 005910-850 1
 o—.
REVISED 8-25-82

, l
• ORDER BLANK

Act:g3 SULLAIR CORPORATION

MICHIGAN CITY, INDIANA, 46360 U.S.A.
UNIT MANUFACTURED UNDER FOLLOWING
MAJOR SRM PATENT US.3423017,3073513-14,3129877
PART NUMBER RECORD ANY DATA
MODEL NUMBER RECORD ANY DATA
SERIAL NUMBER REQUIRED ON ALL ORDERS—NO
ORDER CAN BE MADE WITHOUT
S.N.

SULLAIR CORPORATION i
)1413
VP NO .....s RECORD ANY DATA
SIM NO REQUIRED ON ALL ORDERS IF
NOT RECORDED, CHECK PLATE
ON INSTRUMENT PANEL— NO
ORDER CAN BE MADE —
WITHOU T S.N.

KEY NO. DESCRIPTION PART NO. QTY.

----- ,

1
—..—.1
REVISED, 8-25-82 0-I.

• ORDER BLANK
•

Actg) SULLAIR CORPORATION

MICHIGAN CITY, INDIANA, 46360 U.S.A.
UNIT MANUFACTURED UNDER FOLLOWING
MAJOR SAM PATENT US.3423017,3073513-14,3129877
....-, RECORD ANY DATA
PART NUMBER
MODEL NUMBER RECORD ANY DATA

SERIAL NUMBER REQUIRED ON ALL ORDERS-NO

ORDER CAN BE MADE WITHOUT
S.N.

SULLAIR CORPORATION 1
443
CJP NO ...4_ RECORD ANY DATA
SJM NO - REQUIRO ON ALL ORDERS IF
NOT RECORDED, CHECK PLATE
ON INSTRUHaTT PANEL- NO
ORDER CAN 13E MADE. -
WITHOUT S.N.

KEY NO. DESCRIPTION PART NO. QTY.

, .

' "
 0-1
REVISED 8-2 5- 82

• ORDER BLANK

44-.) SULLAIR CORPORATION

MICHIGAN CITY, INDIANA, 46360 U.S.A.
UNIT MANUFACTURED UNDER FOLLOWING
MAJOR SRM PATENT US.3423017,3073513-14,3129877
PART NUMBER RECORD ANY DATA
r
MODEL NUMBER RECORD ANY DATA

SERIAL NUMBER REQUIRED ON ALL ORDERS-NO

I ORDER CAN BE MADE WITHOUT
S.N.

SULLAIR CORPORATION
*ft)
CM NO .... RECORD ANY DATA
S/M NO REQUIRED ON ALL ORDERS IF
NOT RECORDED, CHECK PLATE
S. ' ON INSTRUMENT PANEL- NO
. VAL.:). ORDER CAN $E MADE -
I 71-. WITHOUT S . N .

•
DESCRIPTION PART NO. QTY.
KEY NO.

. ,

.... , 1
REVISED 8-25-82 0-1
. ....._ . ..._

• ORDER BLANK

440 SULLAIR CORPORATION

MICHIGAN CITY, INDIANA, 46360 U.S.A.
UNIT MANUFACTURED UNDER FOLLOWING
MAJOR SRM PATENT US-3423017,3073.513-14,3129877
PART NUMBER RECORD ANY DATA
MODEL NUMBER RECORD ANY DATA
1
SERIAL NUMBER. ' , REQUIRED ON ALL ORDERS-NO
ORDER CAN BE MADE WITHOUT
S.N.

SULLAIR CORPORATION i
443
ClP NO ....ii RECORD ANY DATA
SIM NO REQUIRED ON -ALL ORDERS IF
NOT RECORDED, CHECK PLATE
ON INSTRUMENT PANEL- NO
ORDER CAN 13E MADE
WITHOUT S.N.

KEY NO. DESCRIPTION PART NO. QTY.:

. _
, ...,

• ,
. _

,;
"•-•

.
REVISED 8-25-S2 • 0-1
..._. _.

• ORDER BLANK
._ . .

44413 SULLAIR CORPORATION

MICHIGAN CITY, INDIANA, 46360 U.S.A. •
UNIT MANUFACTUR ED UNDER FOLLOWING
MAJOR SRM PATENT US.3423017,30 73513-14,3129877
PART NUMBER RECORD ANY DATA
MODEL NUMBER RECORD ANY DATA
SERIAL NUMBER REQUIRED ON ALL ORDERS-NO
ORDER CAN BE MADE WITHOUT
S.N.

*4, SUU_AIR CORPORATION j -

CIF, NO RECORD ANY DATA
WM NO _ REQUIRED ON -ALL ORDERS IT
NOT RECORDED, LiitC1( PLATE
ON INSTRUMENT PANEL- NO
ORDER CAN AE MADE
WITHOUT '.N. .

KEY NO. DESCRIPTION PART NO. QTY

...

....
. .

-.-

.
'