Sullair 1600H AF User Manual PDF

USER MANUAL
PORTABLE AIR COMPRESSOR

1300H[A][F], 1300HH[A][F],
1450HH[A][F], 1600[A][F], 1600H[A][F],
[A] AFTERCOOLED MODELS, [F] FILTERED MODELS
CATERPILLAR IT4
PART NUMBER:
02250207-734 r01
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
COPYRIGHT 2014 SULLAIR
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
201305200000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
SULLAIR TRAINING DEPARTMENT
1-888-SULLAIR or
219-861-5623
www.sullair.com
[email protected]
- Or Write -
Sullair
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
Recommended Oil Lubrication Specifications provided by © 2012 Dexter Axle Company.

TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 TOWING *
8 1.3 PRESSURE RELEASE
9 1.4 FIRE AND EXPLOSION
10 1.5 MOVING PARTS
11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
11 1.7 TOXIC AND IRRITATING SUBSTANCES
13 1.8 ELECTRICAL SHOCK
13 1.9 LIFTING
13 1.10 ENTRAPMENT
13 1.11 JUMP STARTING
14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT
15 1.13 CALIFORNIA PROPOSITION 65
16 1.14 SYMBOLS AND REFERENCES
SECTION 2—DESCRIPTION
21 2.1 INTRODUCTION
21 2.2 DESCRIPTION OF COMPONENTS
23 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
23 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
25 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
27 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
27 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
28 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
29 2.9 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION
36 2.10 PARTS OF THE EVENT CODE
37 2.11 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
38 2.12 MAIN WIRING DIAGRAM
42 2.13 CONTROLLER WIRING DIAGRAM
44 2.14 P & I COMPRESSOR SYSTEM
46 2.15 ID, DLQ AFTERCOOLED
48 2.16 ID, DTQ AFTERCOOLED
50 2.17 AFTERCOOLER AIR SYSTEM, FUNCTIONAL DESCRIPTION
53 2.18 ENGINE EXHAUST AFTERTREATMENT, FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
SECTION 3—INSTALLATION
55 3.1 LOCATING THE PACKAGE
55 3.2 VENTILATION AND COOLING
55 3.3 SERVICE AIR CONDENSATE PIPING
SECTION 4—SPECIFICATIONS
57 4.1 TABLES OF SPECIFICATIONS
58 4.2 LUBRICATION GUIDE—COMPRESSOR
59 4.3 APPLICATION GUIDE
59 4.4 LUBRICATION GUIDE, ENGINE
SECTION 5—OPERATION
61 5.1 GENERAL
61 5.2 PURPOSE OF CONTROLS
63 5.3 COMPRESSOR START-UP PROCEDURE
63 5.4 EXHAUST REGENERATION PROCEDURE
65 5.5 SHUTDOWN PROCEDURE
SECTION 6—MAINTENANCE
67 6.1 GENERAL
67 6.2 DAILY OPERATION
68 6.3 ENGINE COOLANT REQUIREMENTS
68 6.4 DAILY MAINTENANCE
69 6.5 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
69 6.6 MAINTENANCE EVERY 250 HOURS
69 6.9 MAINTENANCE AFTER 4500 HOURS OF OPERATION
69 6.10 MAINTENANCE AFTER 5000 HOURS OF OPERATION
69 6.11 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
80 6.12 TROUBLESHOOTING GUIDE
82 6.13 AIR-STOP FUNCTION TEST
SECTION 7—NOISE CONTROL

83 7.1 NOISE EMISSIONS WARRANTY
83 7.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED
84 7.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD
LOG
Section 1
SAFETY
DO NOT modify the compressor except with written
NOTE factory approval.
Each day, walk around the air compressor and
inspect for leaks, loose or missing parts, damaged
parts or parts out of adjustment. Perform all
recommended daily maintenance.
Inspect for torn, frayed, blistered or otherwise
deteriorated and degraded hoses. Replace as
OPERATOR IS REQUIRED TO READ required.
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL 1.2 TOWING *

Sullair designs and manufactures all of its products PREPARING TO TOW
so they can be operated safely. However, the
responsibility for safe operation rests with those who
use and maintain these products. The following WARNING
safety precautions are offered as a guide which, if
conscientiously followed, will minimize the possibility Do NOT tow the compressor should its
of accidents throughout the useful life of this weight exceed the rated limit of the tow
equipment. Read the CIMA Safety Manual prior to vehicle, as the vehicle may not brake safely
compressor operation and towing, if applicable with excess weight. See rated limit in tow
in your area. vehicle Operator's Manual, and review its
instructions and other requirements for
The air compressor should be operated only by those
safe towing.
who have been trained and delegated to do so, and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, procedures
A. Prior to hitching the air compressor to the tow
and safety precautions in this manual can result in vehicle, inspect all attachment parts and equip-
accidents and injuries. ment, checking for (I) signs of excessive wear or
NEVER start the air compressor unless it is safe to corrosion, (II) parts that are cracked, bent,
do so. DO NOT attempt to operate the air dented or otherwise deformed or degraded, and
(III) loose nuts, bolts or other fasteners. Should
compressor with a known unsafe condition. Tag the
any such condition be present, DO NOT TOW
air compressor and render it inoperative by until the problem is corrected.
disconnecting and locking out all power at source or
otherwise disabling its prime mover so others who B. Back the tow vehicle to the compressor and posi-
may not know of the unsafe condition cannot attempt tion it in preparation for coupling the compressor.
to operate it until the condition is corrected. C. If the compressor is provided with a drawbar
Use and operate the air compressor only in full latched in the vertical upright position, carefully
compliance with all pertinent OSHA requirements unlatch drawbar and lower it to engage the cou-
and/or all pertinent Federal, State and Local codes or pling device. If not, raise drawbar with the jack to
requirements. engage coupling device or otherwise couple the
compressor to the towing vehicle.
* While not towed in the usual sense of the word, many of these instructions are directly applicable to skid-mounted portable air
compressors as well.
5
SECTION 1
WARNING CAUTION
This equipment may be tongue heavy. DO Retract the front screw jack only after
NOT attempt to raise or lower the drawbar attaching the compressor to the tow vehi-
by hand if the weight is more than you can cle. Raise the screw jack to its full up posi-
safely handle. tion and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its
Use the screw jack provided or a chain fall
stowed position, parallel to the drawbar,
if you cannot lift or lower it without avoiding
and reinsert the pin. Make sure the jack is
injury to yourself or others. Keep hands
secured in place prior to towing.
and fingers clear of the coupling device and
all other pinch points. Keep feet clear of If a caster wheel is provided on the screw
drawbar to avoid injury in case it should jack it is part of the screw jack and can not
slip from your hands. be removed. Follow the same procedure for
stowing away the wheeled jack as you
A. Make sure the coupling device is fully engaged, would for the standard screw jack. Pull the
closed and locked. pin connecting the jack to the drawbar and
raise the screw jack to its full up position.
B. If chains are provided, pass each chain through Rotate the screw jack to its stowed posi-
its point of attachment on the towing vehicle; tion, parallel to the drawbar, and reinsert
then hook each chain to itself by passing the the pin. Make sure the jack is secured in
grab hook over (not through) a link. Cross chains place prior to towing.
under the front of drawbar before passing them
through points of attachment on towing vehicle to
E. On two-wheeled models, fully retract front screw
support the front of drawbar in case it should
jack and any rear stabilizer legs. If a caster wheel
accidentally become uncoupled.
is provided on the screw jack it is part of the
C. Make sure that the coupling device and adjacent screw jack, and can not be removed. Follow the
structures on the towing vehicle (and also, if uti- same procedure for stowing away the wheeled
lized, chain adjustment, brake and/or electrical jack as you would for the standard screw jack.
interconnections) DO NOT interfere with or Pull the pin connecting the jack to the drawbar
restrict motion of any part of the compressor, and raise the screw jack to its full upright posi-
including its coupling device, with respect to the tion. Rotate the screw jack to its stowed position,
towing vehicle when maneuvering over any parallel to the drawbar, and reinsert the pin.
anticipated terrain. Make sure the jack is secured in place prior to
towing.
D. If provided, make sure chain length, brake and
electrical interconnections provide sufficient F. Make sure tires are in good condition and are the
slack to prevent strain when cornering and size (load range) specified and are inflated to the
maneuvering, yet are supported so they cannot specified pressures. DO NOT change the tire
drag or rub on road, terrain or towing vehicle sur- size or type. Also, make sure wheel bolts, lugs or
faces which might cause wear that could render nuts are tightened to the specified torques.
them inoperative.
G. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating properly
WARNING and that their lenses are clean and functional.
Also, make sure all reflectors and reflecting sur-
faces, including the slow moving vehicle emblem
This equipment may be tongue heavy. DO
on compressors provided with same, are clean
NOT attempt to raise or lower the drawbar
and functional.
by hand if the weight is more than you can
safely handle. H. Make sure all service air hoses (not air brake
hoses) are disconnected or are fully stowed and
secured on hose reels, if provided.
6
SECTION 1
I. Make sure all access doors and tool box covers E. Avoid potholes, rocks and other obstructions,
are closed and latched. If the compressor is and soft shoulders or unstable terrain.
large enough to hold a man, make sure all per-
F. Maneuver in a manner that will not exceed the
sonnel are out before closing and latching
freedom of motion of the compressor’s drawbar
access doors.
and/ or coupling device, in or on the towing vehi-
J. Make sure parking brakes in towing vehicle are cle’s coupling device and/or adjacent structure
set, or that its wheels are chocked or blocked, or whether towing forward or backing up, regard-
that it is otherwise restrained from moving. Then, less of the terrain being traversed.
release the compressor parking brakes, if pro-
G. DO NOT permit personnel to ride in or on the
vided.
compressor.
K. Make sure the compressor wheels are not
H. Make sure the area behind, in front of, and under
chocked or blocked, and that all tie-downs, if any,
the compressor is clear of all personnel and
are free.
obstructions prior to towing in any direction.
L. Test running brake operation, including break-
I. DO NOT permit personnel to stand or ride on the
away switch operation if provided, before
drawbar, or to stand or walk between the com-
attempting to tow the compressor at its rated
pressor and the towing vehicle.
speed or less when conditions prevail.
M. DO NOT carry loose or inappropriate tools, PARKING OR LOCATING COMPRESSOR
equipment or supplies on or in the compressor. A. Park or locate compressor on a level surface, if
N. DO NOT load this equipment with accessories or possible. If not, park or locate compressor across
tools such that it is unbalanced from side to side grade so the compressor does not tend to roll
or front to back. Such unbalance will reduce the downhill. DO NOT park or locate compressor on
towability of this equipment and may increase grades exceeding 15° (27%).
the possibility of tipping, rolling over, jackknifing, B. Make sure compressor is parked or located on a
etc. Loss of control of the towing vehicle may firm surface that can support its weight.
result.
C. Park or locate compressor so the wind, if any,
TOWING tends to carry the exhaust fumes and radiator
heat away from the compressor air inlet open-
A. Observe all Federal, State, and Local laws while
ings, and also where the compressor will not be
towing this equipment (including those specifying
exposed to excessive dust from the work site.
minimum speed).
D. On steerable models, park compressor with front
B. DO NOT exceed the towing speeds listed below
wheels in straight-ahead position.
under ideal conditions. Reduce your speed
according to posted speed limits, weather, traffic, E. Set parking brakes and disconnect breakaway
road or terrain conditions: switch cable and all other interconnecting electri-
cal and/or brake connections, if provided.
1. Two axle four-wheel or three axle six-wheel
steerable models: 15 MPH (24 km/h). F. Block or chock both sides of all wheels.
2. All other models: 55 MPH (88 km/h). G. If provided, unhook chains and remove them
C. Remember that the portable air compressor may from the points of chain attachment on the towing
approach or exceed the weight of the towing vehicle, then hook chains to bail on drawbar or
vehicle. Maintain increased stopping distances wrap chains around the drawbar and hook them
accordingly. DO NOT make sudden lane to themselves to keep chains off the ground
changes, U-turns or other maneuvers. Such which might accelerate rusting.
maneuvers can cause the compressor to tip, roll H. Lower front screw jack and/or any front and rear
over, jackknife or slide and cause loss of control stabilizer legs. Make sure the surface they con-
of the towing vehicle. Tipping, rolling over, etc. tact has sufficient load bearing capability to sup-
can occur suddenly without warning. U-turns port the weight of the compressor.
especially should be made slowly and carefully.
D. Avoid grades in excess of 15° (27%).
7
SECTION 1
chain fall if you cannot lift or raise the drawbar

without avoiding injury to yourself or others.
K. Move the towing vehicle well clear of the parked
WARNING compressor and erect hazard indicators, barri-
cades and/or flares (if at night) if compressor is
This equipment may be tongue heavy. DO parked on or adjacent to public roads. Park so as
NOT attempt to raise or lower the drawbar not to interfere with traffic.
by hand if the weight is more than you can
safely handle.
NOTE
CAUTION While not towed in the usual sense of the
word, many of these instructions are
directly applicable to skidmounted porta-
Retract the front screw jack only after ble air compressors as well.
attaching the compressor to the tow vehi-
cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to 1.3 PRESSURE RELEASE
the drawbar. Rotate the screw jack to its
stowed position, parallel to the drawbar, A. Open the pressure relief valve at least weekly to
and reinsert the pin. Make sure the jack is make sure it is not blocked, closed, obstructed or
secured in place prior to towing. otherwise disabled.
On two-wheeled models, fully retract front B. Install an appropriate flow-limiting valve between
screw jack and any rear stabilizer legs. If a the compressor service air outlet and the shutoff
caster wheel is provided on the screw jack (throttle) valve, when an air hose exceeding 1/2"
it is part of the screw jack and can not be (13 mm) inside diameter is to be connected to
removed. Follow the same procedure for the shutoff (throttle) valve, to reduce pressure in
stowing away the wheeled jack as you case of hose failure, per OSHA Standard 29 CFR
would for the standard screw jack. Pull the 1926.302 (b) (7) or any applicable Federal, State
pin connecting the jack to the drawbar and and Local codes, standards and regulations.
raise the screw jack to its full up position. C. When the hose is to be used to supply a mani-
Rotate the screw jack to its stowed posi- fold, install an additional appropriate flow-limiting
tion, parallel to the drawbar, and reinsert valve between the manifold and each air hose
the pin. Make sure the jack is secured in exceeding 1/2" (13 mm) inside diameter that is to
place prior to towing. be connected to the manifold to reduce pressure
in case of hose failure.
I. If a caster wheel is provided on the screw jack, it
is part of the screw jack and cannot be removed. D. Provide an appropriate flow-limiting valve for
Follow the same procedure for stowing away the each additional 75 feet (23 m) of hose in runs of
wheeled jack as you would for the standard air hose exceeding 1/2" (13 mm) inside diameter
screw jack. Raise the screw jack to its full upright to reduce pressure in case of hose failure.
position and pull the pin connecting the jack to E. Flow-limiting valves are listed by pipe size and
the drawbar. Rotate the screw jack to its stowed rated CFM. Select appropriate valve accordingly.
position, parallel to the drawbar and reinsert the
pin. Make sure the jack is secured in place prior F. DO NOT use tools that are rated below the maxi-
to towing. mum rating of this compressor. Select tools, air
hoses, pipes, valves, filters and other fittings
J. Disconnect coupling device, keeping hands and accordingly. DO NOT exceed manufacturer’s
fingers clear of all pinch points. If the compressor rated safe operating pressures for these items.
is provided with a drawbar, DO NOT attempt to
lift the drawbar or if hinged, to raise it to the G. Secure all hose connections by wire, chain or
upright position by hand, if the weight is more other suitable retaining device to prevent tools or
than you can safely handle. Use a screwjack or hose ends from being accidentally disconnected
and expelled.
8
SECTION 1
H. Open fluid filler cap only when compressor is not 1.4 FIRE AND EXPLOSION
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
I. Vent all internal pressure prior to opening any
WARNING
line, fitting, hose, valve, drain plug, connection or Do not attempt to operate the compressor
other component, such as filters and line oilers, in any classification of hazardous environ-
and before attempting to refill optional air line ment or potentially explosive atmosphere
anti-icer systems with antifreeze compound. unless the compressor has been specially
J. Keep personnel out of line with and away from designed and manufactured for that duty.
the discharge opening of hoses, tools or other
points of compressed air discharge. A. Refuel at a service station or from a fuel tank
K. DO NOT use air at pressures higher than 30 psig designed for its intended purpose. If this is not
(2.1 bar) for cleaning purposes, and then only possible, ground the compressor to the dis-
with effective chip guarding and personal protec- penser prior to refueling.
tive equipment per OSHA Standard 29 CFR B. Clean up spills of lubricant or other combustible
1910.242 (b) or any applicable Federal, State substances immediately, if such spills occur.
and Local codes, standards and regulations.
C. Shut off air compressor and allow it to cool. Then
L. DO NOT engage in horseplay with air hoses as keep sparks, flames and other sources of ignition
death or serious injury may result. away and DO NOT permit smoking in the vicinity
M. This equipment is supplied with an ASME when adding fuel, checking or adding electrolyte
designed pressure vessel protected by an ASME to batteries, checking or adding fluid, checking
rated relief valve. Lift the handle once a week to diesel engine ether starting aid systems, replac-
make sure the valve is functional. DO NOT lift ing cylinders, or when refilling air line anti-icer
the handle while machine is under pressure. systems antifreeze compound.
N. If the machine is installed in an enclosed area it D. DO NOT permit fluids, including air line anti-icer
is necessary to vent the relief valve to the outside system antifreeze compound or fluid film, to
of the structure or to an area of non-exposure. accumulate on, under or around acoustical mate-
rial, or on any external surfaces of the air com-
O. DO NOT remove radiator filler cap until the cool- pressor. Wipe down using an aqueous industrial
ant temperature is below its boiling point. Then cleaner or steam clean as required. If necessary,
loosen cap slowly to its stop to relieve any remove acoustical material, clean all surfaces
excess pressure and make sure coolant is not and then replace acoustical material. Any acous-
boiling before removing cap completely. Remove tical material with a protective covering that has
radiator filler cap only when cool enough to touch been torn or punctured should be replaced
with a bare hand. immediately to prevent accumulation of liquids or
P. The ethyl ether in the replaceable cylinders used fluid film within the material. DO NOT use flam-
in diesel ether starting aid systems (optional) is mable solvents for cleaning purposes.
under pressure. DO NOT puncture or incinerate E. Disconnect and lock out all power at source prior
those cylinders. DO NOT attempt to remove the to attempting any repairs or cleaning of the com-
center valve core or side pressure relief valve pressor or of the inside of the enclosure, if any.
from these cylinders regardless of whether they
are full or empty. F. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace
Q. If a manual blowdown valve is provided on the any wiring that has cracked, cut, abraded or oth-
receiver, open the valve to ensure all internal erwise degraded insulation, or terminals that are
pressure has been vented prior to servicing any worn, discolored or corroded. Keep all terminals
pressurized component of the compressor air/ and pressure connectors clean and tight.
fluid system.
G. Turn off battery charger before making or break-
ing connections to the battery.
9
SECTION 1
H. Keep grounded and/or conductive objects such temperatures above 150 °F (66 °C). Vapors from
as tools away from exposed live electrical parts the antifreeze compound are heavier than air.
such as terminals to avoid arcing which might DO NOT store compound or discharge treated
serve as a source of ignition. air in confined or unventilated areas. DO NOT
store containers of antifreeze compound in direct
I. Replace damaged fuel tanks or lines immediately
sunlight.
rather than attempt to weld or otherwise repair
them. DO NOT store or attempt to operate the S. Store flammable fluids and materials away from
compressor with any known leaks in the fuel sys- your work area. Know where fire extinguishers
tem. Tag the compressor and render it inopera- are and how to use them, and for what type of
tive until repair can be made. fire they are intended. Check readiness of fire
suppression systems and detectors if so
J. Remove any acoustical material or other material
equipped.
that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to T. DO NOT operate the compressor without proper
attempting weld repairs. flow of cooling air or water or with inadequate
flow of lubricant or with degraded lubricant.
K. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when ser- U. DO NOT attempt to operate the compressor in
vicing and operating the compressor. any classification of hazardous environment
unless the compressor has been specially
L. Keep oily rags, trash, leaves, litter or other com-
designed and manufactured for that duty.
bustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure to 1.5 MOVING PARTS
ventilate thoroughly prior to attempting to start
the engine.
N. DO NOT operate compressor under low over-
hanging leaves or permit such leaves to contact
WARNING
hot exhaust system surfaces when operating the Disconnect and lock out all power at source
compressor in forested areas. and verify at the compressor that all circuits
O. Ethyl ether used in diesel engine ether starting are de-energized to minimize the possibility
aid systems is extremely flammable. Change cyl- of accidental start-up, or operation, prior to
inders, or maintain or troubleshoot these sys- attempting repairs or adjustments. This is
tems only in well-ventilated areas away from especially important when compressors are
heat, open flame or sparks. DO NOT install, remotely controlled.
store or otherwise expose ether cylinders to tem-
peratures above 160 °F (71 °C). Remove ether A. Keep hands, arms and other parts of the body
cylinder from the compressor when operating in and also clothing away from couplings, fans and
ambient temperatures above 60 °F (16 °C). other moving parts.
P. DO NOT attempt to use ether as a starting aid in B. DO NOT attempt to operate the compressor with
gasoline engines or diesel engines with glow the fan, coupling or other guards removed.
plugs as serious personnel injury or property
damage may result. C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
Q. DO NOT spray ether into compressor air filter or when exposed to hot or moving parts.
into an air filter that serves both the engine and
the compressor as serious damage to the com- D. Make sure all personnel are out of and/or clear of
pressor or personal injury may result. the compressor prior to attempting to start or
operate it.
R. Antifreeze compound used in air line anti-icer
systems contains methanol which is flammable. E. When adjusting the controls, it may require oper-
Use systems and refill with compound only in ation of the equipment during adjustment. DO
well-ventilated areas away from heat, open NOT come in contact with any moving parts
flames or sparks. DO NOT expose any part of while adjusting the control regulator and setting
these systems or the antifreeze compound to the engine RPM. Make all other adjustments with
10
SECTION 1
the engine shut off. When necessary, make

adjustment, other than setting control regulator
and engine RPM, with the engine shut off. If nec-
essary, start the engine and check adjustment. If
adjustment is incorrect, shut engine off, readjust,
T4 - WARNING
then restart the engine to recheck adjustment.
Increased DPF skin temperature and
F. Keep hands, feet, floors, controls and walking exhaust gas temperature may occur in the
surfaces clean and free of fluid, water or other event of an unexpected engine/aftertreat-
liquids to minimize the possibility of slips and ment failure. An unexpected failure of the
falls. engine/aftertreatment may increase temper-
ature at the DPF as high as 900 °C (1652 °F)
1.6 HOT SURFACES, SHARP gas temperature and 750 °C (1382 °F) skin
EDGES AND SHARP temperature. This may result in fire, burn, or
CORNERS explosion hazards, which may result in per-
sonal injury or death. Do not expose flam-
A. Avoid bodily contact with hot fluid, hot coolant, mable material or explosive atmospheres to
hot surfaces and sharp edges and corners. exhaust gas or exhaust system components
during regeneration. The aftertreatment skin
B. Keep all parts of the body away from all points of
temperature and the gas temperature are
air discharge and away from hot exhaust gases.
difficult to measure and/or simulate and are
C. Wear personal protective equipment including dependent upon many factors including the
gloves and head covering when working in, on or following: the nature of the engine/after-
around the compressor. treatment failure, the design and packaging
of the aftertreatment, the engine speed/load
D. Keep a first aid kit handy. Seek medical assistance
conditions, the condition of the aftertreat-
promptly in case of injury. DO NOT ignore small
ment and ambient conditions. Therefore,
cuts and burns as they may lead to infection.
the potential temperatures are provided as a
1.6.1 TIER 4 EMISSIONS MODULE guideline even under conditions of unex-
pected engine and/or aftertreatment failure.
General Guidelines: Thermal Protection. The main Proper precautions should be taken to
exhaust piping routes exhaust gas from the engine to ensure that the aftertreatment device is not
the Clean Emissions Module (CEM). Normal mounted in close proximity to components
operating temperatures can reach up to 530 °C (986 that may be damaged by heat.
°F). During regeneration of the Diesel Particulate
Filter (DPF), the Auxiliary Regeneration Device
(ARD) will be in operation, this creating temperatures 1.7 TOXIC AND IRRITATING
above normal engine exhaust temperatures. Gas SUBSTANCES
temperatures during the regeneration period can
reach 750 °C (1382 °F). A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other
Federal, State or Local codes or regulations.
DANGER
11
SECTION 1
should be washed with large quantities of clean

DANGER water for fifteen minutes. A physician, preferably
an eye specialist, should be contacted immedi-
ately.
INHALATION HAZARD!
K. DO NOT store ether cylinders or air line anti-icer
Death or serious injury can result from system antifreeze compound in operator’s cabs
inhaling compressed air without using or in other similar confined areas.
proper safety equipment. See OSHA stan-
dards and/or any applicable Federal, State, L. The antifreeze compound used in air line anti-
and Local codes, standards and regulations freeze systems contains methanol and is toxic,
on safety equipment. harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
B. DO NOT use air line anti-icer systems in air lines swallowed, induce vomiting by administering a
supplying respirators or other breathing air utili- tablespoon of salt, in each glass of clean, warm
zation equipment and DO NOT discharge air water until vomit is clear, then administer two
from these systems into unventilated or other teaspoons of baking soda in a glass of clean
confined areas. water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
C. Operate the compressor only in open or ade-
quately ventilated areas. M. When handling DEF (Diesel Emissions Fluid)
wear protective clothing. Tools and clothing that
D. Locate the compressor so that exhaust fumes are come in contact with DEF must be cleaned.
not apt to be carried towards personnel, air intakes
servicing personnel areas or towards the air intake
of any portable or stationary compressor.
E. Fuels, fluids and lubricants used in this compres-
-IMPORTANT
sor are typical of the industry. Care should be It is very important that all electrical connec-
taken to avoid accidental ingestion and/or skin tors are protected from coming in contact
contact. In the event of ingestion, seek medical with DEF. If not, there is a risk that DEF will
treatment promptly. Wash with soap and water in cause oxidation in the wiring that is not pos-
the event of skin contact. Consult Material Safety sible to clean. The resulting oxidation will
Data Sheet for information pertaining to the spe- result in a wiring/connection failure. Water
cific fluid. and compressed air fail to remove DEF. If a
F. Wear goggles or a full face shield when adding connector has been in contact with DEF, it
antifreeze compound to air line anti-icer systems. must be changed immediately to prevent
the chemical from further migrating into the
G. Wear an acid-resistant apron and a face shield or wiring cable harness, which happens at a
goggles when servicing the battery. If electrolyte speed of 0.6 m/h.
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. -WARNING
Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, DO NOT In case of DEF contact with eyes or skin,
induce vomiting and call a physician immediately. the affected area must be thoroughly rinsed
with lukewarm water. If you breathe any
I. Wear goggles or a full face shield when testing
fumes, make sure and breathe fresh air.
ether 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 yourself
and other personnel.
J. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
12
SECTION 1
1.8 ELECTRICAL SHOCK I. Keep lift operator in constant attendance when-

ever compressor is suspended.
A. Keep the towing vehicle or equipment carrier,
J. Set compressor down only on a level surface capa-
compressor hoses, tools and all personnel at
ble of supporting at least its net weight plus an
least 10 feet (3 m) from power lines and buried
additional 10% allowance for the weight of water,
cables.
snow, ice, mud, stored tools, and/or equipment.
B. Stay clear of the compressor during electrical
K. If the compressor is provided with parking
storms! It can attract lightning.
brakes, make sure they are set, and in any
C. Keep all parts of the body and any hand-held event, block or chock both sides of all running
tools or other conductive objects away from wheels before disengaging the lifting hook.
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO 1.10 ENTRAPMENT
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed A. Make sure all personnel are out of compressor
live parts of the electrical system. before closing and engaging enclosure doors.
D. Attempt repairs in clean, dry and well lighted and B. If the compressor is large enough to hold a man
ventilated areas only. and if it is necessary to enter it to perform service
adjustments, inform other personnel before
1.9 LIFTING doing so, or else secure the access door in the
open position to avoid the possibility of others
A. If the compressor is provided with a lifting bail, closing and possibly latching the door with per-
then lift by the bail provided. If no bail is provided, sonnel inside.
then lift by sling. Compressors to be air lifted by
helicopter must not be supported by the lifting 1.11 JUMP STARTING
bail, but by slings instead. In any event, lift only in
full compliance with OSHA Standards 29 CFR A. Observe all safety precautions mentioned else-
1910 subpart N or any other Local, State, Military where in this manual.
and Federal regulations that may apply.
B. Batteries may contain hydrogen gas which is
B. Inspect lifting bail and points of attachment for flammable and explosive. Keep flames, sparks
cracked welds and for cracked, bent, corroded or and other sources of ignition away.
otherwise degraded members and for loose bolts
C. Batteries contain acid which is corrosive and poi-
or nuts prior to lifting.
sonous. DO NOT allow battery acid to contact
C. Make sure entire lifting, rigging and supporting eyes, skin, fabrics or painted surfaces as serious
structure has been inspected, is in good condition personal injury or property damage could result.
and has a rated capacity of at least the net weight Flush any contacted areas thoroughly with water
of the compressor plus an additional 10% allow- immediately. Always wear an acid-resistant
ance for weight of water, snow, ice, mud, stored apron and face shield when attempting to jump
tools, and equipment. If your are unsure of the start the compressor.
weight, then weigh compressor before lifting.
D. Remove all vent caps (if so equipped) from the
D. Make sure lifting hook has a functional safety battery or batteries in the compressor. DO NOT
latch or equivalent, and is fully engaged and permit dirt or foreign matter to enter the open
latched on the bail. cells.
E. Use guide ropes or equivalent to prevent twisting E. Check fluid level. If low, bring fluid to proper level
or swinging of the compressor once it has been before attempting to jump start (not applicable to
lifted clear of the ground. maintenance-free batteries).
F. DO NOT attempt to lift in high winds. F. DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60 °F (16
G. Keep all personnel out from under and away
°C) before attempting to jump start or it may
from the compressor whenever it is suspended.
explode.
H. Lift compressor no higher than necessary.
13
SECTION 1
G. Cover open cells of all compressor batteries with tery in the starting vehicle. When jump starting
clean dampened cloths before attempting to 24V compressors and if the starting vehicle is
jump start. provided with two (2) 12V batteries connected in
series, connect the jumper cable to the negative
H. Attempt to jump start only with a vehicle having a
(NEG) (-) terminal of the grounded battery.
negative ground electrical system with the same
voltage, and is also equipped with a battery or R. Check your connections. DO NOT attempt to
batteries of comparable size or larger than sup- start a 24V compressor with one 12V battery in
plied in the compressor. DO NOT attempt to the starting vehicle. DO NOT apply 24V to one
jump start using motor generator sets, welders or 12V battery in the compressor.
other sources of DC power as serious damage
S. Connect the other end of this same jumper cable
may result.
to a clean portion of the compressor engine
I. Bring the starting vehicle alongside the compres- block away from fuel lines, the crank case
sor, but DO NOT permit metal to metal contact breather opening and the battery.
between the compressor and the starting vehicle.
T. Start the compressor in accordance with normal
J. Set the parking brakes of both the compressor (if procedure. Avoid prolonged cranking.
provided) and the starting vehicle or otherwise
U. Allow the compressor to warm up. When the
block both sides of all wheels.
compressor is warm and operating smoothly at
K. Place the starting vehicle in neutral or park, turn normal idle RPM, disconnect the jumper cable
off all non-essential accessory electrical loads from the engine block in the compressor, then
and start its engine. disconnect the other end of this same cable from
the grounded negative (NEG) (-) terminal of the
L. Use only jumper cables that are clean, in good
battery in the starting vehicle. Then disconnect
condition and are heavy enough to handle the
the other jumper cable from the positive (POS)
starting current.
(+) terminal of the battery in the compressor, or if
M. Avoid accidental contact between jumper cable provided with two (2) 12V batteries connected in
terminal clips or clamps and any metallic portion series, from the ungrounded battery in the com-
of either the compressor or the starting vehicle to pressor, and finally, disconnect the other end of
minimize the possibility of uncontrolled arcing this same jumper cable from the positive (POS)
which might serve as a source of ignition. (+) terminal of the battery in the starting vehicle
or from the positive (POS) (+) terminal of the
N. Positive battery terminals are usually identified
ungrounded battery in the starting vehicle, if it is
by a plus (+) sign on the terminal and the letters
provided with two (2) 12V batteries connected in
POS adjacent to the terminal. Negative battery
series.
terminals are usually identified by the letters
NEG adjacent to the terminal or a negative (-) V. Remove and carefully dispose of the dampened
sign. cloths, as they may now be contaminated with
acid, then replace all vent caps.
O. Connect one end of a jumper cable to the posi-
tive (POS) (+) battery terminal in the starting
vehicle. When jump starting 24V compressors 1.12 IMPLEMENTATION OF
and if the starting vehicle is provided with two (2) LOCKOUT/TAGOUT
12V batteries connected in series, connect the
The energy control procedure defines actions
jumper cable to the positive (POS) (+) terminal of
necessary to lockout a power source of any machine
the ungrounded battery.
to be repaired, serviced or set-up, where unexpected
P. Connect the other end of the same jumper cable motion, or an electrical or other energy source, would
to the positive (POS) (+) terminal of the starter cause personal injury or equipment damage. The
motor battery in the compressor when jump start- power source on any machine shall be locked out by
ing 24V compressors, to the positive (POS) (+) each employee doing the work except when motion
terminal of the ungrounded battery in the com- is necessary during setup, adjustment or trouble-
pressor. shooting.
Q. Connect one end of the other jumper cable to the A. The established procedures for the application of
grounded negative (NEG) (-) terminal of the bat- energy control shall cover the following elements
14
SECTION 1
and actions and shall be initiated only by Autho- 1. The lock shall be removed by the
rized Persons and done in the following sequence: “Authorized” person who put the lock on the
energy-isolating device. No one other than
1. Review the equipment or machine to be the person/persons placing padlocks and
locked and tagged out. lockout hasps on power shall remove
2. Alert operator and supervisor of which padlock and lockout hasps and restore
machine is to be worked on, and that power power. However, when the authorized
and utilities will be turned off. person who applied the lock is unavailable to
remove it his/her Supervisor may remove
3. Check to make certain no one is operating padlock/padlocks and lockout hasps and
the machine before turning off the power. restore power only if it is first:
4. Turn off the equipment using normal a. verified that no person will be exposed to
shutdown procedure. danger.
5. Disconnect the energy sources: b. verified that the “Authorized” person who
a. Air and hydraulic lines should be bled, applied the device is not in the facility.
drained and cleaned out. There should c. noted that all reasonable efforts to con-
be no pressure in these lines or in the tact the “Authorized” person have been
reservoir tanks. Lockout or tag lines or made to inform him or her that the lock-
valves. out or tagout device has been removed.
b. Any mechanism under tension or pres- d. ensured that the “Authorized” person is
sure, such as springs, should be notified of lock removal before returning
released and locked out or tagged. to work.
c. Block any load or machine part prior to 2. Tagout System—Tags are warning devices
working under it. affixed at points of power disconnect and are
d. Electrical circuits should be checked with not to be removed by anyone other that the
person placing tag on power lockout. Tags
calibrated electrical testing equipment shall never be by-passed, ignored, or
and stored energy and electrical capaci- otherwise defeated
tors should be safely discharged.
6. Lockout and/or Tagout each energy source 1.13 CALIFORNIA
using the proper energy isolating devices PROPOSITION 65
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person
performing work. Each person shall be WARNING
provided with their own padlock and have
possession of the only key. If more than one CALIFORNIA PROPOSITION 65 WARNING
person is working on a machine each person
shall affix personal lock and tag using a Diesel engine exhaust and some of its con-
multi-lock device. stituents are known to the State of Califor-
7. Tagout devices shall be used only when nia to cause cancer, birth defects and other
power sources are not capable of being reproductive harm.
locked out by use of padlocks and lockout
hasp devices. The name of the person Battery posts, terminals and related acces-
affixing tag to power source must be on tag sories contain lead and other compounds
along with date tag was placed on power known to the State of California to cause
source. cancer and birth defects and other repro-
8. Release stored energy and bring the ductive harm. Wash hands after handling.
equipment to a “zero mechanical state”.
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
15
SECTION 1
1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable
symbols.
DIESEL FUEL HEARING PROTECTION
ROTARY COMPRESSOR
HARD HAT
TEST RUN
DRAIN SAFETY GLASSES
HIGH PRESSURE
HEARING PROTECTION
SHUT-OFF VALVE
W/ SAFETY
DO NOT REMOVE
NO
MANUAL
ENGINE DO NOT BREATHE

COMPRESSED AIR
COMPRESSOR
DO NOT STAND ON
SERV. VALVE
ENGINE OIL
DO NOT OPERATE
ENGINE COOLANT W/ DOORS OPEN
WATER
DO NOT OPEN
OIL
DO NOT STACK
DO NOT ELECTRICAL SHOCK
CLOSED MECHANICAL
AIR FLOW
FUSE
HOT SURFACE
LOW PRESSURE
PRESSURIZED VESSEL
READ MANUAL
PRESSURIZED
COMPONENT
BRAKES SAFETY SYMBOLS 1
16
SECTION 1
DANGEROUS OUTLET ENGINE START
ENGINE ECM
REMOTELY
CONTROLLED
READ/WRITE DATA
CORROSIVE
INTAKE AIR
EXHAUST GAS
WARNING
FAN GUARD
DO NOT
MAINTENANCE
BELOW TEMPERATURE BELT GUARD
DO NOT TOW SERVICE POINT
BAR/PSI
LOW TEMPERATURE
BATTERY
BATTERY DISCONNECT STD AIR
OFF A/C AIR
ON
24 HOURS
RESET
BELTS
NO FORKLIFT FILTER
STRAINER
FORK LIFT HERE
SAFETY SYMBOLS 2
DIRECTION OF ROTATION
17
SECTION 1
RADIATOR HOUR METER
AIR-CIRCULATING COMPRESSOR AIR

FAN PRESSURE
AIR-COOLED START
OIL COOLER
CONTROL
LIQUID-COOLED
OIL COOLER
ENGINE PREHEAT
LOW TEMP AID
LUBRICATION
ENGINE WARNING
TRAILER TOWING
MODE
FUEL LEVEL
AXEL
ENGINE RPM
LUBRICANT GREASE
ENGINE OIL
EXAMINE, CHECK PRESSURE
ENGINE COOLANT
CRUSH/PINCH POINT TEMPERATURE
COMPRESSOR
FUNCTIONAL ARROW TEMPERATURE
DO NOT MIX
ENGINE INTAKE COOLANTS
AIR FILTER
AFTERCOOLER
PRESSURE CONTROL BYPASS VALVE
INLET VALVE SPRING

DRAIN HEATER
INTERNAL FUEL
BATTERY HEATER
COMPRESSOR
EXTERNAL FUEL
OIL HEAT
STACKING LIMIT
SIDE DOOR T-LATCH BY NUMBER
SAFETY SYMBOLS 3
18
SECTION 1
DO NOT OPERATE WATER DRAIN

WHILE STACKED
PRESSURIZED SPRING SEVER (FAN)
DO NOT MIX FLUIDS

DEF FLUID ONLY
AUTO START/STOP
RUN
SAFETY SYMBOLS 4
FLUID DRAIN
19
SECTION 1
20
1600F LP USER MANUAL
Section 2
DESCRIPTION
2.1 INTRODUCTION aftertreatment, compressor inlet system, compressor
cooling and lubrication system, compressor
Sullair Portable Air Compressor models offer discharge system, capacity control system,
superior performance and reliability while requiring instrument panel and electrical system. The machine
only minimal maintenance. is also supplied with sound deadening insulation to
lower noise emissions to meet EPA and/or any
The compressor is equipped with a Sullair rotary
Federal, State, or Local noise requirement. The
screw compressor unit. Compared to other
Sullair compressor unit is driven by an industrial
compressors, Sullair’s compressor is unique in
engine designed to provide enough horsepower for
mechanical reliability and compressor durability. No
more than adequate reserve at rated conditions.
inspection is required of the working parts within the
Refer to Engine Operator’s Manual for a more
compressor unit.
detailed description of the engine.
As you continue reading this manual and come to
The engine cooling system is comprised of a
learn how the compressor operates and is cared for,
radiator, high capacity fan and thermostat. The high
you will see how surprisingly easy it is to keep a
capacity fan pushes air through the radiator, keeping
Sullair compressor in top operating condition.
the engine at the proper operating temperature.
Read the Maintenance section to keep your
The same fan also cools the fluid in the compressor
compressor in top operating condition. Should any
cooling and lubrication system through the
problem or question arise which cannot be answered
compressor fluid cooler (which is mounted adjacent
in this text, contact your nearest Sullair
to the radiator). As air passes through the cooler, the
representative or the Sullair Service Department.
heat of compression is removed from the fluid.
2.2 DESCRIPTION OF The same fan also cools the engine intake air supply
COMPONENTS (which is mounted adjacent to the radiator). As air
passes through the air to air aftercooler heat is
Refer to Figure 2-1. The components and removed which was introduced by the engine’s turbo
assemblies of the Sullair Portable Air Compressor charger. The engine is coupled to the compressor
models are clearly shown. The package includes a unit with a non-lubricated, vulcanized rubber disk and
compressor, diesel engine, engine exhaust a drive flange-type coupling.
21
1600F LP USER MANUAL SECTION 2
Figure 2-1: .Main Component Locations
19. DISCHARGE AIR

1. INLET VALVE 7. FUEL COOLER 13. E-STOP
FILTER (IF EQUIPPED)
2. LOUVERS (IF 8. AFTERCOOLER (IF 20. COMPRESSOR
14. ENGINE MUFFLER
EQUIPPED) EQUIPPED) FLUID FILTER
21. ENGINE &
9. ENGINE CHARGE AIR
3. THERMAL VALVE 15. MANUAL BOX COMPRESSOR AIR
COOLER
INTAKE FILTERS
16. BATTERY
4. REGULATOR VALVES 10. ENGINE RADIATOR
DISCONNECT SWITCH
11. COMPRESSOR
5. FLUID STOP VALVE 17. FUEL TANK
FLUID COOLER
6. ENGINE COOLANT FILL 12. RECEIVER TANK 18. CAT CEM MODULE
22
SECTION 2 1600F LP USER MANUAL
2.3 SULLAIR COMPRESSOR and thermal valve.

UNIT, FUNCTIONAL Fluid is used in the system as a coolant and a
DESCRIPTION lubricant. The fluid is housed in the receiver tank.
Sullair compressors feature the Sullair compressor Upon start-up, the fluid temperature is cool, and
unit, a single-stage, positive displacement, flood routing to the cooler is not required. The fluid first
lubricated-type compressor. This unit provides enters the thermal valve and then flows on to the
continuous compression to meet your needs. compressor unit, bypassing the cooler. As the
compressor continues to operate, the temperature of
the fluid rises and the thermal valve element begins
NOTE to shift. This forces a portion of the fluid to the fluid
cooler. The cooler is a radiator-type that works in
With a Sullair compressor, there is no conjunction with the engine fan. The fan pushes air
maintenance or inspection of the internal through the cooler removing the heat of compression
parts of the compressor unit permitted in from the fluid. From the cooler, the fluid is routed
accordance with the terms of the warranty. back to the thermal valve.
Before the temperature of the fluid reaches the valve
Sullair compressors are factory-filled with Sullair set point, cooled fluid is mixed with warmer fluid.
AWF lubricant. For more information on fluid fill, refer When the temperature of the fluid reaches 170°F
to Specifications on page 57. (76.7°C), the thermal element shifts completely
causing all fluid to flow to the cooler. The thermal
Fluid is injected into the compressor unit and mixes
valve incorporates a pressure relief valve, which
directly with the air as the rotors turn, compressing
allows fluid to bypass the cooler, if the cooler
the air. The fluid flow has three basic functions:
becomes plugged or frozen. This helps assure that
1. As coolant, it controls the rise of air tempera- fluid will continue to be provided to the compressor
ture normally associated with the heat of for lubrication. After the fluid passes through the
compression. thermal valve it is then directed through the main
fluid filter. There, the fluid is filtered in preparation for
2. Seals the clearance paths between the
injection into the compression chamber and bearings
rotors and the stator and also between the
of the compressor unit. The filter has a replaceable
rotors themselves.
element and a built-in bypass valve which allows the
3. Acts as a lubricating film between the rotors fluid to flow even when the filter element becomes
allowing one rotor to directly drive the other, plugged and requires changing or when the viscosity
which is an idler. of the fluid is too high for adequate flow. The filter
housing includes a pressure differential gage to
After the air/fluid mixture is discharged from the
monitor the cleanliness of the compressor oil filter.
compressor unit, the fluid is separated from the air.
Please refer to the Maintenance section 6.11.2 for
At this time, the air flows through a separator and an
further details. After the fluid is properly filtered, it
aftercooler (if provided) then to the service line while
then flows on to the compressor unit where it
the fluid is being cooled in preparation for reinjection.
lubricates, seals and cools the compression chamber
as well as lubricates the bearings and gears.
2.4 COMPRESSOR COOLING
AND LUBRICATION The fluid stop valve functions on shutdown when it
SYSTEM, FUNCTIONAL shuts off the fluid supply to the compressor unit. The
DESCRIPTION fluid stop valve is held open by a pressure signal
from the compressor discharge. At shutdown, the
Refer to Figure 2-2. The compressor cooling and pressure signal is lost and the fluid stop valve closes,
lubrication system is designed to provide adequate isolating the compressor unit from the cooling
lubrication as well as maintain the proper operating system. This prevents oil from pooling into the
temperature of the compressor. In addition to the compressor unit.
cooler and fan, the system consists of a main filter
23
Figure 2-2: Cooling and Lubrication System
1. COMPRESSOR FLUID FILTER 4. COOLER

2. THERMAL VALVE 5. RECEIVER TANK
6. COMPRESSOR FLUID FILTER
3. OIL STOP VALVE
RESTRICTION GAUGE
NOTE
Arrows indicate direction of fluid flow
within the Cooling and Lubrication System.
24
2.5 COMPRESSOR DISCHARGE The receiver tank is code rated. A minimum

SYSTEM, FUNCTIONAL pressure/check valve, located downstream from the
DESCRIPTION receiver, helps assure a minimum receiver pressure
of 65 psig (4.5 bar) during all conditions. This
Refer to Figure 2-3. The Sullair compressor unit pressure is necessary for proper air/fluid separation
discharges compressed air/fluid mixture into the and proper fluid circulation.
receiver tank.
A minimum pressure/check valve is also used to
The receiver tank has three functions: prevent compressed air in the service line from
bleeding back into the receiver on shutdown when
1. It acts as a primary fluid separator.
the compressor is being run in parallel with other
2. Serves as the compressor fluid storage compressors tied to a large air system.
sump.
A pressure relief valve (located on the wet side of the
3. Houses the final fluid separator. separator) is set to ensure the receiver tank pressure
will not exceed its rated pressure. A temperature
The compressed air/fluid mixture enters the receiver
switch will shut down the compressor if the discharge
tank and is directed against the tank side wall. By
temperature reaches 250°F (121°C).
change of direction and reduction of velocity, large
droplets of fluid separate and fall to the bottom of the Fluid is added to the receiver tank via a capped fluid
receiver tank. The fractional percentage of fluid filler. A fluid level gauge glass enables the operator
remaining in the compressed air collects on the to visually monitor the receiver tank fluid level.
surface of the final separator element as the
compressed air flows through the separator. As more
and more fluid collects on the element’s surface, the
fluid descends to the bottom of the separator. A WARNING
return line (or scavenge tube) leads from the bottom
of the separator element to the inlet region of the DO NOT remove caps, plugs, and/or other
compressor unit. Fluid collecting on the bottom of the components when compressor is running
separator element is returned to the compressor by or pressurized.
the pressure difference between the area Stop compressor and relieve all internal
surrounding the separator element and the pressure before doing so.
compressor inlet. An orifice (protected by a strainer)
is included in this return line to help assure proper
flow.
25
Figure 2-3: Discharge System (with optional aftercooler and discharge filter)
1. RECEIVER TANK 5. DISCHARGE FILTER

2. MINIMUM PRESSURE/CHECK VALVE 6. MOISTURE SEPARATOR
3. AFTERCOOLED AIR VALVE 7. AFTERCOOLER
4. STANDARD AIR VALVE 8. SERVICE AIR OUT
26
2.6 CONTROL SYSTEM, HIGH PRESSURE MODE—

FUNCTIONAL DESCRIPTION 80 TO 150 PSIG (5.5 TO 10.3 BAR) FOR “H”
MODELS. 80 TO 175 PSIG (5.5 TO 12.1 BAR)
Refer to Compressor System Schematic for P & I
COMPRESSOR SYSTEM on page 44 and Figure 6- FOR 1450 HH MODELS. 80 TO 200 PSIG (5.5
4: Pneumatic Control System on page 72. The TO 13.8 BAR) FOR 1300 HH MODELS.
purpose of the control system is to regulate the When the HIGH/LOW switch is switched to the
amount of air intake in accordance with the amount “HIGH” position, the low pressure regulator is
of compressed air demand. The control system blocked off allowing the high pressure regulator to
consists of an inlet valve, high and low pressure take over control of the machine. Pressure from the
regulators, pressure reducing regulator, a blowdown reducing regulator fully opens the inlet valve and the
valve, the Controller, a START/RUN selector switch, Controller commands maximum speed (1800 rpm)
and the HIGH/LOW selector switch. from the engine. As the pressure reaches the set
START MODE—0 TO 65 PSIG (0 TO 4.5 BAR) point of the system the high pressure regulator
cracks open and closes the inlet valve and the
Push OFF/ON/START switch to “ON” position to Controller returns the engine back to idle, until a
initialize the Controller. Once the Controller says demand for air is seen.
“READY” on LCD, press OFF/ON/START switch to
the “START” position. In the “START” Position, the SHUTDOWN
inlet valve is held closed by the springs in the inlet The blowdown valve is normally closed. When the
valve. The valve is cracked open by vacuum in the compressor is shutdown, system pressure backs up
compressor and is allowed to build up to pressure. to the inlet valve causing the check spring in the inlet
The reason for keeping the valve closed during the valve to close the air inlet valve. This sends a
start is to allow the engine to warm up without being pressure signal to the blowdown valve causing it to
loaded by the compressor. Air pressure is contained open and vent the pressure in the system. After the
in the receiver tank by the minimum pressure valve pressure is vented, the blowdown valve spring
which has a set point of 65 psig (4.5 bar). At this returns the blowdown valve to the closed position.
point the valve opens allowing the air to pass to the
service valve. After engine has warmed up the
machine automatically transfers to “RUN” mode.
2.7 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
LOW PRESSURE MODE - 80 TO 100 PSIG (5.5
The inlet system consists of two air filters, a
TO 6.9 BAR)
compressor air inlet valve and interconnecting piping
With the HIGH/LOW switch in the “LOW” position, to the engine and compressor. Also, nylon tubing and
and the controller in “RUN” mode, the service valve air filter restriction indicator gauges are provided.
can now be opened. Pressure from the reducing
The air filters are a 2-stage unit with a safety element
regulator opens up the inlet valve and the Controller
dry element-type filter. This filter is capable of
increases the engine speed to full load (1800 rpm).
cleaning extremely dirty air. However, in such cases,
As the demand for air decreases, the Controller
frequent checks of the air filter will be required.
commands the engine to reduce speed to idle (1400
Referring to the instrument panel, the engine air filter
rpm) and the inlet valve closes, where it stabilizes
restriction gauge or the compressor air filter
until the air demand is required again. If the machine
restriction gauge will indicate when restriction of the
is not marked with an “H” or “HH”, it is a single
air passing through the filter becomes too high.
pressure machine and will not have a HIGH/LOW
switch. The machine will run as if it is in the “LOW” At this time, change the air filter element. Refer to
position. Daily Operation on page 67. These indicators should
be checked daily, after start-up under normal
conditions.
The compressor air inlet valve controls the amount of
air intake of the compressor in response to the air
demand.
27
2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Refer to the Controller Manual, Sullair Part No. 02250201-742.
Figure 2-4: Controller Instrument Panel
Lamp Indicators Switches/Gauges/Features

1. COMPRESSOR OK LAMP 19. POWER ON/OFF SWITCH
2. COMPRESSOR WARNING LAMP 20. MENU SELECT/EXIT SWITCH
3. COMPRESSOR SHUT DOWN LAMP 21. MENU TOGGLE SWITCH
4. ENGINE OK LAMP 22. FORCE/INHIBIT REGENERATION SWITCH
5. CHECK ENGINE LAMP 23. CABIN LIGHT SWITCH
6. ENGINE SHUTDOWN LAMP 24. HIGH/LOW PRESSURE SELECTOR SWITCH (ONLY ON
DUAL PRESSURE MODELS)
7. BATTERY DISCONNECT LAMP 25. SERVICE AIR PRESSURE GAUGE (P1)
8. COMPRESSOR AIR FILTER WARNING LAMP 26. COMPRESSOR TEMPERATURE GAUGE
9. HIGH COMPRESSOR TEMPERATURE LAMP 27. ENGINE TEMPERATURE GAUGE
10. CABIN LIGHT LAMP 28. FUEL LEVEL GAUGE
11. REMOTE START LAMP 29. ENGINE CONTROLLER DIAGNOSTICS SERVICE PORT
12. DIESEL PARTICULATE FILTER (DPF) LAMP 30. ENGINE CONTROLLER PORT COVER
13. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP 31. KEY PORT
14. REGENERATION INHIBIT LAMP 32. CONTRAST BUTTONS
15. LOW FUEL LAMP
16. HIGH COOLANT TEMPERATURE LAMP
17. ENGINE AIR FILTER WARNING LAMP
18. WAIT TO START LAMP
28
2.9 ENGINE CONTROL MODULE, If this is the case, unless there are several
FUNCTIONAL DESCRIPTION occurrences of the code in a very short period of
time, or, the ECM is indicating an Active Code at the
Diagnostic Fault Codes are provided to indicate an present time, there is most likely nothing wrong with
electrical or electronic problem has been detected by the system.
the ECM (Engine Control Module). In some cases,
If there is an error the controller should display a brief
the engine performance can be affected when the
message containing the Failure Mode Indicator (FMI)
condition causing the code exists. More frequently,
and Suspect Parameter Number (SPN) in the LCD of
however, the operator cannot detect any difference
the master gauge. This message helps to pinpoint
in the engine performance.
the source of the problem and aid in troubleshooting
The controller indicates an engine performance the compressor..
problem has occurred whenever the Engine Warning
Lamp is flashing. The diagnostic code may indicate
the cause of the problem, and should be corrected. NOTE
If the controller does not indicate a problem with the
Only Active diagnostic codes can be read in
engine performance, but a diagnostic code is logged
this manner. Logged diagnostic codes must
by the ECM, an abnormal condition was detected
be retrieved with an Electronic Service Tool.
that did not affect performance.
Refer to Table 2-1 below for possible performance of

active diagnostic codes.
Table 2-1: Diagnostic Codes

J1939 CATERPILLAR DATA LINK (CDL)
CODE DESCRIPTION CODE DESCRIPTION
Accelerator Pedal Position 2: Erratic,
29-2
Intermittent, or Incorrect
Accelerator Pedal Position 2: Voltage Above
29-3
Normal
Accelerator Pedal Position 2: Voltage Below
29-4
Normal
Accelerator Pedal Position 2: Abnormal
29-8
Frequency, Pulse Width, or Period.
Accelerator Pedal Position 1: Erratic, Throttle Position Sensor: Erratic, Intermittent,
91-2 91-2
Intermittent, or Incorrect. or Incorrect.
Accelerator Pedal Position 1: Voltage Above Throttle Position Sensor: Voltage Above
91-3 91-3
Normal Normal
Accelerator Pedal Position 1: Voltage Below Throttle Position Sensor: Voltage Below
91-4 91-4
Normal Normal
Accelerator Pedal Position 1: Abnormal Throttle Position Sensor: Abnormal
91-8 91-8
Frequency, Pulse Width, or Period. Frequency, Pulse Width, or Period.
Engine Oil Pressure Sensor: Voltage Above
100-3 Engine Oil Pressure: Voltage Above Normal 100-3
Normal
Engine Oil Pressure Sensor: Voltage Below
100-4 Engine Oil Pressure: Voltage Below Normal 100-4
Normal
Engine Oil Pressure Sensor: Calibration
100-13 Engine Oil Pressure: Calibration Required 100-13
Required
Engine Crankcase Pressure: Voltage Above Crankcase Air Pressure Sensor: Voltage
101-3 101-3
Normal Above Normal
Engine Crankcase Pressure: Voltage Below Crankcase Air Pressure Sensor: Voltage
101-4 101-4
Normal Below Normal
29

Engine Crankcase Pressure: Calibration Crankcase Air Pressure Sensor: Calibration
101-13 101-13
Required Required
Atmospheric Pressure Sensor: Voltage
108-3 Barometric Pressure: Voltage Above Normal 274-3
Above Normal
Atmospheric Pressure Sensor: Voltage
108-4 Barometric Pressure: Voltage Below Normal 274-4
Below Normal
Atmospheric Pressure Sensor: Calibration
108-13 Barometric Pressure: Calibration Required 274-13
Required
Engine Coolant Temperature: Voltage Above Engine Coolant Temperature Sensor:
110-3 110-3
Normal Voltage Above Normal
Engine Coolant Temperature: Voltage Below Engine Coolant Temperature Sensor:
110-4 110-4
Normal Voltage Below Normal
Engine Injector Metering Rail #1 Pressure: Fuel Rail Pressure Sensor: Voltage Above
157-3 1797-3
Voltage Above Normal Normal
Engine Injector Metering Rail #1 Pressure: Fuel Rail Pressure Sensor: Voltage Below
157-4 1797-4
Voltage Below Normal Normal
Engine Injector Metering Rail #1 Pressure: Fuel Rail Pressure Sensor: Not Responding
157-7 1797-7
Not Responding Properly Properly
Keyswitch Battery Potential: Erratic,
158-2 1834-2 Ignition Key Switch loss of signal
Intermittent, or Incorrect
Battery Potential / Power Input 1: Erratic, Electrical System Voltage: Erratic,
168-2 168-2
Intermittent, or Incorrect Intermittent, or Incorrect
Battery Potential / Power Input 1: Voltage Electrical System Voltage: Voltage Above
168-3 168-3
Above Normal Normal
Battery Potential / Power Input 1: Voltage Electrical System Voltage: Voltage Below
168-4 168-4
Below Normal Normal
Engine Air Inlet Temperature: Voltage Above Air Inlet Temperature Sensor: Voltage Above
172-3 2526-3
Normal Normal
Engine Air Inlet Temperature: Voltage Below Air Inlet Temperature Sensor: Voltage Below
172-4 2526-4
Normal Normal
Engine Fuel Temperature 1: Voltage Above Fuel Temperature Sensor: Voltage Above
174-3 174-3
Normal Normal
Engine Fuel Temperature 1: Voltage Below Fuel Temperature Sensor: Voltage Below
174-4 174-4
Normal Normal
Engine Speed: Abnormal Frequency, Pulse Engine Speed Sensor: Abnormal Frequency,
190-8 190-8
Width, or Period Pulse Width, or Period
Engine Exhaust Gas Recirculation EGR Differential Pressure Sensor: Voltage
411-3 3387-3
Differential Pressure: Voltage Above Normal Above Normal
Engine Exhaust Gas Recirculation EGR Differential Pressure Sensor: Voltage
411-4 3387-4
Differential Pressure: Voltage Below Normal Below Normal
Engine Exhaust Gas Recirculation EGR Differential Pressure Sensor:
411-13 3387-13
Differential Pressure: Calibration Required Calibration Required
Engine Exhaust Gas Recirculation EGR Temperature Sensor: Voltage Above
412-3 3386-3
Temperature: Voltage Above Normal Normal
Engine Exhaust Gas Recirculation EGR Temperature Sensor: Voltage Below
412-4 3386-4
Temperature: Voltage Below Normal Normal
Engine Start Enable Device 1: Current Below Ether Injection Control Solenoid: Current
626-5 2417-5
Normal Below Normal
30

Engine Start Enable Device 1: Current Above Ether Injection Control Solenoid: Current
626-6 2417-6
Normal Above Normal
Calibration Memory: Erratic, Intermittent, or Programmed Parameter Fault: Erratic,
630-2 268-2
Incorrect Intermittent, or Incorrect
Calibration Module: Erratic, Intermittent, or Personality Module: Erratic, Intermittent, or
631-2 253-2
Incorrect Incorrect
637-11 Engine Timing Sensor: Other Failure Mode 261-11 Engine Timing Offset fault
637-13 Engine Timing Sensor: Calibration Required 261-13 Engine Timing Calibration: Calibration
Engine Injector Cylinder #01: Erratic, Cylinder #1 Injector: Erratic, Intermittent, or
651-2 1-2
Intermittent, or Incorrect Incorrect
Engine Injector Cylinder #01: Current Below
651-5 1-5 Cylinder #1 Injector: Current Below Normal
Normal
Engine Injector Cylinder #01: Current Above
651-6 1-6 Cylinder #1 Injector: Current Above Normal
Normal
Engine Injector Cylinder #01: Not Cylinder #1 Injector: Not Responding
651-7 1-7
Responding Properly Properly
652-2 2-2
Normal
Normal
652-7 2-7
653-2 3-2
Normal
Normal
653-7 3-7
654-2 4-2
Normal
Normal
654-7 4-7
655-2 5-2
Normal
Normal
655-7 5-7
31

656-2 62-2
Normal
Normal
656-7 6-7
ECU 8 Volts DC Supply: Voltage Above
678-3 41-3 8 Volt DC Supply: Voltage Above Normal
Normal
ECU 8 Volts DC Supply: Voltage Below
678-4 41-4 8 Volt DC Supply: Voltage Below Normal
Normal
Engine Speed Sensor #2: Abnormal Secondary Engine Speed Sensor: Abnormal
723-8 342-8
Frequency, Pulse Width, or Period Frequency, Pulse Width, or Period
Engine Fuel Pump Pressurizing Assembly Fuel Rail #1 Pressure Valve Solenoid:
1347-5 1779-5
#1: Current Below Normal Current Below Normal
1347-6 1779-6
#1: Current Above Normal Current Above Normal
1348-5 1780-5
#2: Current Below Normal Current Below Normal
1348-6 1780-6
#2: Current Above Normal Current Above Normal
Auxiliary Temperature #1: Voltage Above Auxiliary Temperature Sensor: Voltage
1385-3 1836-3
Normal Above Normal
Auxiliary Temperature #1: Voltage Below Auxiliary Temperature Sensor: Voltage Below
1385-4 1836-4
Normal Normal
Auxiliary Pressure Sensor: Voltage Above
1387-3 Auxiliary Pressure #1: Voltage Above Normal 1835-3
Normal
Auxiliary Pressure Sensor: Voltage Below
1387-4 Auxiliary Pressure #1: Voltage Below Normal 1835-4
Normal
Engine Charge Air Cooler Outlet Engine Charge Air Cooler #1 Outlet
2630-3 3372-3
Temperature: Voltage Above Normal Temperature Sensor: Voltage Above Normal
Engine Charge Air Cooler Outlet Engine Charge Air Cooler #1 Outlet
2630-4 3372-4
Temperature: Voltage Below Normal Temperature Sensor: Voltage Below Normal
Engine Exhaust Gas Recirculation (EGR)
2791-5 3405-5 EGR Valve Control: Current Below Normal
Valve Control: Current Below Normal
Engine Exhaust Gas Recirculation (EGR)
2791-6 3405-6 EGR Valve Control: Current Above Normal
Valve Control: Current Above Normal
Exhaust Gas Temperature 1: Voltage Above Aftertreatment #1 Exhaust Gas Temperature
3241-3 3485-3
Normal #1 Sensor: Voltage Above Normal
Exhaust Gas Temperature 1: Voltage Below Aftertreatment #1 Exhaust Gas Temperature
3241-4 3485-4
Normal #1 Sensor: Voltage Below Normal
Particulate Trap Intake Gas Temperature: DPF #1 Intake Temperature Sensor: Voltage
3242-3 2452-3
Voltage Above Normal Above Normal
Particulate Trap Intake Gas Temperature: DPF #1 Intake Temperature Sensor: Voltage
3242-4 2452-4
Voltage Below Normal Below Normal
Engine Exhaust Gas Recirculation Inlet EGR Intake Pressure Sensor: Voltage Above
3358-3 3385-3
Pressure: Voltage Above Normal Normal
32

Engine Exhaust Gas Recirculation Inlet EGR Intake Pressure Sensor: Voltage Below
3358-4 3385-4
Pressure: Voltage Below Normal Normal
Engine Exhaust Gas Recirculation Inlet EGR Intake Pressure Sensor: Calibration
3358-13 3385-13
Pressure: Calibration Required Required
Aftertreatment #1 Fuel Pressure Control: ARD Fuel Pressure #1 Control: Current
3479-5 2461-5
Current Below Normal Below Normal
Aftertreatment #1 Fuel Pressure Control: ARD Fuel Pressure #1 Control: Current
3479-6 2461-6
Current Above Normal Above Normal
Aftertreatment #1 Fuel Pressure #1: Voltage ARD Fuel Pressure #1 Sensor: Voltage
3480-3 2460-3
Above Normal Above Normal
3480-4 2460-4
Below Normal Below Normal
Aftertreatment #1 Ignition: Current Below Aftertreatment #1 Ignition Transformer
3484-5 2465-5
Normal Primary: Current Below Normal
Aftertreatment #1 Ignition: Current Above Aftertreatment #1 Ignition Transformer
3484-6 2465-6
Normal Primary: Current Above Normal
Aftertreatment #1 Air Pressure Control: ARD Air Pressure Control Actuator: Current
3487-5 2489-5
Aftertreatment #1 Air Pressure Control: ARD Air Pressure Control Actuator: Current
3487-6 2489-6
Aftertreatment #1 Air Pressure Control: Not ARD Air Pressure Control Actuator: Not
3487-7 2489-7
Responding Properly Responding Properly
Aftertreatment #1 Air Pressure Control: ARD Air Pressure Control Actuator:
3487-8 2489-8
Abnormal Frequency, Pulse Width, or Period Abnormal Frequency, Pulse Width, or Period
Aftertreatment #1 Air Pressure Actuator ARD Air Pressure Control Actuator Position
3488-3 2490-3
Position: Voltage Above Normal Sensor: Voltage Above Normal
Aftertreatment #1 Air Pressure Actuator ARD Air Pressure Control Actuator Position
3488-4 2490-4
Position: Voltage Below Normal Sensor: Voltage Below Normal
Sensor Supply Voltage 1: Voltage Above 5 Volt Sensor DC Power Supply: Voltage
3509-3 262-3
Normal Above Normal
Sensor Supply Voltage 1: Voltage Below 5 Volt Sensor DC Power Supply: Voltage
3509-4 262-4
Normal Below Normal
Sensor Supply Voltage 2: Voltage Above 5 Volt Sensor DC Power Supply #2: Voltage
3510-3 2131-3
Normal Above Normal
Sensor Supply Voltage 2: Voltage Below 5 Volt Sensor DC Power Supply #2: Voltage
3510-4 2131-4
Normal Below Normal
Sensor Supply Voltage 3: Voltage Above
3511-3 3482-3 Sensor Supply #3: Voltage Above Normal
Normal
Sensor Supply Voltage 3: Voltage Below
3511-4 3482-4 Sensor Supply #3: Voltage Below Normal
Normal
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor: Voltage
3563-3 1785-3
Pressure: Voltage Above Normal Above Normal
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor: Voltage
3563-4 1785-4
Pressure: Voltage Below Normal Below Normal
Engine Intake Manifold #1 Absolute Intake Manifold Pressure Sensor: Calibration
3563-13 1785-13
Pressure: Calibration Required Required
DPF #1 Intake Pressure: Voltage Above DPF #1 Intake Pressure Sensor: Voltage
3609-3 3464-3
Normal Above Normal
33

DPF #1 Intake Pressure: Voltage Below DPF #1 Intake Pressure Sensor: Voltage
3609-4 3464-4
Normal Below Normal
DPF #1 Intake Pressure: Calibration DPF #1 Intake Pressure Sensor: Calibration
3609-13 3464-13
Required Required
Aftertreatment 1 Secondary Air Pressure: Aftertreatment #1 Secondary Air Pressure
3837-3 3493-3
Voltage Above Normal Sensor: Voltage Above Normal
3837-4 3493-4
Voltage Below Normal Sensor: Voltage Below Normal
3837-13 3493-13
Calibration Required Sensor: Calibration Required
4077-3 2497-3
Above Normal Above Normal
4077-4 2497-4
Below Normal Below Normal
Aftertreatment #1 Transformer Secondary Aftertreatment #1 Ignition Transformer
4265-6 3180-6
Output: Current Above Normal Secondary: Current Above Normal
Aftertreatment #1 Fuel Injector #1 Heater Aftertreatment #1 Fuel Injector #1 Heater:
4301-5 3182-5
Control: Current Below Normal Current Below Normal
Aftertreatment #1 Fuel Injector #1 Heater Aftertreatment #1 Fuel Injector #1 Heater:
4301-6 3182-6
Control: Current Above Normal Current Above Normal
DPF #1 Soot Loading Sensor: Data Drifted
4783-21 DPF #1 Mean Soot Signal: Data Drifted Low 3397-21
Low
Engine Exhaust Manifold Bank #1 Flow Engine Exhaust Manifold Bank #1 Flow
5276-5 Balance Valve Actuator Control: Current 3409-5 Balance Valve Solenoid: Current Above
Below Normal Normal
Engine Exhaust Manifold Bank #1 Flow Engine Exhaust Manifold Bank #1 Flow
5276-6 Balance Valve Actuator Control: Current 3409-6 Balance Valve Solenoid: Current Above
Above Normal Normal
Aftertreatment #1 Fuel Pump Relay Control: Aftertreatment Fuel Pump Relay: Current
5423-5 3427-5
Aftertreatment #1 Fuel Pump Relay Control: Aftertreatment Fuel Pump Relay: Current
5423-6 3427-6
Aftertreatment #1 Fuel Flow Diverter Valve ARD Fuel Flow Diverter Actuator: Current
5424-5 3413-5
Control: Current Below Normal Below Normal
Aftertreatment #1 Fuel Flow Diverter Valve ARD Fuel Flow Diverter Actuator: Current
5424-6 3413-6
Control: Current Above Normal Above Normal
Aftertreatment #1 DPF Soot Mean DPF #1 Soot Loading Sensor: Special
5495-14 3397-14
Calibration Offset: Special Instruction Instruction
Aftertreatment #1 Identification: Erratic, Aftertreatment #1 Identification Number
5576-2 3468-2
Intermittent, or Incorrect Module: Erratic, Intermittent, or Incorrect
Aftertreatment #1 Identification Number
Aftertreatment #1 Identification: Abnormal
5576-8 3468-8 Module: Abnormal Frequency, Pulse Width,
Frequency, Pulse Width, or Period
or Period
Aftertreatment #1 Identification: Special Aftertreatment #1 Identification Number
5576-14 3468-14
Instruction Module: Special Instruction
Engine Fuel Delivery Absolute Pressure: Fuel Pressure Sensor - Before Fuel Filter:
5578-3 289-3
Voltage Above Normal Voltage Above Normal
5578-4 289-4
Voltage Below Normal Voltage Below Normal
34

5578-13 289-13
Calibration Required Calibration Required
Engine Filtered Fuel Delivery Absolute Fuel Pressure Sensor - After Fuel Filter:
5580-3 460-3
Pressure: Voltage Above Normal Voltage Above Normal
5580-4 460-4
Pressure: Voltage Below Normal Voltage Below Normal
5580-13 460-13
Pressure: Calibration Required Calibration Required
Aftertreatment #1 DPF Air Control Module: ARD Air Pressure Control System: Voltage
5591-3 3472-3
Voltage Above Normal Above Normal
Aftertreatment #1 DPF Air Control Module: ARD Air Pressure Control System: Voltage
5591-4 3472-4
Voltage Below Normal Below Normal
Aftertreatment #1 DPF Air Control Module: ARD Air Pressure Control Module: Current
5591-6 3471-6
Aftertreatment #1 DPF Air Control Module: ARD Air Pressure Control System: Abnormal
5591-9 3472-9
Abnormal Update Rate Update Rate
Aftertreatment #1 DPF Air Control Module: ARD Air Pressure Control System: Special
5591-14 3472-14
Special Instruction Instruction
DPF #1 Soot Loading Sensor: Voltage Above
520204-3 3397-3
Normal
DPF #1 Soot Loading Sensor: Voltage Below
520204-4 3397-4
Normal
DPF #1 Soot Loading Sensor: Abnormal
520204-9 3397-9
Update Rate
520204-12 3397-12 DPF #1 Soot Loading Sensor: Failure
DPF #1 Soot Loading Sensor: Calibration
520204-13 3397-13
Required
520204-19 3397-19 DPF #1 Soot Loading Sensor: Data Error
Table 2-2: Event Codes

Event Codes Description Event Codes Description
E198 (1) Low Fuel Pressure E1008 (2) High DPF #1 Intake Temperature
E198 (2) Low Fuel Pressure E1014 (2) Low DPF #1 Intake Temperature
E360 (1) Low Engine Oil Pressure E1025 (2) Aftertreatment #1 Failed to Ignite
E360 (2) Low Engine Oil Pressure E1026 (2) Aftertreatment #1 Loss of Combustion
E360 (3) Low Engine Oil Pressure E1036 (1) High Crankcase Pressure
E361 (1) High Engine Coolant Temperature E1036 (2) High Crankcase Pressure
E361 (2) High Engine Coolant Temperature E1045 (2) Low Intake Manifold Pressure
E361 (3) High Engine Coolant Temperature E1050 (1) High Aftertreatment #1 Fuel Pressure #1
E362 (1) Engine Overspeed E1050 (2) High Aftertreatment #1 Fuel Pressure #1
E362 (3) Engine Overspeed E1051 (1) High Aftertreatment #1 Fuel Pressure #2
E363 (1) High Fuel Supply Temperature E1051 (2) High Aftertreatment #1 Fuel Pressure #2
E363 (2) High Fuel Supply Temperature E1052 (1) Low Aftertreatment #1 Fuel Pressure #1
E363 (3) High Fuel Supply Temperature E1052 (2) Low Aftertreatment #1 Fuel Pressure #1
35
Table 2-2: Event Codes

E390 (1) Fuel Filter Restriction E1053 (1) Low Aftertreatment #1 Fuel Pressure #2
E390 (2) Fuel Filter Restriction E1053 (2) Low Aftertreatment #1 Fuel Pressure #2
E396 (1) High Fuel Rail Pressure E1070 (1) Aftertreatment Fuel Injector #1 not responding
E398 (1) Low Fuel Rail Pressure E1070 (2) Aftertreatment Fuel Injector #1 not responding
E441 (1) Idle Elevated to Increase Battery E1090 (2) High EGR Intake Pressure
Voltage
E443 (1) High Auxiliary Pressure E1092 (1) High EGR Temperature
E443 (2) High Auxiliary Pressure E1092 (2) High EGR Temperature
E443 (3) High Auxiliary Pressure E1093 (2) Low EGR Differential Pressure
E445 (1) High Auxiliary Temperature E1094 (2) High EGR Differential Pressure
E445 (2) High Auxiliary Temperature E1095 (2) Low EGR Mass Flow Rate
E445 (3) High Auxiliary Temperature E1096 (1) High EGR Mass Flow Rate
E499 (3) Fuel Rail #1 Pressure Leak E1096 (2) High EGR Mass Flow Rate
E539 (1) High Intake Manifold Air Temperature E1154 (2) Low DPF #1 Intake Pressure
E539 (2) High Intake Manifold Air Temperature E1156 (1) High DPF #1 Intake Pressure
E539 (3) High Intake Manifold Air Temperature E1170 (2) Low Aftertreatment #1 Secondary Air Pressure
E583 (1) High Air Inlet #1 Differential Pressure E1171 (1) Engine Idle Shutdown Occurred
E583 (2) High Air Inlet #1 Differential Pressure E1172 (2) Engine Idle Shutdown Pending
E593 (2) Aftertreatment Insufficient Temperature E1172 (3) Engine Idle Shutdown Pending
to Complete Regeneration
E678 (3) Ground Level Shutdown E1187 (2) Engine Exhaust Manifold Bank #1 Flow
Balance Valve Stuck Closed
E991 (3) DPF Active Regeneration Inhibited Due E1188 (1) Engine Exhaust Manifold Bank #1 Flow
to Permanent System Lockout Balance Valve Stuck Open
E992 (3) DPF Active Regeneration Inhibited Due E1190 (3) Low Aftertreatment Cooling Fan Speed
to Permanent System Lockout
E993 (2) DPF Active Regeneration Inhibited Due E1217 (3) Delayed Engine Shutdown Override
to Inhibit Switch
E995 (2) High DPF #1 Soot Loading E1218 (2) High Unfiltered Fuel Pressure
E995 (3) High DPF #1 Soot Loading E1220 (2) Low Cranking Fuel Rail Pressure
E997 (1) High DPF #1 Ash Loading E1239 (1) DPF #1 Conditions Not Met for Active
Regeneration
E997 (2) High DPF #1 Ash Loading E2143 (1) Low Engine Coolant Level
E1008 (1) High DPF #1 Intake Temperature E2143 (2) Low Engine Coolant Level
E2143 (3) Low Engine Coolant Level
2.10 PARTS OF THE EVENT CODE

The “E” identifies the code as an event code. The • E360(2) Low Oil Pressure
“XX(X)” represents a numeric identifier for the event • E360(3) Low Oil Pressure
code. The fourth “(X)” assigns one of three levels to
the active event code according to the severity of the The definition for the levels of severity for an event
abnormal system condition. This is followed by a are defined below:
description of the code. Refer to the following Level 1 - Level 1 alerts the operator that an engine
example: system requires attention. The operator should check
• E360(1) Low Oil Pressure the involved system condition or the operator should
36
perform maintenance on the involved system at the 2.11 ELECTRICAL SYSTEM,

earliest possible time. FUNCTIONAL DESCRIPTION
Level 2 - Level 2 requires a change in the operation
Refer to Section 2.12: MAIN WIRING DIAGRAM.
of the engine or the performance of a maintenance
The electrical system is comprised of not only the
procedure. Failure to correct the problem that caused
necessary equipment required to operate the
this warning may result in damage to the engine
compressor, but also a system to shut it down in the
components.
event of a malfunction. The components of the
Level 3 - Level 3 requires an immediate safe electrical system are an engine starter (with an
shutdown of the engine in order to avoid damage to integral solenoid), battery, an alternator with a built-in
the engine or injury to personnel around the voltage regulator, a compressor discharge
engine.The problem that caused the event must be temperature switch (which will shut down the
corrected before engine operation can resume. compressor should the compressor temperature
exceed 250°F [121°C]), a low coolant shutdown
switch and low fuel shutdown protection. The engine
coolant level detector is located in the deaeration
tank for the engine cooling system. It will shut the
compressor down or prevent it from being started if
the engine coolant level drops too low. In addition,
there is a starter protection relay which prevents
accidental starter engagement after the engine is
running or whenever there is pressure in the receiver
tank.
37
2.12 MAIN WIRING DIAGRAM
02250197-144(r03) L
38
02250197-144(r03) R
39
SECTION 2
02250197-144(R03) S2
40
41
2.13 CONTROLLER WIRING DIAGRAM
02250200-843-R02 left
42
2.13 CONTROLLER WIRING DIAGRAM
02250200-843 r02 right
43
2.14 P & I COMPRESSOR SYSTEM
44
2.14 P & I—ENGINE SYSTEM
45
2.15 ID, DLQ AFTERCOOLED
46
02250204-774R00
SECTION 2
2.15 ID, DLQ AFTERCOOLED
KEY DESCRIPTION KEY DESCRIPTION
NOTES: A18: 2” NPT AIR DISCHARGE

A19: 3/4” NPT AIR DISCHARGE (LP ONLY)
SECTION 2
1: DIMENSIONS ARE IN INCHES

[ ] DIMENSIONS ARE IN MILLIMETERS. A20: BATTERY ACCESS
2: ALL DOORS REQUIRE 45” [1143 MM] CLEARANCE. A21: AIR FILTER ELEMENT ACCESS
ALL DOORS ARE PAD/KEY LOCKABLE. A22: AIR/OIL SEPARATOR ELEMENT ACCESS
3: REFERENCE: A STANDARD CONTAINER SIZE IS 92” WIDE X A23: FUEL SELECTOR VALVE
94” TALL X 232” LONG. A24: DISCHARGE VALVE CONTROL
4: REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’LONG A25: BLOCK HEATER INLET (OPTIONAL)
CUBE CONTAINER. A26: STROBE LIGHT
5: APPROX. WET WEIGHT = 21,000 LBS. [9526 KG.], A27: CEM ACCESS
APPROX. DRY WEIGHT = 19,000 LB [8619 KG.] A28: FILTER/H2O TRAP ACCESS
6: THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS. A29 D-RING FOR DISCHARGE HOSE SAFETY LANYARD
A1: ENGINE COOLANT DRAIN
A2: ENGINE OIL DRAIN
A3: COMPRESSOR OIL DRAIN
A4: WATER CONDENSATE DRAIN (DO NOT PLUG)
(ONLY REQ’D ON AFTER-COOLED MACHINES)
A5: CONTAINMENT FRAME DRAIN
A6: LIFTING BAIL ACCESS COVER
A7: TOW EYE/TIEDOWN (4-PLACES)
A8: INSTRUMENT PANEL DOOR
A9: E-STOP
A10: OVERALL HEIGHT
A11: OVERALL LENGTH
A12: OVERALL WIDTH
A13: AIR EXHAUST
A14: ENGINE FUEL FILL
A15: ENGINE COOLANT FILL
A16: ENGINE FUEL CONNECTION PORTS
A17: AIR INTAKE
47
2.16 ID, DTQ AFTERCOOLED
48
02250204-773 R00
SECTION 2
2.16 ID, DTQ AFTERCOOLED
KEY DESCRIPTION KEY DESCRIPTION
NOTES: A18: AIR INTAKE

A19: 2” NPT AIR DISCHARGE
SECTION 2
1: DIMENSIONS ARE IN INCHES

[ ] DIMENSIONS ARE IN MILLIMETERS. A20: 3/4” NPT AIR DISCHARGE (LP ONLY)
2: ALL DOORS REQUIRE 45” [1143 MM] CLEARANCE. A21: BATTERY ACCESS
ALL DOORS ARE PAD/KEY LOCKABLE. A22: AIR FILTER ELEMENT ACCESS
3: REFERENCE: A STANDARD CONTAINER SIZE IS 92” WIDE X 94” A23: AIR/OIL SEPARATOR ELEMENT ACCESS
TALL X 232” LONG. A24: SAFETY CHAINS
4: REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’LONG A25: TRACK WIDTH
CUBE CONTAINER. A26: WHEEL CHOCKS
5: APPROX. WET WEIGHT = 21,000 LBS. [9526 KG.], A27: FUEL SELECTOR VALVE
APPROX. DRY WEIGHT = 19,000 LB [8619 KG.] A28: DISCHARGE VALVE CONTROL
6: THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS. A29: BLOCK HEATER INLET (OPTIONAL)
A1: ENGINE COOLANT DRAIN A30: STROBE LIGHT
A2: ENGINE OIL DRAIN A31: JACK
A3: COMPRESSOR OIL DRAIN A32: CEM ACCESS
A4: WATER CONDENSATE DRAIN (DO NOT PLUG) A33: FILTER/H2O TRAP ACCESS
(ONLY REQ’D ON AFTER-COOLED MACHINES) A34: D-RING FOR DISCHARGE HOSE SAFETY LANYARD
A5: CONTAINMENT FRAME DRAIN
A6: LIFTING BAIL ACCESS COVER
A7: TOW EYE/TIEDOWN (4-PLACES)
A8: FORK LIFT POCKET (OPTIONAL)
A9: INSTRUMENT PANEL DOOR
A10: E-STOP
A11: OVERALL HEIGHT
A12: OVERALL LENGTH
A13: OVERALL WIDTH
A14: AIR EXHAUST
A15: ENGINE FUEL FILL
A16: ENGINE COOLANT FILL
A17: ENGINE FUEL CONNECTION PORTS
49
2.17 AFTERCOOLER AIR with respect to the type of air that is required for the
SYSTEM, FUNCTIONAL application.
DESCRIPTION
Depending upon the application, the compressed air
Refer to Figure 2-5. The purpose of the aftercooler can be by-passed around the aftercooler for
unprocessed air or it can be routed through the
air system is to operate the air compressor in
aftercooler for cooling. The ambient air, which is
conditions when compressed air temperatures are
drawn through the aftercooler by the engine fan,
required to be 10 to 25°F (5 to 13°C) over ambient cools the compressed air as it passes through the
temperature. This compressor has one main aftercooler core. Cooled air enters the moisture
discharge valve. The discharge plumbing within the separator where condensation is removed and
compressor allows the user to switch between discharged. This condensation does carry some oil
standard air to aftercooled air through a set a valves. and it should be disposed of properly in accordance
with local regulations. From the moisture separator
These valves are labeled on the machine to help
the compressed air goes to the compressor service
assist the user to select the proper valve orientation
50
valve.
NOTE
Aftercooler system should not be operated in
ambient conditions below 32°F (0°C). If it is
necessary to operate in these conditions, Sul-
lair can supply optional equipment to accom-
modate this requirement.
To operate in the non-aftercooled mode, close
the two aftercooler service valves completely
and open non-aftercooler valve.
Figure 2-5: Discharge System
1. RECEIVER TANK 5. DISCHARGE FILTER

2. MIN PRESSURE/CHECK VALVE 6. MOISTURE SEPARATOR
3. AFTERCOOLER AIR VALVE 7. AFTERCOOLER
4. STANDARD AIR VALVE 8. SERVICE AIR OUT
51
52
2.18 ENGINE EXHAUST and reducing the soot to ash. This system allows the
AFTERTREATMENT, unit to keep the particulate concentrations of the
FUNCTIONAL DESCRIPTION exhaust at levels that comply with EPA/EU regulations.
If the aftertreatment is working correctly, it will not affect
Refer to Figure 2-6. The Clean Emissions Module the engine performance. The engine will still function
(CEM) or aftertreatment serves as the means of normally during aftertreatment regeneration.
achieving the Tier IV emissions requirements set forth Regeneration can be engaged by two methods:
by the EPA/ EU (69 FR 38957-39273, 29 Jun 2004) to
be phased in from 2008-2015. The module itself 1. Regeneration Switch (manual force/ inhibition)
consists of a Diesel Particulate Filter (DPF), Muffler, 2. ECU controlled (automatically managed) .
Exhaust Outlet, Diesel Oxidation Catalyst (DOC) Inlet
Cap, Absolute pressure sensor, CEM Connector to
ECM, Combustion Air Valve, Exhaust inlet, Outlet cap,
and a Caterpillar RS head. The basic function of the WARNING
aftertreatment is to remove soot and other solid
particulates from the exhaust via the DPF. The level of Regenerated exhaust gases can reach tempera-
soot is monitored by the engine and, when needed, the tures of up to 1800ºF. DO NOT come into direct
system will automatically regenerate the DPF by raising contact with these gases.
the temperature in the DPF through active combustion
Figure 2-6: Exhaust System
1. MUFFLER A1. FROM ENGINE TURBO CHARGE

2. DPF (Diesel Particulate Filter) A2. FROM ENGINE FUEL SYSTEM
3. EXHAUST PIPE A3. ENGINE COOLANT
4. AUXILIARY REGENERATION DEVICE. A4. ENGINE CHARGE AIR COOLER
A5. FROM ENGINE EXHAUST OUTLET
53
Instead of expelling exhaust gases to the atmosphere as module adds diesel fuel and air from the turbocharger to
typical exhaust systems do, exhaust exits the engine burn the exhaust fumes and reduce the accumulated
turbocharger and enters the inlet of the CEM, where the soot to ash. The information in Table 5-1 on page 64
level of soot loading in the DPF is measured by the describes the reaction of the system at various stages of
pressure differential across the DPF. This information in the soot loading profile. For detailed CEM component
conjunction with engine speed is used to determine if information please see the Engine Operator's Manual
conditions are correct to initiate an automatic please see the Engine Operator's Manual
regeneration cycle. During regeneration the CAT-RS
54
Section 3
INSTALLATION
3.1 LOCATING THE PACKAGE Compressor and engine intakes are located above
the double set of doors on the engine and
Position the compressor on a level surface, if compressor side. Canopy discharge (for cooling air)
possible. If unable to locate the compressor on a and engine exhaust is located on the roof at the rear
level surface, position the compressor on a grade of the package. Canopy intake (for cooling air) is
surface which will not allow the compressor to slide located on the front and sides and along the frame.
downhill.
Maintain a 6 ft. (1.8 m) minimum separation between
DO NOT locate compressor on surface grades the package and any surrounding walls.
exceeding 15 degrees.
If ductwork is installed, the total restriction on intake
The compressor package should be placed on a must not exceed 0.1 inches H20 (25 Pascals). The
surface or foundation capable of supporting 10% total restriction on the outlet must not exceed 0.1
more than the compressor weight. Take into inches H20 (25 Pascals).
consideration additional weight allowances for stored
tools, rainwater, snow, ice and mud.
3.3 SERVICE AIR CONDENSATE
No piping loads or moments should be transmitted to PIPING
the air and fuel connections provided with the
package. A shut-off valve is included to isolate the package
from the supply line as required.
Locate compressor so the wind, if any, will help carry
the exhaust fumes and package heat away from the No piping loads or moments should be transmitted to
compressor air inlet openings. The compressor the air connections provided with the package.
coolers should not be exposed to excessive dust Condensate drains shall be connected to a non-
from the worksite. Contaminants on the coolers will pressurized gravity feed drain. If the compressor
directly affect the packages ability to run in high drains are manifolded together, care should be taken
ambient temperatures. to ensure that this drain is not pressurized when the
machine condensate drains (both automatic and
3.2 VENTILATION AND manual) are in operation.
COOLING All condensate should be disposed of in accordance
Select a location that allows an unrestricted flow of with local governing laws.
free ventilation air through the package.
Avoid any recirculation or ingestion of heated gases.
55
NOTES
56
Section 4
SPECIFICATIONS
4.1 TABLES OF SPECIFICATIONS
Table 4-1: Overall Specifications
Model Series DTQ (Tandem Axle) DLQ
Length (in / mm) 262/6655 210/5334
Width (in / mm) 102/2591 88 / 2235
Height (in / mm) 101/2565 86/2187
Wet Weight (lbs / kg)* 22,200/10070 21,200/9616
Track width (in / mm) 91/2311 n/a
Tire Size 245/70R17.5H n/a
Tire Pressure (psi / bar) 130/9.0 n/a
Wheel Size 17.5 n/a
Lug Nut Torque (ft*lbs / Nm) 300/407 n/a
Max Towing Speed (mph / km/h) 55 / 89 n/a
Axle Rating (lbs / kg) 12000/5443 n/a
(*) Aftercooled add 500 lbs/227 kg
Forklift pocket option adds 740 lbs/336 kg
Table 4-2: Compressor Specifications

Compressor 1300H/1600H 1600 1300HH 1450HH
Type Rotary Screw Rotary Screw Rotary Screw Rotary Screw
Maximum Operating
150 psig (10.3 bar) 125 psig (8.5 bar) 200 psig (14 bar) 200 psig (14 bar)
Pressure
Rated Pressure 150 psig (10.3 bar) 100 psig (7 bar) 200 psig (14 bar) 175 psig (12.1 bar)
1300/1600 Free
Rated Delivery 1600 Free CFM 1300 Free CFM 1450 Free CFM
CFM
Pressurized Pressurized Pressurized Pressurized
Cooling
Compressor Fluid Compressor Fluid Compressor Fluid Compressor Fluid
Lubricating Compressor
See table - page 54 See table - page 54 See table - page 54 See table - page 54
Fluid
Compressor System Oil 45 US gallons 45 US gallons 45 US gallons 45 US gallons
Capacity (170 liters) (170 liters) (170 liters) (170 liters)
Operating Tilt 15° 15° 15° 15°
Engine - 24 Volt Engine - 24 Volt Engine - 24 Volt Engine - 24 Volt
Electrical System Instrument System - Instrument System Instrument System Instrument System
24 Volt - 24 Volt - 24 Volt - 24 Volt
1700 CA @ 1700 CA @ 1700 CA @ 1700 CA @
Battery (2)
32°F(0°C) 32°F(0°C) 32°F(0°C) 32°(0°C)
57
Table 4-2: Compressor Specifications

Compressor 1300H/1600H 1600 1300HH 1450HH
(8D) 1400 CCA @ (8D) 1400 CCA @ (8D) 1400 CCA @ (8D) 1400 CCA @
Battery (2) continued
0°F (-18°C) 0°F (-18°C) 0°F (-18°C) 0°F (-18°C)
Alternator 95 Amp 95 Amp 95 Amp 95 Amp
Service Valves 2.5" npt 2.5" npt 2.5" npt 2.5" npt
Aux. Service Valves (2) .75" npt (2) .75" npt (2) .75" npt (2) .75" npt
Sound Level (US EPA)a 76 dBA 76 dBA 76 dBA 76 dBA
aSound level measured per US 40 CFR Ch.1 Part 204.
Table 4-3: Engine Specifications

Engine 1300H/1600 1300HH/1450HH/1600H
Make Caterpillar Caterpillar
Type C15 Tier IV/Stage IIIB C15 Tier IV/Stage IIIB
Rated Speed 1800 RPM 1800 RPM
Horsepower, SAE 475 HP (354 kw) 540 HP (403 kw)
Cylinders 6 6
Cycles 4 4
Bore x Stroke 5.4 x 6.75 in (138 x 171 mm) 5.4 x 6.75 in (138 x 171 mm)
Displacement 928 cu.in (15.2 liters) 928 cu.in (15.2 liters)
Lubricating System Full Pressure Fluid Full Pressure Fluid
Type of Motor Oil See Engine Operator’s Manual See Engine Operator’s Manual
Fuel Tank Capacity 244 U.S. gallons (924 liters) 244 U.S. gallons (924 liters)
Engine Cooling System Capacity 20 U.S. gallons (76 liters) 20 U.S. gallons (76 liters)
Idle Speed 1400 RPM 1400 RPM
4.2 LUBRICATION GUIDE—COMPRESSOR

Table 4-4: Lubricant Information
Fluid Type Change Period, Hours Ambient Temperature Range 0F(0C)
Sullair AWF (*) 1500 -20 to 120 (-29 to 49)
D-A Torque Fluid 300 10 to 110 (-12 to 43)
SAE 10W SE, SF, SG, CD 300 0 to 100 (-18 to 38)
MIL-L-2104E 10W 300 0 to 100 (-18 to 38)
(*) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5gallons/18.9 liters), 250030-758 (55 gallons,208 liter drum)
58
4.3 APPLICATION GUIDE under conditions where severe oil oxidations can
occur.
Water must be drained from the receiver tank
periodically. In high ambient temperature and high
humidity conditions, condensed moisture may
emulsify with the oil forming a “milky” color. ATF or
SAE 10W is especially prone to this condition. The
fluid should be changed if this condition develops.
CAUTION
DO NOT mix types of fluids. Combinations
of different fluids may lead to operational
problems such as foaming, filter plugging,
orifice or line plugging.
When ambient conditions exceed those noted or if

conditions warrant use of other extended life
lubricants, contact Sullair for recommendations.
Figure 4-1: Fluid Fill Location
Sullair encourages the user to participate in a fluid
1. SIGHT GLASS 2. FLUID FILL analysis program. This could result in a fluid change
interval differing from that stated in the manual.
Sullair offers a fluid analysis program for Sullair
AWF. Contact your local Sullair representative for
Refer to Section 4.2: Lubrication Guide— details.
Compressor. Sullair Air Compressors are supplied
with Sullair AWF which is heavy duty multi-viscosity, 4.4 LUBRICATION GUIDE,
all-weather fluid. This fluid also allows an extended ENGINE
change interval.
The fluids in Lubrication Guide—Compressor on Refer to the Engine Operator’s Manual for oil
page 58 can be used. Any of these oils are suitable specifications.
59
NOTES
60
Section 5
OPERATION
5.1 GENERAL
While Sullair has built into this compressor a Before starting your Sullair compressor, read this
comprehensive array of controls and indicators to section thoroughly and familiarize yourself with the
assure you that it is operating properly, you will want controls and indicators—their purpose, location and
to recognize and interpret the readings which will call use.
for service or indicate the beginning of a malfunction.
5.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE
OFF/ON Switch / START Switch (Up) * The engine switch is used to both energize the compressor’s electrical
system and engage the engine/starter. It also has a built-in anti-restart
device that protects the starter from engaging while the engine is running.
The switch must be turned back to the “off” position before the engine can
be re-started.
NOTE
When restarting the compressor, the controller will not
allow restart until system pressure falls below 10 psig
(0.7 bar) or less. More than 10 psig (0.7 bar) can put
extra load on the starter.
Voltmeter * Monitors the condition of the batteries and the charging circuit. The
normal reading is 24 to 28 volts.
Service Air Pressure Gauge * Continually monitors the pressure inside the receiver tank at various load
and unload conditions.
Engine Temperature Gauge * Monitors the temperature of the engine water. The normal operating
temperature should read approximately 160ºF to 210ºF (71ºC to 99ºC).
Controller * Depicts system related diagnostics. Can be used for system performance
monitoring.
Compressor Temperature Gauge * Monitors the temperature of the air/fluid mixture leaving the compressor
unit. The normal reading should be approximately 170ºF to 190ºF (77ºC
to 88ºC).
System Pressure Sensor Prevents starter engagement when the air system is pressurized.
Fluid Level Sight Glass Monitors the fluid level in the receiver tank. Proper level is always visible
in the sight glass. Check the level when the compressor is shutdown.
Receiver Tank Temperature Switch Opens the electrical circuit to shut down the compressor when then
receiver tank temperature reaches 250ºF (121ºC).
ON/OFF Start Switch Structure Allows the engine to run at unload speed (lower pressure until properly
cooled down. refer to controller manual 02250201-242
61
CONTROL OR INDICATOR PURPOSE

Notes*
Control Regulating Valve Provides an air signal to the inlet valve and engine to close the inlet valve
and reduce engine speed to control air delivery according to demand.
Minimum Pressure/Check Valve Maintains a minimum of 65 psig (4.5 bar) in the compressor receiver tank.
This valve restricts receiver air discharge from receiver/receiver tank
when pressure falls to 65 psig (4.5 bar). Also prevents back flow into the
receiver tank during upload conditions and after shutdown.
High/Low Pressure Selector Switch * Select high pressure 150 psig (10.3 bar) or low pressure 100 psig (6.9
(only on dual pressure models) bar) at instrument panel to correspond to operator’s needs.
Pressure Relief Valve Opens receiver tank pressure to atmosphere should pressure inside the
receiver tank exceed the pressure relief valve setting.
Air Inlet Valve Regulates the amount of air allowed to enter the compressor. This
regulation is determined by the amount of air being used at the service
line.
Thermal Valve Regulates flow of fluid to and around the fluid cooler. Designed to
maintain a minimum operating temperature; used for fast warm-up at
start-up and to eliminate condensation during operation.
Blowdown Valve Vents surplus receiver tank pressure to the atmosphere during operation
and shutdown.
Coolant Level Switch Shuts the compressor down and/or prevents it from being started if the
engine coolant level drops too low.
Regeneration Switch * To manually control the exhaust aftertreatment is in soot indicator levels of
15 - 105%
DPF Lamp * Indicates DPF is above 80% soot loading. Warns operator that
regeneration is required.
Regeneration Inhibited Lamp * Indicates regeneration is inhibited by operator, application, or Cat ET.
High Exhaust System Temperature (HEST) Indicates that the exhaust aftertreatment is in active regeneration.
Lamp *
Cabin Light Switch * Manually turns interior compressor lighting on.
Menu select switch * Allows the user to make selections in the controller menu, and navigate
the menu structure
Menu Toggle switch * Allows the user to scroll the menu options
* Indicates item is part of the compressor controller.
62
5.3 COMPRESSOR START-UP “Start” position. The LCD panel will show the
PROCEDURE following message:
1. Turn on the system power supply by dis-

engaging the battery disconnect switch.
2. Toggle the <ON> switch, located on the con-
troller, to the “on” position. The controller will
power up and a self-diagnostic program will
be initiated. During the initiation process, the
gauges will wag (the needles on each gauge
will sweep through its full scale) to verify all
relevant sensors are operational. Also, a
communication link will be established with
the engine ECU. During this time, several WARNING
messages will be displayed on the panel.
Some of these messages may not be If the machine does not start successfully
noticed by the operator because the control- when starter disengages, the starter will
ler steps through the initialization phase automatically engage up to four more times
rather quickly. However, the operator should after brief pauses to try and start the
see the following messages during this step: machine.
Once the compressor has started, the unit

will enter a warm-up phase. At this point, the
unit is not producing usable compressed air
and the service valve should still be closed.
The following message will be displayed on
the LCD panel:
When the system has successfully initial-

ized, the following message will be displayed
on the LCD Graphic Display:
Once the proper operating conditions are

met, the machine will automatically switch
into run mode and provide pressurized ser-
vice air.
3. Toggle the <ON> switch to the “Start” posi-
tion. You do not have to hold the switch in the 5.4 EXHAUST REGENERATION
PROCEDURE
The aftertreatment constantly monitors the soot
levels of the exhaust gas. If soot levels detected by
the indicator reach above 80% the engine Electronic
Control Module (ECM) lights the DPF lamp , on
the controller screen, and should automatically
trigger the ARD to ignite diesel fuel passing through
the DPF until soot levels return to normal (< 10%).
63
.
During regeneration the HEST Lamp , on the
controller screen, should be lit. If for some reason the
emissions module is not automatically engaged
regeneration can be achieved, manually, by pressing DANGER
and holding the <REGEN> Switch in the "force"
Regenerated exhaust gas can reach temper-
position , on the controller, for 15 seconds. This atures as high as1800F. DO NOT come into
will manually force the regeneration process at soot direct contact with these gases.
levels of 15% - 105%. If regeneration is not desired
the automatic regeneration process can be halted by
engaging the <REGEN> Switch in the "inhibit"
position , on the controller. If regeneration is
WARNING
inhibited the DPF Inhibited Lamp , on the Under no circumstances should the soot
level reach above 140% as this will fault the
controller screen, should be lit. Regeneration DPF and halt unit operation until it is
inhibition should not be a regular practice, as replaced. If for some reason the regenera-
allowing soot load percentages to get above 116% tion methods mentioned in this document
could cause the unit to abnormally shut down and do not work and soot levels are close to, at,
fault the DPF. The Unit will NOT be able to function or above 116%, shut the unit down immedi-
until the faulted DPF is replaced. Force regeneration ately until this issue is resolved.
to re-engage automatic feature. If for some reason
the regeneration methods do not work and soot
levels are close too, at, or above 100% shut the unit
down immediately until this issue is resolved. For
troubleshooting and next steps please refer to the
Troubleshooting Guide on page 80, Engine
Operator's Manual, or contact your CAT dealer
Table 5-1: Active Regeneration Operation Sequence
Soot Level Timer Operator Engine De- Engine Shutdown Engine

Indication Rate Strategy Strategy Protection
<80% NA
80% NA
Engine De-Rate Low Soot Mode
100% NA ! Yellow
begins at -25%
116% NA ! Yellow
** Pre-Emptive Idle Down

116% +5min (Programmable—Enable/Disable)
116% +10min *** Rolling Shutdown Trigger
REGEN Disabled Service

Engine De-Rate Level Regen Only
120% NA
at -60%
Yellow Red
Engine Shutdown
140% NA ! ! Replace DPF
30 sec Rolling Shutdowns
64
5.5 SHUTDOWN PROCEDURE during this time as the controller will auto-
matically disconnect power to all systems so
1. Close the service valve. that the battery is not inadvertently drained
after shutdown.
2. Place the <ON> switch in the “off” position.
The following message will be displayed in
the LCD graphic display:
WARNING
The E-Stop (emergency stop switch) should
be used only in the event of an emergency.
Refrain from using the E-Stop to shut the
machine down during normal operations.
All usage of the E-Stop is logged in perma-
nent memory for use by service technicians
when troubleshooting a machine. Non-
emergency use of E-Stop is considered
3. The unit will continue to run, though it will not equipment abuse and could void the manu-
produce usable air. At the end of the cool facturer’s warranty.
down cycle, the engine will be shut down.
The controller will stay powered up, and a
new message will be displayed: 4. Engage battery disconnect switch.
WARNING
It is a good practice to engage the battery
disconnect after use. The engine and the
compressor controller systems continually
draw power after the controller is powered
down. Over time, this will deplete the batter-
The controller will continue to monitor the ies. If the batteries are left on per applica-
system pressures and will not power down tion requirements, like remote start
until all pressures drop below 10 PSI (0.7 applications, a battery maintainer should be
bar). This final process may take 3 to 5 min- used to keep the batteries fully charged.
utes. Operator interaction is not necessary
65
NOTES
66
Section 6
MAINTENANCE
6.1 GENERAL 1. Check the fluid level in the compressor
receiver tank. Should the level be low, simply
A good maintenance program is the key to long add the necessary amount.
compressor life. Below is a program that when 2. If the addition of fluid becomes too frequent,
adhered to, should keep the compressor in top a simple problem has developed which is
operating condition. For engine maintenance causing this excessive loss. Refer to Section
6.12 under Excessive Compressor Fluid
requirements, refer to the Engine Operator's Consumption for a probable cause and rem-
Manual for a detailed description of service edy.
instructions. Refer to Parts Replacement and
3. Drain water from the fuel/water separator
Adjustment Procedures for a detailed description of and control system coalescing filter.
specific compressor system components. Prior to
performing maintenance, read the CIMA Safety 4. Check the fuel level in the fuel tank.
Manual, if applicable. 5. Check the engine oil level.
6. Check the engine coolant level
7. Check for proper tire inflation. Refer to tire
CAUTION sidewall for tire manufacturer’s recommen-
dations.
DO NOT remove caps, plugs and/or other After a routine start has been made, it is necessary to
components when compressor is running perform an inspection to ensure all operations are
or pressurized. performing correctly. Perform the following
Stop compressor and relieve all internal inspections to prevent unnecessary problems.
pressure before doing so.
1. Observe the instrument panel gauges and
be sure they monitor the correct readings for
their particular phase of operation.
6.2 DAILY OPERATION
2. After the compressor has warmed up, it is
Prior to starting the compressor, it is necessary to recommended that a general check on the
perform a daily inspection. Perform the following overall compressor and instrument panel be
maintenance operations to prevent unnecessary made to assure that the compressor is
running properly.
problems.
3. Check the engine soot load percentage on
the controller display.
NOTE 4. Check the air filter restriction gauges. Should
they indicate restriction, replace the
True system oil level can only be deter- elements immediately. Refer to Air Filter
mined after the compressor has warmed up Maintenance section 6.11.3.
to operating temperature and run for a 5. If equipped, check aftercooler condensate
short period of time. This releases trapped drain system functionality.
oil within the oil cooling system. Short run-
ning periods may trap additional oil within
the plumbing. Awareness of how the com-
pressor operated and shutdown will help
keep the system from being over filled.
67
6.3 ENGINE COOLANT Finally, fill the system with the recommended coolant
REQUIREMENTS using only one brand/type. Cross contamination,
which is caused by adding different types of engine
coolants, may result in the depletion or dropout of
coolant additives; thus leaving cooling system
WARNING surfaces unprotected against corrosion. Corrosion to
radiator surfaces may reduce cooling efficiency and
Please note: not following the recommen- radiator life expectancy. It is extremely important to
dations of the coolant requirements may evacuate/purge all air within the cooling system
induce cooling system inefficiencies which before replacing the radiator cap. Engine coolant
may result in engine overheating. Non rec- must not only maintain proper freeze protection
ommended coolant can drastically reduce levels but also maintain proper corrosion inhibitor
the life expectancy of the cooling circuit levels. Please contact the coolant manufacture for
and engine. specifics on testing methods and suggested coolant
maintenance intervals.
This machine is factory filled with Mobil Delvac
Extended Life Coolant. It is an ethylene glycol based, Coolant Service Life
OAT inhibited coolant. This coolant is able to protect
the cooling system from freezing, extend the boiling Coolant Type Service Life
point, provide corrosion protection for all metals
within the cooling system; especially for systems with Mobil Delvac EXTENDED *Six Years/12,000 Hours
LIFE Coolant/Antifreeze
aluminum radiators, provide liner cavitation
protection for heavy duty diesel engines, and be safe Caterpillar ELC *Six Years/12,000 Hours
to use with all seals/gasket materials.
This coolant should never be mixed with a different
*(using manufactures extender additive to system at
coolant type, color, or brand. If radiator coolant is to 3 years or 6000 hours
be added, for any reason, be sure that the coolant
added is the same as what is in the cooling system,
as well as what is recommended.
6.4 DAILY MAINTENANCE
The Engine Coolant type should follow these See Initial Startup Shutdown/Procedure for general
recommended specifications: operation.
• Organic acid technology (OAT)
• Premixed coolant pH range of 8.0 to 9.5.
• Contains no silicates, phosphates, borates,
nitrates and amines
CAUTION
• Solution states that it is formulated for use
in heavy duty diesel applications The radiator and engine cooling system
• Protects all standard metals within the cool- must be drained and flushed periodically.
ing system (i.e. brass, copper, steel, solder, Refer to the OEM Engine Manual for more
cast iron, and aluminum.) information. Replace the coolant with a
• Meets specification requirements of current solution of 50% ethylene glycol and 50%
industry standards which include: ASTM D water or as required for your geographic
3306, Cat EC-1 location. DO NOT use a leak sealing type of
• Meets or exceeds performance require- antifreeze. Should a 100% water solution be
ments of current industry standards which used, a non-chromate rust inhibitor must
include: ASTM D 6210, John Deere H24A2
be added. DO NOT mix coolant types.
and H24C2.
If you are not sure of the coolant that is installed
originally or want to change to a different type, the
cooling system must be cleaned with a commercial NOTE
cleaning agent (such as CAT Cooling System
Cleaner p/n 4C-4611) and then completely flushed Dispose of fluids in accordance with appli-
and filled with water (preferably distilled) several cable federal, state and local regulations.
times to remove all traces of cleaner and old coolant.
68
6.5 MAINTENANCE AFTER 2. (If equipped) Replace the water condensate

INITIAL 50 HOURS OF element and the discharge air filter element.
OPERATION 3. Concerning compressor models with running
gear and brakes:
After the initial 50 hours of operation, a few simple
maintenance routines can rid the system of any Depending on the compressor’s working
possible foreign materials, if any. Perform the environment and the amount of travel it encounters,
following maintenance operations to prevent the braking system may require more frequent
unnecessary problems. adjustment which is left to the discretion of the end-
user. See Sections 6.11.7 through 6.11.11.
1. Clean the receiver tank return line (or scav-
enge tube) orifice and strainer.
2. Change compressor fluid filter
6.9 MAINTENANCE AFTER 4500
HOURS OF OPERATION
3. Check Engine Operator’s Manual for
required service. 1. Replace CEM spark plugs.
4. Inspect and check fan belt tension. If neces- 2. Check Engine Operator's Manual for
sary, adjust the tension to 160 lbs while cold. required service.
6.6 MAINTENANCE EVERY 250 6.10 MAINTENANCE AFTER 5000

HOURS HOURS OF OPERATION
1. Change the engine oil, engine filter, and fuel 1. Replace the CEM DPF element.
system filters. Refer to the Engine Operator’s
2. Check Engine Operator's Manual for
Manual for requirements and other mainte- required service.
nance items.
6.7 MAINTENANCE EVERY 300 6.11 PARTS REPLACEMENT AND

HOURS ADJUSTMENT
PROCEDURES
When using other approved oil types listed in Table
4-4, change the fluid and filter at the interval 6.11.1 COMPRESSOR FLUID CHANGE
described in that section per oil type. Refer to Main PROCEDURE
Fluid Filter Servicing on page 69. Perform the Warm-up the compressor for 5 to 10 minutes to warm
following after every 300 hours of operation: the fluid. Shut the compressor off and relieve all
1. Clean the return line orifice and strainer. internal pressure before proceeding. Drain the fluid
by opening the valve that is bulkhead mounted to the
2. Inspect and check fan belt tension. If neces- frame (see ID drawings under Section 2.15 and
sary, adjust the tension to 160 lbs while cold. Section 2.16 for location of drain port). Change the
compressor fluid and replace the fluid filter element.
3. Clean the radiator, oil cooler and aftercooler
For element replacement see procedure for servicing
exterior. Depending on how contaminated
the fluid filter in this section. Fill the receiver tank with
the atmosphere may be, more frequent
fluid according toSection 6.11.2: Main Fluid Filter
cooler and radiator cleaning may be neces-
Servicing.
sary in dusty conditions. service.
4. Check the battery level and fill with water if 6.11.2 MAIN FLUID FILTER SERVICING
necessary. Refer to Figure 6-1. The main fluid filter is located
5. Check Engine Operator's Manual for schematically in the coolant line between the
required service. receiver tank and the compressor unit. The main filter
element is replaceable. For installation of the filter
6.8 MAINTENANCE EVERY 1500 element, follow the procedure explained below.
HOURS 1. The compressor MUST be shut off and sys-
tem pressure MUST be relieved.
1. When using Sullair AWF, change the com-
pressor fluid and replace the fluid filter ele- 2. Drain by removing drain plug at bottom of
ment. bowl and catching drainage in a container.
69
3. Rotate bowl counterclockwise and remove. 2. Unlatch and remove the service cover. Make
certain the latches are folded back.
4. Remove element and O-ring from housing
and discard. This element is NOT cleanable. 3. Remove the primary filter from the housing.
5. Make sure mounting surface of filter head is 4. Clean the interior of the housing by using a
clean. damp cloth. DO NOT blow out dirt with com-
pressed air as this may introduce dust down-
6. Apply a light film of compressor oil to O-ring stream of the filter.
and place it in its proper position.
7. Place new, clean element in bowl, over center- SECONDARY ELEMENT REMOVAL
perforated tub. 8. Inspect bowl seal and The secondary element serves as a safety element.
replace if necessary. The secondary element must be replaced after every
third primary element change.
8. Replace bowl. Rotate clockwise and hand-
tighten. 1. Gently pull the element off the outlet tube
and out of the housing.
9. Replace drain plug. Torque to 15 to 20 ft-lbs.
(20 to 27 N·m). 2. Carefully wipe the inside of the outlet tube
with a clean cloth.
Figure 6-2: Air Filter Assembly
Figure 6-1: Main Fluid Filter Assembly 1. ACCESS COVER 4. SECONDARY ELEMENT**
2. VACUATOR™ VALVE 5. AIR CLEANER HOUSING
1. FLUID FILTER BYPASS 4. ELEMENT
3. Primary Filter Element *
2. FILTER HEAD 5. BOWL
3. BOWL SEAL (O-RING) 6. FLUID STOP VALVE
* Primary replacement element, P/N 02250155-691 (qty 2)
** Secondary replacement element, P/N 02250155-692 (qty 2)
6.11.3 AIR FILTER MAINTENANCE
Refer to Figure 6-2. Maintenance should be 6.11.4 CONTROL SYSTEM ADJUSTMENT
performed when indicated on the instrument panel Refer to Figure 6-3 and Figure 6-4. Prior to adjusting
located by the engine air filter restriction gauges. the control system, it is necessary to determine the
Both air filters are two- stage with a primary element desired operating pressure range as well as the
and secondary element each. maximum pressure at which the machine is to
PRIMARY ELEMENT REMOVAL operate. This pressure must is stamped on the
machine serial number plate. The following
1. Clean the exterior of the air filter housing.
explanation applies to a typical dual pressure
machine with a desired operating range of 100 to 150
70
psig (6.9 to 10.3 bar). This information will apply to a speed should be 1800 RPM on the instru-
machine with any other operating range except for ment panel. If not, repeat step, but adjust the
the stated operating pressure. unload service pressure up or down as
needed until 100 psig (6.9 bar) is maintained
For single pressure machines, there is only one when engine speed is 1800 rpm.
regulator to set and the “HI/LO” switch is omitted. 3. For 150 psig (10.3 bar), turn the “HI/LO”
Follow the procedure for setting up the low pressure switch to "HI" position. Close the service
regulator. valve and set the HI pressure control regula-
tor to maintain 155 to 165 psig (10.7 to 11.4
1. Start the machine and let it warm-up and bar) discharge pressure. Open the service
enter full “RUN” mode. valve to maintain 150 psig (10.3 bar) and
check for 1800 RPM full-load speed. If lower
2. Open service valve slightly until engine tries speed is observed, raise the setting of the
to speed up. Slowly close the service valve. low pressure control regulator until rated
With service valve closed, check and adjust speed is achieved.
the pressure at the reducing regulator to a
minimum of 70 psig (4.8 bar) and not to 4. For 200 psig(13.8 bar) “H” machines, with
exceed 75 psig (5.2 bar). With service valve the service valve closed, the high pressure
still closed, and the "HI/LO" switch in the regulator should be set to maintain 215 to
"LO" position, adjust the low-pressure back- 225 psig (97.5 to 102.1 bar). Open the ser-
pressure regulator so the service pressure is vice valve to maintain 200 psig (13.8 bar)
between 115 to 125 psig (7.9 to 8.6 bar) with and check for 1800 RPM full-load speed. If
the engine at 1400 rpm. Open the service lower speed is observed, raise the setting of
valve to load the compressor to maintain 100 the low pressure control regulator until rated
psig (6.9 bar) discharge pressure. Operating speed is achieved.
Figure 6-3: Control System Assembly

1. COMPRESSOR UNIT 6. REDUCING PRESSURE REGULATOR
2. AIR INLET VALVE 7. RUN/START SOLENOID
3. C PRO ENCLOSURE 8. HI/LOW SOLENOID
4. HIGH PRESSURE REGULATOR 9. BLOW DOWN VALVE
5. LOW PRESSURE REGULATOR 10. RECIRCULATION VALVE
71
Figure 6-4: Pneumatic Control System
1. LOW PRESSURE REGULATOR 5. START/RUN SOLENOID VALVE

2. HIGH PRESSURE REGULATOR 6. HIGH/LOW SOLENOID VALVE
3. REDUCING REGULATOR 7. P2 CONTROL PRESSURE TRANSDUCER
4. CONTROL AIR PRESSURE GAUGE
72
AUXILIARY SIGNAL AIR ALTERNATIVELY…

The adjustment for the Auxiliary Signal air is as
1. Use the auxiliary safety relief valve as an
follows: indicator for control air pressure. This
method relies on a properly functioning relief
valve. It is set to activate at 100 psi (6.9 bar).
2. Start up the compressor (if it not running
already) and wait for it to go through the
warm up cycle.
3. On the auxiliary regulator, loosen jam nut on
set screw and increase regulator pressure
slowly until the relief valve activates.
4. Slowly decrease regulator pressure until
relief valve closes.
5. Then rotate set screw additional ½ turn and
lock jam nut. The system should be set at 80
to 90 psi (5.5 to 6.2 bar).
6.11.5 SEPARATOR ELEMENT REPLACEMENT
Refer to Figure 6-6. When the need for a separator
element replacement is indicated by the Compass
Controller, use the following procedure for separator
replacement.
Figure 6-5: Auxiliary Air Tank
1. Remove the air receiver tank lid by removing
1. AUXILIARY AIR - REDUCING REGULATOR the hex head capscrews and washers.
2. RELIEF VALVE
3. AIR SUPPLY PORTS
CAUTION
1. With the compressor off and system air To assist with the removal of the tank lid,
pressure bled down, remove the auxiliary Sullair has provided a jack bolt at the bot-
safety relief valve. Refer to Figure 6-5. tom of the lid pivot shaft. Simply jack the lid
2. In its place install a tee and necessary fitting up until it will clear the dowel pin located on
to install a 0 to 200 psi (0 to 10 bar) gauge the top tank flange underneath the lid.
and the auxiliary safety relief valve. Rotate out of the way.
3. Start up the compressor and wait for it to go
through the warm up cycle 2. Remove the elements from the separator
4. On the auxiliary regulator, loosen the jam nut chamber by gently rocking back and forth
on the adjustment set screw. and pulling upward and discarding.
5. Adjust the auxiliary reducing regulator to 3. Before installing the new separator ele-
produce 80 to 90 psi (5.5 to 6.2 bar). ments, make sure to lubricate the sealing O-
6. Tighten jam nut on set screw. ring on each element with a lubricating com-
7. Shut down the compressor and wait for the pound (i.e. Silglyde). Then install the new
system pressure to bleed down. separator elements by firmly pressing down-
ward until the element is fully seated on the
8. Remove the pressure gauge, tee, additional baffle plate inside the tank.
fittings and safety relief valve.
9. Re-install the safety relief valve to its original 4. Next, inspect the tank flange O-ring and
configuration within the system before the replace if necessary. Before installing the lid,
adjustment procedure. re lubricate the O-ring (i.e. Silglyde). Rein-
stall the tank lid. Install the capscrews and
washers finger tight, then gradually tighten in
73
a crisscross pattern in 4 to 5 steps. Always 6.11.6 RUNNING GEAR—BRAKE SHOE

tighten the capscrews alternately at opposite MAINTENANCE AND ADJUSTMENT
sides of the cover. Torque lubricated cap-
screws to 322 ft-lbs. (440 N·m).
5. Clean or replace fluid return line strainer. WARNING
6. Clean the fluid return line orifice installed in
the side of the compressor unit air end. Before proceeding...
Park or locate the compressor on flat stable
ground. Block or chock both sides of all
wheels. Use proper personal protection
equipment when performing these tasks
described below.
The highway tow-able running gear utilizes a

electronically actuated braking system. The brakes in
this system require periodic maintenance. The brakes
should be adjusted (1) after the first 200 miles of
operation when the brake shoes and drums have
"seated," (2) at 3,000 mile intervals, (3) or as use
and performance requires.
1. Elevate on side of the axle being worked on
off the ground and remove the tire and brake
drum. (If the shoe linings wore into the brake
drum, the brake adjusters may have to be
backed-off to remove the drum. The access
port is located on the backside of the drum
assembly and will be covered with a rubber
plug. If a brake adjuster tool is not available,
a flat screwdriver may be substituted.
2. Clean the brake assembly and drum.
3. Inspect the shoe linings and drum. If there is
noticeable wear, cracks, or grooves that are
present, replacement is required. If the shoe
linings are oil soaked they must be replaced
with new.
4. Make sure the brake adjuster rotates freely
and functions properly within the brake
assembly. Make sure springs, hold-downs,
cables and actuators are functional. If any of
these components look damaged or are
excessively worn, replacement is required.
5. As a general rule, if any component of the
brake system is questionable, replace the
Figure 6-6: Separator Element Assembly item with new.
6. Once the brake assembly passes inspection
1. GROUNDING PLATE 6. CAPSCREW it can be re-assembled. The drum and lin-
2. DAVIT ASSY. SUPPORT. 7. SPRING LOCK ings must be cleaned of all oils, lubricants
WASHER and dirt. Use brake cleaner or equivalent to
clean. Do not touch linings or drum once
3. SEPARATOR ELEMENTS (6) 8. WASHER
cleaned.
4. RECEIVER TANK 9. LOCK WASHER
7. Lightly lubricate anchor plate shoe contact
5. HEX NUT 10. O-RING surfaces with suitable brake lube.
74
8. If assembly utilizes a manual actuated cable, 6.11.8 BRAKE LUBRICATION

make sure the cable is still attached in its Before reassembling, apply a light film of grease or
proper location. anti-seize compound on the brake anchor pin, the
9. Replace the drum and tire. actuation arm bushing and pin, and the areas on the
backing plate that are in contact with the brake shoes
10. Remove the rubber plug to access the
and magnet lever arm. Apply a light film of grease on
adjuster. Rotate the adjuster out until the
point the tire cannot be rotated. From this the actuating block mounted on the actuation arm.
point the shoes have to be centered within
the brake assembly. Note the amount of ten-
sion required to turn the adjuster. Further
lengthen the adjuster out until a noticeable
CAUTION
increase in effort is felt. The lining should
now be centered within the assembly. The Do not get grease or oil on the brake linings,
adjuster can be backed off until the tire drums or magnets.
rotates by hand again. A very slight amount
of drum to lining drag is acceptable. Replace
the adjuster access port plug.
11. Lower the compressor and re-torque the lug CAUTION
nuts.
POTENTIAL ASBESTOS DUST HAZARD!
12. Complete the rest of the running gear in the Some older brake linings may contain asbestos
same manner. dust, which has been linked to serious or fatal ill-
6.11.7 BRAKE CLEANING AND INSPECTION nesses. Certain precautions need to be taken
when servicing brakes:
Your brake system must be inspected and serviced 1. Avoid creating or breathing dust.
immediately if a loss of performance is indicated.
2. Avoid machining, filing or grinding the brake
With normal use, servicing at one year intervals is linings.
usually adequate. With increased usage,
3. Do not use compressed air or dry brushing
maintenance should be performed more frequently for cleaning (dust can be removed with a
as required. Magnets and shoes must be changed damp brush).
when they become excessively worn or scored, a
condition which can reduce vehicle braking.
6.11.9 RUNNING GEAR LUBRICATION
Clean the backing plate, magnet arm, magnet, and Refer to Figure 6-7. An inspection of the running gear
brake shoes. Make certain that all the parts removed should be made on a routine basis. On four-wheel
are replaced in the same brake and drum assembly. steerable running gear models, front-axle pivot joints
Inspect for any loose or worn parts, stretched or and rod ends are fitted with grease zerks which
deformed springs and replace as necessary. should be lubricated every six months.
75
Figure 6-7: Running Gear Lubrication
6.11.10 BEARING LUBRICATION - GREASE Grease should be replaced every 12,000 miles or 12
months. Prior to repacking bearings, all old grease
should be removed from the wheel hub cavity and
bearings. Bearings should be packed by a packing
CAUTION machine, if possible. If a packing machine is
unavailable, packing by the hand method is
Do not mix Lithium, calcium, sodium or barium acceptable. The method to pack bearing cones is as
complex greases due to possible compatibility
follows:
problems. When changing from one type of
grease to another, it is necessary to ensure all 1. Place a quantity of grease onto the palm of
the old grease has been removed. your hand.
2. Press a section of the widest end of the
Determine if your axle bearings are filled with grease bearing into the outer edge of the grease pile
or oil. Axle bearings filled with grease will have a closest to the thumb forcing grease into the
black plastic dust cover. Axle bearings filled with oil interior of the bearing between two adjacent
will have a clear transparent dust cover with a rubber rollers.
plug at the end. 3. Repeat this while rotating the bearing from
roller to roller.
4. Continue this process until you have the
entire bearing completely filled with grease.
76
5. Before reinstalling, apply a light coat of

grease onto the bearing cup mating surface.
Figure 6-8: Packing a bearing

Table 6-1: Recommended Wheel Bearing
Lubrication Specifications - Grease *
Thickener Type Lithium Complex
Dropping Point 215°C (419°F) Minimum

Consistency NLGI No.2
EP, Corrosion & Oxidation
Additives Inhibitors
Viscosity 80 Minimum
Approved Grease Sources
ConocoPhilips/76 Multiplex RED #2, L427 Super
Lubricants/Kendall Blu Grease
Lithoplex MP #2, Lithoplex CM
Citgo #2, Mystik JT-6 Hi-Temp Grease
#2
Exxon/Mobile Ronex, MP, Mobilith AW 2,
Company Mobil 1 Synthetic Grease
Oil Center Research of
Oklahoma Liquid-O-Ring No. 167L
Pennzoil-Quaker State
Synthetic Red Grease
Company
Gadus S3 V220C, Gadus S5
Shell V220, Rotella Heavy Duty
Lithium Complex #2
Royal 98 Lithium Complex EP
Royal Mfg. Company #2
Chevron Ulti-Plex Grease EP
Chevron Texaco #2, Texaco Starplex Moly
MPGM #2
Valvoline Multi-Purpose GM,
Valvoline
Valvoline Durablend
Great Plains
Lubricants Lithium Complex EP #2
Chem Arrow Arrow 2282 *Source Material: Dexter Axle Company. http://l.b5z.net/
i/u/6149609/f/Instruction_Sheets/059-831-00A.pdf
77
6.11.11WHEEL BEARING LUBRICATION - OIL the proper functioning and reliability of your portable
Determine if your axle bearings are filled with grease compressor axle. The wheel bearings are lubricated
or oil. Axle bearings filled with grease will have a through the use of a oil-bath. See Table 6-1 for
black plastic dust cover. Axle bearings filled with oil company approved oil sources. Oil level should be
will have a clear transparent dust cover with a rubber checked every month. The oil can be filled through
plug at the end. the rubber plugged hole in the clear end cap. Oil
should be replaced every year or 12,000 miles,
Refer to Figure 6-9. Proper lubrication is essential to whichever comes first
Table 6-2: Recommended Oil Lubrication Specifications*

Use: Axle hubs with tapered roller bearings
Service Designation: API-GL-5
Viscosity: SAE 80W-90
Pour Point: -180°C (0°F) Maximum
Additives: Corrosion and oxidation inhibitors, foam inhibitors, EP
additives
Compatibility: Must be compatible with nitrile and neoprene seals and
polycarbonate plastic oil caps
Approved Sources:
Company Product Description
Ashland Oil Valvoline Dura Blend
Ashland Oil Valvoline Power Lube
CITGO Petroleum Company CITGO Premium Gear Oil MP
CITGO Petroleum Company Mystik JT-7
CITGO Petroleum Company Mystik Power Lube
Exxon Company USA Gear Oil GX 80W-90
Kendall Refining Company Kendall NS-MP Hypoid Gear Lube
Lubriplate Division / Fiske Brothers Refining Lubriplate APG 90
Mobile Oil Corporation Mobilube SHC
Mobile Oil Corporation Mobil 1 Synthetic Gear Lube
Phillips 66 Petroleum Superior Multi-Purpose Gear Lube
Phillips 66 Petroleum Philguard Gear Oil
Phillips 66 Petroleum Philsyn Gear Oil
Pennzoil Products Company Gear Plus 80W-90 GL-5
Pennzoil Products Company Gear Plus Super 75W-90
Pennzoil Products Company Gear Plus Super EW 80W-90
Pennzoil Products Company Multi-Purpose 4092 Gear Lube
Oil Center Research Liquid-O-Ring 750 GX
Sun Refining and Marketing Company Sonoco Ultra
Sun Refining and Marketing Company Sonoco Dura Gear
Shell Oil Company Spirax A
Shell Oil Company Spirax G
Shell Oil Company Spirax HD
Shell Oil Company Spirax S
Texaco Oil Company Multigear EP
Texaco Oil Company Multigear SS
Troco Division / Royal Manufacturing Multigear Select Gear Oil
Union Oil Company Unocal MP Gear Lube
Union Oil Company 76 Triton Syn Lube EP
*Source Material: http://dexteraxle.com/i/u/6149609/f/9-15K_Catalog_5-12/Oil_Specification_5-12.pdf
78
1. DUST COVER
2. INNER LOCK NUT
3. WASHER
*4. RUBBER PLUG - OIL FILL
POINT(oil filled hubs only)
5. OUTER LOCK NUT
6. TANG WASHER
7. OUTER BEARING
8. HUB ASSEMBLY
9. INNER BEARING
Figure 6-9: Wheel Bearing Assembly
6.11.12 AXLE BEARING ADJUSTMENT

The correct end-play adjustment for the bearings is 4. Finger tighten the inner lock nut and snug.
0.001” to 0.010”. Refer to Figure 6-9. 5. Back out the inner lock nut 1/4 to 3/8 of a
1. Remove the dust cover on the hub assembly. turn.
Disengage the tang washer holding the outer 6. Install the tang washer and outer lock nut.
locking nut. Then remove the nut and tang Bend two tangs over the inner lock nut.
washer. Torque the outer lock nut to 150 ft-lbs., insur-
2. Rotate the hub assembly slowly while tight- ing the inner lock nut does not turn. Bend
ening the inner locknut to 100 ft-lb. to seat two tangs over the flats on the outer lock nut
the bearings. to secure.
3. Loosen the inner lock nut to remove the pre- 7. Install the dust cover and refill the hub
load torque. DO NOT ROTATE THE HUB! assembly with new oil.
79
6.12 TROUBLESHOOTING GUIDE

Table 6-3 is based on both the data obtained from • Check for loose wiring.
actual tests conducted at our factory and real applied • Check for damaged piping.
situations. It contains symptoms and usual causes
• Check for parts damaged by heat or an
for the described problems. However, DO NOT
electrical short circuit - usually apparent by
assume that these are the only problems that may
discoloration or a burnt odor. Should your
occur. All available data concerning the trouble
problem persist after making the recom-
should be systematically analyzed before
mended check, consult your nearest Sullair
undertaking any repairs or component replacement
representative or the Sullair.
procedures.
Table 6-3: Troubleshooting Guide

SYMPTOM PROBABLE CAUSE REMEDY
Compressor will not start No fuel Check fuel level and add fuel if necessary.
Plugged fuel filter Replace the fuel filter element.
Battery Check electrolyte level and add distilled water and
recharge if necessary.
Loose battery cables; tighten cables.
Dirty battery cables; clean thoroughly.
Plugged air filter Replace the air filter element.
Engine problems may have developed Refer to Engine Operator’s Manual
Instrument panel problems may have Refer to Controller Manual. Sullair Part No.
developed 02250201-742.
Compressor shuts down No fuel Check fuel gauge and add fuel if necessary.
with air demand present Compressor discharge temperature Cooling air flow is insufficient; clean cooler and
switch is open check for proper ventilation.
Low fluid sump level; add fluid.
Dirty compressor fluid filter; change element.
Thermostatic element is not functioning properly;
change the thermostatic element.
Defective discharge temperature switch; check for
a short or open circuit to the engine fuel solenoid.
Should this checkout normal, it could be possible
that the temperature switch itself is defective.
Instrument panel problems may have Refer to Controller Manual. Sullair Part No.
developed 02250201-742.
Aftertreatment soot load >100%. Force a regeneration cycle to reduce soot loading.
If problem persists, contact your local CAT dealer.
Compressor will not build Air demand is too great Check service lines for leaks of open valves.
up full discharge pressure Dirty air filter Check the filter gauges on instrument panel and
change element if required.
Pressure regulator out of adjustment Adjust regulator according to control adjustment
instructions in the Maintenance section.
Defective pressure regulator Check diaphragm and replace if necessary (kit
available).
Defective air inlet cylinder Replace cylinder
Aftertreatment soot load >100%. Force a regeneration cycle to reduce soot loading.
If problem persists, contact your local CAT dealer.
80

Improper unloading with Fluid charge lost from spring chamber Add fluid to inlet valve spring chamber by
an excessive pressure on inlet valve pressure regulating valve removing plugs in the top of the spring chamber
build-up causing pressure is set too high and filing with compressor fluid.
relief valve to open Some fluid may leak from the control regulator at
first but will stop leaking when fluid level in the
spring chamber equalizes.
Running blowdown valve pressure Readjust.
regulating valve set too high
Leak in control system causing loss of Check control lines.
pressure signal Worn seals in inlet valve. Replace seals (kit
available).
Defective pressure regulating valves; repair valves
(kits available).
Inlet valve jammed Free or replace valve.
Restriction in the control system Check all control lines and components.
Ice and other contaminants could cause
restrictions.
Defective pressure relief valve Replace pressure relief valve.
Insufficient air delivery Plugged air filter Replace.
Plugged air/fluid separator Replace separator element and also change
compressor fluid and fluid filter at this time.
Defective pressure regulator Adjust or repair.
Engine speed too low Readjust engine speed.
Control air cylinder defective Replace cylinder.
Excessive compressor Clogged return line Clear orifice.
fluid consumption Leak in the lubrication system Check all pipes, connections and components
Separator element damaged or not Change separator element.
functioning properly
Defective minimum pressure/check Repair or replace.
valve
Fluid receiver tank overfilled Drain to proper level.
Compressor overheating Loose or broken fan belt Tighten or change belt
Dirty fluid cooler core Clean core thoroughly.
Dirty aftercooler Clean core thoroughly.
Dirty radiator core Clean core thoroughly.
Faulty thermostat element Change thermostat element.
Plugged fluid cooler tube (internal) Clean tube thoroughly.
Low receiver tank fluid level Refill.
Plugged compressor fluid filter Change element.
81

Engine overheating Loose or broken fan belt Tighten or change belt.
Dirty radiator core Clean thoroughly.
Dirty oil cooler Clean thoroughly.
Low water level Refill.
Dirty aftercooler Clean thoroughly.
Low fluid level Refill.
Faulty water pump Change pump.
Plugged radiator Clean and flush thoroughly.
Defective engine thermostat Replace engine thermostat.
Shutdown panel lights Faulty switch indicated by light Replace the switch.
Check engine light Engine safety switch (low coolant) fault Replace the switch (Caterpillar part).
Engine warning flashing Count number of flashes. This will flash Determine trouble code and call Caterpillar
light trouble code. Service Representative to correct problem.
Regeneration will not Regeneration Switch in the inhibit Force regeneration, or restart the unit.
automatically engage. position.
Unit derated on its own Soot load >100% Force regeneration, or restart the unit.
Inspect spark plugs.
Inspect CEM ARD ignitor temperature sensor.
Compressor shuts down Compressor discharge temperature Insufficient cooling airflow due to low hydraulic
with air demand present switch is open fluid level; add fluid and check for leaks
Compressor overheating Low cooling airflow due to low hydraulic Add fluid and check for leaks
fluid level
Low cooling airflow due to incorrectly Verify controller is loaded with correct machine
programmed machine. configuration file.
(located on the engine air-intake) when it receives a

NOTE test signal from the Air-Stop control panel.Locate the
Air Stop control panel which is mounted along the
Additional troubleshooting tips are available fuel tank on the curbside of the machine. Push the
in the Controller Manual. Sullair part no. test switch to ‘ON’. Start the compressor if it is not
02250201-742 running already. Make sure the compressor is set to
run on low pressure. Open the service valve slowly to
create demand and raise the rpm of the engine to
6.13 AIR-STOP FUNCTION TEST high idle. Just before 1800 rpm the Air Shut Off
solenoid will pull the valve closed, and the engine will
This test should be performed bi-annually, every shut-down. After completing the functionality test,
1000 hours of run time, or per local requirements. make sure the test switch on the Air-Stop control
The test checks the function of the Air-Stop valve panel is moved to the ‘OFF’ position.
82
Section 7
NOISE CONTROL
7.1 NOISE EMISSIONS control prior to its sale or delivery to the ulti-
WARRANTY mate purchaser or while it is in use.
2. The use of the compressor after such device
Sullair warrants to the ultimate purchaser and each
or element of design has been removed or
subsequent purchaser that this air compressor was
rendered inoperative by any person.
designed, built and equipped to conform at the time
of sale to the first retail purchaser, with all applicable Among those acts included in the prohibition against
U.S. E.P.A. and/or any Federal, State or Local noise tampering are the acts listed below:
control regulations.
1. Removal or rendering inoperative any of the
This warranty is not limited to any particular part, following:
component, or system of the air compressor. Defects
a. Engine exhaust system or parts thereof
in the design, assembly, or in any part, component,
or system of the compressor which, at the time of b. Compressor air intake system or part thereof
sale to the first retail purchaser, caused noise
c. Enclosure of part thereof
emissions to exceed Federal standards are covered
by this warranty for the life of the air compressor. 2. Removal of any of the following:
a. Vibration isolators
7.2 TAMPERING WITH THE
NOISE CONTROL SYSTEM IS b. Control silencer
PROHIBITED c. Floor panel
Federal Law prohibits the following acts or the d. Fan shroud
causing thereof:
e. Acoustical materials including fiberglass
1. The removal or rendering inoperative by any foam or foam tape
persons, other than for purposes of mainte-
3. Operation with canopy doors open for any
nance, repair, or replacement, of any device
purpose other than starting, stopping, adjust-
or element of design incorporated into any
ment, repair, replacement of parts or mainte-
new compressor for the purpose of noise
nance.
83
7.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

The following instructions and maintenance record log book, for the proper maintenance, use and repair of this
compressor, is intended to prevent noise emission degradation.
NOISE EMISSION MAINTENANCE AND MAINTENANCE RECORD LOG
1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION
At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints
and connections are tight, and that the muffler is in good condition. DO NOT operate compressor with defective exhaust
system. Remove and replace any defective parts by ordering with part numbers indicated in the Parts List.
Maintenance Performed
By
Location
Date
By
Location
Date
2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION

In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet
system should be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections
are tight, that there are no other leaks in the system, and that the filter element(s) are intact. DO NOT operate compressor
with defective air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts
List.
By
Location
Date
By
Location
Date
84
3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact.
DO NOT operate compressor with defective engine mounting system. Remove and replace defective parts by ordering
with part numbers indicated in Parts List.
By
Location
Date
By
Location
Date
4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION

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

At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material
missing or damaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate compressor with defective
acoustical material. Remove and replace defective parts by ordering with part numbers indicated in the Parts List.
By
Location
Date
By
Location
Date
85
6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.

In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to make sure
all systems are operating properly and that engine runs at rated speed and pressure. DO NOT operate malfunctioning or
improperly adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required.
By
Location
Date
By
Location
Date
86
NOTES
WWW.SULLAIR.COM
SULLAIR
3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451
Printed in the U.S.A.

Specifications subject to change
without prior notice.
E12EP

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USER MANUAL

PORTABLE AIR COMPRESSOR

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

Recommended Oil Lubrication Specifications provided by © 2012 Dexter Axle Company.

SECTION 7—NOISE CONTROL

1.1 GENERAL 1.2 TOWING *

chain fall if you cannot lift or raise the drawbar

the engine shut off. When necessary, make

should be washed with large quantities of clean

1.8 ELECTRICAL SHOCK I. Keep lift operator in constant attendance when-

1.14 SYMBOLS AND REFERENCES

DIESEL FUEL HEARING PROTECTION

DRAIN SAFETY GLASSES

ENGINE DO NOT BREATHE

DO NOT ELECTRICAL SHOCK

DANGEROUS OUTLET ENGINE START

BELOW TEMPERATURE BELT GUARD

DO NOT TOW SERVICE POINT

BATTERY DISCONNECT STD AIR

OFF A/C AIR

RADIATOR HOUR METER

AIR-CIRCULATING COMPRESSOR AIR

INLET VALVE SPRING

DO NOT OPERATE WATER DRAIN

PRESSURIZED SPRING SEVER (FAN)

DO NOT MIX FLUIDS

Figure 2-1: .Main Component Locations

19. DISCHARGE AIR

2.3 SULLAIR COMPRESSOR and thermal valve.

Figure 2-2: Cooling and Lubrication System

1. COMPRESSOR FLUID FILTER 4. COOLER

2.5 COMPRESSOR DISCHARGE The receiver tank is code rated. A minimum

1. RECEIVER TANK 5. DISCHARGE FILTER

2.6 CONTROL SYSTEM, HIGH PRESSURE MODE—

2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Figure 2-4: Controller Instrument Panel

Lamp Indicators Switches/Gauges/Features

Refer to Table 2-1 below for possible performance of

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-1: Diagnostic Codes

Table 2-2: Event Codes

Table 2-2: Event Codes

2.10 PARTS OF THE EVENT CODE

perform maintenance on the involved system at the 2.11 ELECTRICAL SYSTEM,

2.12 MAIN WIRING DIAGRAM

2.12 MAIN WIRING DIAGRAM

2.13 CONTROLLER WIRING DIAGRAM

2.13 CONTROLLER WIRING DIAGRAM

02250200-843 r02 right

2.14 P & I COMPRESSOR SYSTEM

2.14 P & I—ENGINE SYSTEM

NOTES: A18: 2” NPT AIR DISCHARGE

1: DIMENSIONS ARE IN INCHES