Sullair 185cfm Compressor Operator Manual - Sunflower · PDF file©SULLAIR CORPORATION The...

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

misuse of this equipment will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

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

and all subsequent serial numbers.

02250174-684 R01

200803010000

PORTABLE AIR COMPRESSOR125, 130, 49HP AND 185

CATERPILLAR, DEUTZ AND JOHN DEERE

AIR CARE SEMINAR TRAININGSullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,and servicing of Sullair products. Individual seminars on portable compressors and compressor electricalsystems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facilitylocated at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting commonfaults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,contractor maintenance, and service personnel.

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

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or219-879-5451 (ext. 5623)

www.sullair.com

- Or Write -Sullair Corporation

3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1—SAFETY

3 1.1 GENERAL 3 1.2 TOWING 6 1.3 PRESSURE RELEASE 7 1.4 FIRE AND EXPLOSION 8 1.5 MOVING PARTS 9 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 9 1.7 TOXIC AND IRRITATING SUBSTANCES 10 1.8 ELECTRICAL SHOCK 10 1.9 LIFTING 10 1.10 ENTRAPMENT 11 1.11 JUMP STARTING 12 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT 13 1.13 CALIFORNIA

PROPOSITION 65 14 1.14 SYMBOLS AND REFERENCES

SECTION 2—DESCRIPTION 17 2.1 INTRODUCTION 17 2.2 DESCRIPTION OF COMPONENTS 19 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 19 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-

AL DESCRIPTION 20 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 21 2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 24 2.7 PIPING AND INSTRUMENTATION—COMPRESSOR SYSTEM 26 2.8 PIPING AND INSTRUMENTATION—ENGINE SYSTEM 28 2.9 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 29 2.10 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION 31 2.11 WIRING DIAGRAM—CAT & JD 32 2.12 WIRING DIAGRAM—DEUTZ 33 2.13 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION 33 2.14 COMPRESSOR SHUTDOWN & WARNING SYSTEM, FUNCTIONAL DE-

TABLE OF CONTENTS

SCRIPTION

SECTION 3—SPECIFICATIONS 35 3.1 SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR 37 3.2 SPECIFICATIONS – 125, 130 AND 185 DEUTZ 39 3.3 SPECIFICATIONS—125, 130, 49 HP AND 185 JOHN DEERE 40 3.4 LUBRICATION GUIDE – COMPRESSOR 41 3.5 APPLICATION GUIDE 41 3.6 LUBRICATION GUIDE – ENGINE

SECTION 4—GENERAL 43 4.1 GENERAL 43 4.2 PURPOSE OF CONTROLS 44 4.3 INITIAL STARTUP/SHUTDOWN PROCEDURE 44 4.4 RESTART PROCEDURE

SECTION 5—MAINTENANCE 45 5.1 GENERAL 45 5.2 ENGINE COOLANT REQUIREMENT FOR RADIATORS 45 5.3 DAILY MAINTENANCE 45 5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 46 5.5 MAINTENANCE EVERY 50 HOURS 46 5.6 MAINTENANCE EVERY 100 HOURS 46 5.7 MAINTENANCE EVERY 250 HOURS 46 5.8 MAINTENANCE EVERY 1500 HOURS 46 5.9 PART REPLACEMENT AND ADJUSTMENT PROCEDURES 52 5.10 TROUBLESHOOTING

SECTION 6—NOISE CONTROL 55 6.1 NOISE EMISSIONS WARRANTY 55 6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED 56 6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD

LOG

Section 1

3

SAFETY

1.1 GENERALSullair Corporation designs and manufactures all ofits products so they can be operated safely.However, the responsibility for safe operation restswith those who use and maintain these products. Thefollowing safety precautions are offered as a guidewhich, if conscientiously followed, will minimize thepossibility of accidents throughout the useful life ofthis equipment. Read the CIMA Safety Manualprior to compressor operation and towing, ifapplicable in your area.

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

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

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

DO NOT modify the compressor except with writtenfactory approval.

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

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

1.2 TOWING PREPARING TO TOW

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

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

(I)

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

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

SECTION 1

4

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

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

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

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

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

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

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

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

WARNINGThis equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.

Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands.


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

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

SECTION 1

5

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

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

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

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

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

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

O. Test running brake operation, including break-away switch operation if provided, beforeattempting to tow the compressor at its ratedspeed or less when conditions prevail.

P. DO NOT carry loose or inappropriate tools,equipment or supplies on or in the compressor.

Q. DO NOT load this equipment with accessories ortools such that it is unbalanced from side to sideor front to back. Such unbalance will reduce thetowability of this equipment and may increasethe possibility of tipping, rolling over, jackknifing,etc. Loss of control of the towing vehicle mayresult.

TOWING A. Observe all Federal, State, and Local laws while

towing this equipment (including those specifyingminimum speed).

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

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

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

2. All other models: 55 MPH (88 km/h).C. Remember that the portable air compressor may

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

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

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

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

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

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

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

PARKING OR LOCATING COMPRESSOR

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

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

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

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

SECTION 1

6

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

F. Block or chock both sides of all wheels.

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

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

I. If a caster wheel is provided on the screw jack, itis part of the screw jack and cannot be removed.Follow the same procedure for stowing away the

wheeled jack as you would for the standardscrew jack. Raise the screw jack to its full uprightposition and pull the pin connecting the jack tothe drawbar. Rotate the screw jack to its stowedposition, parallel to the drawbar and reinsert thepin. Make sure the jack is secured in place priorto towing.

J. Disconnect coupling device, keeping hands andfingers clear of all pinch points. If the compressoris provided with a drawbar, DO NOT attempt tolift the drawbar or if hinged, to raise it to theupright position by hand, if the weight is morethan you can safely handle. Use a screwjack orchain fall if you cannot lift or raise the drawbarwithout avoiding injury to yourself or others.

K. When possible, stow hinged drawbar in the verti-cal upright position. Make certain it is securelylatched in the vertical upright position. Keep feetclear of drawbar at all times to avoid crushingaccidents in case it should slip from your handsor otherwise fall to the ground.

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

1.3 PRESSURE RELEASE A. Open the pressure relief valve at least weekly to

make sure it is not blocked, closed, obstructed orotherwise disabled.

B. Install an appropriate flow-limiting valve betweenthe compressor service air outlet and the shutoff(throttle) valve, when an air hose exceeding 1/2"(13 mm) inside diameter is to be connected tothe shutoff (throttle) valve, to reduce pressure incase of hose failure, per OSHA Standard 29 CFR1926.302 (b) (7) or any applicable Federal, Stateand Local codes, standards and regulations.

C. When the hose is to be used to supply a mani-fold, install an additional appropriate flow-limitingvalve between the manifold and each air hose


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

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

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

SECTION 1

7

exceeding 1/2" (13 mm) inside diameter that is tobe connected to the manifold to reduce pressurein case of hose failure.

D. Provide an appropriate flow-limiting valve foreach additional 75 feet (23 m) of hose in runs ofair hose exceeding 1/2" (13 mm) inside diameterto reduce pressure in case of hose failure.

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

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

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

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

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

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

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

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

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

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

O. DO NOT remove radiator filler cap until the cool-ant temperature is below its boiling point. Then

loosen cap slowly to its stop to relieve anyexcess pressure and make sure coolant is notboiling before removing cap completely. Removeradiator filler cap only when cool enough to touchwith a bare hand.

P. The ethyl ether in the replaceable cylinders usedin diesel ether starting aid systems (optional) isunder pressure. DO NOT puncture or incineratethose cylinders. DO NOT attempt to remove thecenter valve core or side pressure relief valvefrom these cylinders regardless of whether theyare full or empty.

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

1.4 FIRE AND EXPLOSION

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

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

C. Shut off air compressor and allow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen adding fuel, or when checking or addingelectrolyte to batteries, or when checking or add-ing fluid, or when checking diesel engine etherstarting aid systems or replacing cylinders, orwhen refilling air line anti-icer systems antifreezecompound.

D. DO NOT permit liquids, including air line anti-icersystem antifreeze compound or fluid film, toaccumulate on bottom covers or on, under oraround acoustical material, or on any external orinternal surfaces of the air compressor. Wipedown using an aqueous industrial cleaner or

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

SECTION 1

8

steam clean as required. If necessary, removeacoustical material, clean all surfaces and thenreplace acoustical material. Any acoustical mate-rial with a protective covering that has been tornor punctured should be replaced immediately toprevent accumulation of liquids or fluid film withinthe material. DO NOT use flammable solventsfor cleaning purposes.

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

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

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

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

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

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

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

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

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

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

O. Ethyl ether used in diesel engine ether startingaid systems is extremely flammable. Change cyl-inders, or maintain or troubleshoot these sys-tems only in well-ventilated areas away fromheat, open flame or sparks. DO NOT install,store or otherwise expose ether cylinders to tem-peratures above 160 °F (71 °C). Remove ethercylinder from the compressor when operating inambient temperatures above 60 °F (16 °C).

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

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

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

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

1.5 MOVING PARTSA. Keep hands, arms and other parts of the body

and also clothing away from belts, pulleys andother moving parts.

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

C. Wear snug-fitting clothing and confine long hairwhen working around this compressor, especially

SECTION 1

9

when exposed to hot or moving parts inside theenclosure.

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

E. Make sure all personnel are out of and clear ofthe compressor prior to attempting to start oroperate it.

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

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

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

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

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant,hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points ofair discharge and away from hot exhaust gases.

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

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

1.7 TOXIC AND IRRITATING SUBSTANCES

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

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

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

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

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

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

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

DANGER

INHALATION HAZARD!

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

SECTION 1

10

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

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

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

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

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

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

1.8 ELECTRICAL SHOCKA. Keep the towing vehicle or equipment carrier,

compressor hoses, tools and all personnel atleast 10 feet (3 m) from power lines and buriedcables.

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

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

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

1.9 LIFTINGA. If the compressor is provided with a lifting bail,

then lift by the bail provided. If no bail is provided,then lift by sling. Compressors to be air lifted byhelicopter must not be supported by the liftingbail, but by slings instead. In any event, lift only infull compliance with OSHA Standards 29 CFR1910 subpart N or any other Local, State, Militaryand Federal regulations that may apply.

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

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

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

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

F. DO NOT attempt to lift in high winds.

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

H. Lift compressor no higher than necessary.

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

J. Set compressor down only on a level surfacecapable of supporting at least its net weight plusan additional 10% allowance for the weight ofsnow, ice, mud or stored tools and equipment.

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

1.10 ENTRAPMENTA. Make sure all personnel are out of compressor

before closing and latching enclosure doors.

B. If the compressor is large enough to hold a manand if it is necessary to enter it to perform service

SECTION 1

11

adjustments, inform other personnel beforedoing so, or else secure the access door in theopen position to avoid the possibility of othersclosing and possibly latching the door with per-sonnel inside.

1.11 JUMP STARTINGA. Observe all safety precautions mentioned else-

where in this manual.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

P. Connect the other end of the same jumper cableto the positive (POS) (+) terminal of the startermotor battery in the compressor, or when jumpstarting 24V compressor, to the positive (POS)(+) terminal of the ungrounded battery in thecompressor.

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

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

S. Connect the other end of this same jumper cableto a clean portion of the compressor engineblock away from fuel lines, the crank casebreather opening and the battery.

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

U. Allow the compressor to warm up. When thecompressor is warm and operating smoothly at

SECTION 1

12

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

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

1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT

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

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

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

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

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

4. Turn off the equipment using normalshutdown procedure.

5. Disconnect the energy sources:a. Air and hydraulic lines should be bled,

drained and cleaned out. There shouldbe no pressure in these lines or in the

reservoir tanks. Lockout or tag lines orvalves.

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

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

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

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

7. Tagout devices shall be used only whenpower sources are not capable of beinglocked out by use of padlocks and lockouthasp devices. Name of person affixing tag topower source must be on tag along with datetag was placed on power source.

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

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

B. General Security

1. The lock shall be removed by the“Authorized” person who put the lock on theenergy-isolating device. No one other thanthe person/persons placing padlock adlockout hasp on power shall remove padlockand lockout hasps and restore power.However, when the authorized person whoapplied the lock is unavailable to remove ithis/her Supervisor may remove padlock/padlocks and lockout hasps and restorepower only if it is first:a. verified that no person will be exposed to

danger.

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

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

SECTION 1

13

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

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

1.13 CALIFORNIA PROPOSITION 65

WARNINGCALIFORNIA PROPOSITION 65 WARNING

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

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

SECTION 1

14

1.14 SYMBOLS AND REFERENCES

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

Safety Symbols-1

SECTION 1

15

Safety Symbols-2

SECTION 1

16

Safety Symbols-3

Section 2

17

125, 130, 49HP AND 185 USER MANUAL

DESCRIPTION2.1 INTRODUCTION The Sullair 125, 130, 49HP, and 185 CFM StandardPortable Air Compressors offer superiorperformance, reliability and require a minimal amountof maintenance. Compared to other compressors,Sullair’s are unique in terms of reliability anddurability. Compressor internal components requireno routine maintenance inspections.

2.2 DESCRIPTION OF COMPONENTS

Figure 2-1 shows the main components andsubassemblies of the Sullair 125, 130, 49HP, and185 Standard Portable Air Compressors. Thesepackages include a heavy duty rotary screw aircompressor, a diesel engine, fuel tank, compressorinlet system, compressor cooling and lubricationsystem, compressor discharge system, capacitycontrol system, instrument panel and electricalsystem. A low profile canopy offers improvedhandling and mobility. A clamshell canopy provideseasy access to all serviceable components.

125, 130, 49HP AND 185 USER MANUAL SECTION 2

18

1. Minimum Pressure/Check Valve

2. Radiator/Fluid Cooler Assembly

3. Pressure Regulator & Blowdown Manifold

4. Service Valves

5. Fuel Tank

6. Engine Air Filter

7. Thermal Valve/Compressor Fluid Filter

8. Compressor Air Filter

9. Battery

10. Compressor Unit

11. Fluid Fill

12. Fluid Level Sight Glass

13. Receiver Tank

Figure 2-1: Sullair Rotary Screw Portable Air Compressor

SECTION 2 125, 130, 49HP AND 185 USER MANUAL

19

The control system can easily be adjusted forpressures from 80 to 125 psig (5.6 to 8.6 bar). Thecompressor unit is driven by an industrial dieselengine designed to provide enough horsepower toprovide an adequate reserve under rated conditions.

Refer to the Engine Operator’s Manual for a moredetailed description of the engine. The enginecooling system is comprised of a radiator, highcapacity fan, and thermostat. The high capacity fanpushes air through the radiator to maintain theengine’s specified operating temperature. The samefan also cools the fluid in the compressor cooling andlubrication system.

The engine radiator and the compressor fluid coolerare next to each other allowing the fan air to pushthrough both simultaneously. As air passes throughthe fluid cooler, the heat of compression is removedfrom the fluid.

2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

Sullair compressors are single-stage, positivedisplacement, flood lubricated-type compressors thatprovide continuous (pulse-free) compression to meetvarious demand loads. Sullair compressors requireno routine maintenance or inspection of their internalparts or systems. The compressor works by injectingfluid into the compressor unit where it mixes directlywith the air as the rotors turn. The fluid flow has threemain functions:

1. It acts as a coolant, to control the rise of airtemperature which is generated by compres-sion (heat of compression).

2. Seals the leakage paths between the rotorsand the stator and also between the rotorsthemselves.

3. Lubricates the rotors allowing one rotor todirectly drive the other.

After the air/fluid mixture is discharged from thecompressor unit, the fluid is separated from the air.At this time, the air flows to the service line and thefluid is cooled in preparation for re-injection.

2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-2. The compressor cooling andlubrication system is designed to provide adequatelubrication as well as maintain the proper operatingtemperature of the compressor. In addition to thefluid cooler and interconnecting piping, the systemconsists also of three other components: a fluid filter,thermal valve, and a fan which perform the followingfunctions:

• The fluid filter removes and collects any contami-nants in the fluid.

• The thermal valve functions as a temperature regu-lator directing fluid either to the cooler or to thecompressor unit.

• The fan pushes air through the cooler dissipatingthe heat resulting from compression of the fluid.

The functions of the lubrication system are explainedin more detail below. Fluid is used in the system as acoolant and as a lubricant: the sump serves as thefluid reservoir. At start-up, fluid flows from the sumpto the fluid thermal valve. Fluid circulation is achievedby forcing the fluid from the high pressure region ofthe sump to a lower pressure area in the compressorunit. A minimum pressure device (See CompressorDischarge System, Functional Description on page20) is provided to assure adequate fluid flow underall conditions. When entering the thermal valve uponstart-up, the fluid temperature is cool and thus it isnot necessary to route it through the cooler. The fluidflows through the fluid filter and on to the compressorunit bypassing the cooler. As the compressorcontinues to operate, the temperature of the fluidrises and the thermostatic control opens, allowing aportion of the fluid into the cooler.

When the temperature reaches 170°F (77°C), thethermostat is fully open allowing all fluid entering thethermal valve to flow to the cooler.

The cooler is a radiator type that works in concertwith the engine fan. The fan pushes air through thecooler removing the heat from the fluid. From thecooler, the fluid is then routed back through the fluidfilter. All fluid flowing to the compressor unit passesthrough this filter. The fluid leaving the filter flows tothe compressor unit where it lubricates, seals andcools the compression chamber; and lubricates thebearings and gears.


20

2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-2. The Sullair compressor unitdischarges a compressed air/fluid mixture into thereceiver tank. The receiver tank has three functions:

1. It acts as a primary fluid separator.

2. Serves as the compressor fluid reservoir.

3. Houses the air/fluid separator.

The compressed air/fluid mixture enters the receivertank and is directed against the side of the sump.Because of a change of direction and reduction ofvelocity, large droplets of fluid separate and fall to thebottom of the sump. The small amount of fluidremaining in the compressed air collects on thesurface of the separator element as the compressedair flows through the separator. As more fluid collects

on the element surface, it then flows to the bottom ofthe separator. A return line (or scavenge tube) leadsfrom the bottom of the separator element to the inletregion of the compressor unit. Fluid collecting on thebottom of the separator element is returned to thecompressor by the pressure difference between thearea surrounding the separator element and thecompressor inlet. An orifice (protected by a strainer)is included in this return line to assure proper andunobstructed flow. The receiver tank is code rated at200 psig (13.8 bar) working pressure. A minimumpressure device located downstream from theseparator, ensures a minimum receiver pressure of80 psig (5.5 bar) during all conditions. Keeping thispressure level stable is necessary for proper air/fluidseparation and proper fluid circulation. A pressurerelief valve (located on the wet side of the separator)is set to open if the sump pressure exceeds 200 psig(13.8 bar).

1. Fluid Cooler

2. Compressor

3. Thermal Valve

4. Fluid Filter

5. Receiver/Tank

Figure 2-2: Compressor Cooling and Lubrication System


21

2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-3 or Figure 2-4. The purpose of thecontrol system is to regulate the amount of air intakeand match it to the demand (required output) on thecompressor. The control system consists of apressure regulating valve(s), air inlet valve, systemblowdown valve, engine speed control, and tubingconnecting the various components of thecompressor and engine. The functional descriptionsof the control system are described by relating them

to four distinct phases of operation. They apply toany control system with the exception of those withspecified pressures which are dependent onpressure requirements. The given values apply to acompressor with an operating pressure range of 100to 110 psig (6.9 to 7.6 bar).

START – 0 TO 40 PSIG (0 TO 2.8 BAR)When the compressor is started, the sump pressurequickly rises from 0 to 40 psig (0 to 2.8 bar). Duringthis period the pressure regulator valve is inactive. Atthis pressure range the idle warm-up control keepsthe inlet valve closed for engine idle operation. Within30 seconds of starting the compressor (theinstrument panel annunciator light goes off after 30seconds) turn the handle of the warm-up selectorvalve (located on the instrument panel) from theSTART to the RUN position. The inlet valve is fullyopen due to inlet pressure, and the compressoroperates at full capacity. When the compressoroperates at full capacity, the engine runs at fullspeed.

WARNINGDO NOT remove caps, plugs and/or other components when the compressor is run-ning or pressurized. Stop the compressor and relieve all internal pressure before removing these items.

1. Receiver/Tank2. Minimum Pressure/Check Valve3. Internal Air/Oil Separator Element

4. Compressor Unit5. Service Air Outlets

Figure 2-3: Compressor Discharge System


22

5

43

11

1

2

8

6

7

9

10

SA_0000023

14

13

16

17

18

15

12

1. Air Pressure Gauge 2. Idle Warm-Up Valve 3. Inlet Valve 4. Orifice 5. Regulator/Blowdown Valve Manifold6. Strainer 7. Minimum Pressure/Check Valve 8. Fluid Fill/Fluid Level Sight Glass 9. Thermal Valve

10. Fluid Filter11. Compressor Unit 12. Air Filter13. Fluid Cooler 14. Engine Speed Control Cylinder15. Instrument Panel16. Air 17. Fluid/Air 18. Fluid

Figure 2-4: Control System with Piping and Instrumentation

BLANK PAGE

23


24

2.7 PIPING AND INSTRUMENTATION—COMPRESSOR SYSTEM


25

1. Filter, Air

2. Gauge, Filter Restriction (Optional)

3. Inlet Valve

4. Compressor

5. Gauge, Temperature

6. Switch, Temperature

8. Valve, Relief

9. Receiver, Air/Oil

10. Glass, Sight Oil Level

12. Valve, Minimum Pressure/Check

13. Valve, Ball

14. Engine Speed Control Cylinder

15. Regulator Blowdown Manifold

17. Orifice

18. Valve, Blowdown N.C.

19. Strainer

21. Valve, Thermal Bypass

22. Cooler, Oil

23. Filter, Oil

27. Gauge, Pressure

28. Valve, Pressure Regulator

29. Valve, 3-Way Selector

31. Valve, Check

T1 Compressor Discharge Temperature Switch


26

2.8 PIPING AND INSTRUMENTATION—ENGINE SYSTEM


27

1. Turbocharger, Compressor

3. Muffler, Engine

4. Fuel Level Sender

5. Rain Cap, Exhaust System

6. Fuel Filter W/ Water Separator

7. Fuel Transfer Pump (Internal To Engine)

8. Hand Operated Fuel Priming Pump

9. Filter, Fuel

10. Gauge, Fuel Level

11. Fuel Tank Cap W/Vent

12. Thermostat, Thermocord (Optional)

14. Oil Pump (Integral To Engine)

15. By-Pass Valve (Internal To Engine)

16. Cooler, Oil (Internal To Engine)

17. Filter, Oil

18. Water Pump (Integral To Engine)

19. Radiator, Engine

20. Engine Thermostat (Integral To Engine)

25. Sensor, Coolant Temperature

26. Sensor, Engine Oil Pressure

29. Jacket Water Heater (Optional)

30. Oil Level (Dipstick)

31. Filter, Air

32. Tank, Fuel

33. Engine Oil Pan

34. Gauge, Filter Restriction

L1 Coolant Level

L2 Fuel Level

L3 Oil Level (Dipstick)

P7 Oil Pressure

T9 Coolant Temperature


28

NORMAL OPERATION – 80 TO 100 PSIG (5.6 TO 6.9 BAR) When the warm-up control selector valve handle ismoved to the RUN position, the sump pressure risesabove 80 psig (5.6 bar). At this time, the inlet valveremains fully open for maximum air output. Theengine will continue to run at full speed during thisphase of operation.

MODULATION – 100 TO 110 PSIG (6.9 TO 7.5 BAR) If the demand on the compressor is less than itsrated capacity, the service line pressure will riseabove 100 psig (6.9 bar). The pressure regulatingvalve gradually opens, applying pressure to the inletvalve piston and engine speed control. This causesthe inlet valve to partially close and reduces theengine speed. As the pressure increases, the inletvalve piston will further close the inlet valve and theengine speed will decrease until it reaches its presetidle speed. When the demand on the compressorincreases, the sump pressure falls below 110 psig(7.6 bar). The pressure regulating valve closes, theair inlet valve opens fully, and the engine speedincreases to its preset full load rating.

Between the pressure regulating valve and the inletvalve, there is a small orifice that vents a smallamount of air into the atmosphere when the pressureregulating valve is open. This allows changes in airoutput to conform to air demand. This orifice alsodischarges any accumulated moisture from theregulator.

SHUTDOWN The blowdown valve is normally closed. At shutdownthe back pressure in the compressor inlet signals theblowdown valve to vent the sump pressure into theatmosphere.

2.9 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

The air inlet system consists of two air filters, acompressor air inlet valve and interconnecting pipingto the engine and the compressor.

The air filters are two-stage dry element type filtersthat are capable of cleaning extremely dirty air.However, when operating in dirty environments, thefilters should be checked more frequently.

See Air Filter Maintenance on page 47 for Air FilterMaintenance Procedures.


29

2.10 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Refer to Figure 2-5 for the locations of the followingindicators and controls:

1. The air pressure gauge continuously moni-tors the sump pressure under various loadconditions.

2. The engine switch energizes the system andstarts the compressor. The engine switch ispressed to the ON position to energize theelectrical system, and pressed momentarilyto the START position to engage the starterand start the compressor.

3. The idle warm-up control is turned fromSTART to RUN after sufficient warm-up isachieved for full compressor operation.

4. The shutdown indicator light indicates engineand compressor safety shutdown status.

5. The Hourmeter indicates the accumulatedhours of operation.

6. The cold weather starting aid glow plugsshould be used for starting in cold weather.Press the button and hold for 10-30 seconds(depending upon ambient temperature).Release the button prior to starting.

7. The optional Engine Voltage Gauge monitorsthe voltage level of the engine storage bat-tery.

8. The optional Engine Oil Pressure Gaugemonitors the pressure of the lubricating oil inthe engine.

9. The optional Engine Coolant TemperatureGauge monitors the temperature ofthe engine coolant in the engine.

10. The optional Tachometer monitors the oper-ating speed of the engine.

11. The optional fuel level gauge indicates thefluid level in the fuel tank.

12. The optional Compressor Discharge Tem-perature Gauge monitors the temperature ofthe air/oil mixture in the sump.

WARNINGDO NOT use aerosol types of starting aids such as ether.Such use could result in an explosion and personal injury.If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again.


30

1. System air pressure2. Start stop switch3. Warm-up control4. Shutdown indicator5. Hourmeter6. Cold weather starting. (Glow plugs)

7. Engine voltage (optional)8. Engine oil pressure (optional)9. Engine coolant temperature (optional)10. Engine RPM (optional)11. Fuel level (optional)12. Compressor discharge temperature

(optional)

Figure 2-5: Instrument Panel Group (Optional Full Gauge Panel Shown)


31

2.11 WIRING DIAGRAM—CAT & JD


32

2.12 WIRING DIAGRAM—DEUTZ


33

2.13 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION

The electrical system consists of the basic electricalelements required to operate the compressor andalso has a system feature that automatically shutsdown the compressor when a malfunction occurs.The system’s components include: an engine starter,battery, alternator/ voltage regulator, and a fuelsolenoid. It also has a compressor dischargetemperature switch that will shut the compressordown if the compressor temperature exceeds 250° F(121° C). It has an engine water temperature switchset to shut down the compressor when the coolanttemperature reaches 225° F (107° C) and an oilpressure switch that will shut down the compressor ifthe engine oil pressure goes too low. An underspeedsensor shuts down the compressor if the enginespeed falls below 1500 rpm.

2.14 COMPRESSOR SHUTDOWN & WARNING SYSTEM, FUNCTIONAL DESCRIPTION

The Shutdown System and Annunciator Module(SSAM) continuously monitors the status of thecompressor. In the event of a shutdown condition,the SSAM will shut down the compressor and display(flashing) the appropriate code on the instrumentpanel annunciator light. The display will continueflashing until the ignition switch is turned OFF. Theshutdown codes are:

• One flash: high compressor discharge temperature• Two flashes: high engine coolant temperature• Three flashes: low engine oil pressure• Four flashes: low engine speed• Five flashes: low fuel level (optional)

The SSAM also provides startup logic for thecompressor. When the ignition switch is in the ONposition, the annunciator light will illuminate for 30seconds. During this 30 second period, pressing theignition switch will engage the engine starter. The lowengine speed switch is inactive during this startuptime interval. By the end of these 30 seconds, theannunciator light goes out and the engine STARTcycle is disabled. At this time the system runs allsafety checks including low fuel level (if installed).

34

BLANK PAGE

Section 3

35


SPECIFICATIONS3.1 SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR

Table 3-1: Overall Specifications—Caterpillar

Model Series Length1 Width Height Weight (wet)in mm in mm in mm lb kg

125, 130 and 185 2-Wheel 130.8 3322 59.2 1504 53.8 1368 2130 966

125, 130 and 185 Less Running Gear 69.1 1765 40.9 1040 41.7 1060 1885 855

1 Length over drawbar for 2 – wheel version

Table 3-2: Compressor Specifications—Caterpillar

Compressor 125 130 185Type Rotary Screw Rotary Screw Rotary ScrewMaximum Operating Pressure 125 psig (8.6 bar) 125 psig (8.6 bar) 125 psig (8.6 bar)

Pressure Delivery 125 Free CFM(59 L/S)

130 Free CFM(61 L/S)


Rated Pressure 100 psig (6.9 bar) 100 psig (6.9 bar) 100 psig (6.9 bar)

Cooling Pressurized Compressor Fluid

Pressurized Compressor Fluid


Lubricating Compressor Fluid See Section 3.4 See Section 3.4 See Section 3.4

Sump Capacity 3 US gallons(11 liters)

3 US gallons(11 liters)


Track Width 50.9” (1294 mm) 50.9” (1294 mm) 50.9” (1294 mm)Tire Size (Load Range) ST175/80D13 ST175/80D13 ST175/80D13Tire Pressure 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)Wheel Size 13 x 4.5 13 x 4.5 13 x 4.5Lug Nut Torque 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm)Operating Tilt (maximum) 15° 15° 15°Electrical System 12 volt 12 volt 12 voltCompressor Discharge Temperature Shutdown 250°F (121°C) 250°F (121°C) 250°F (121°C)

Service Valves (2) 3/4” (2) 3/4” (2) 3/4”Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)Axle Rating 3700 lbs. (1678 kg) 3700 lbs. (1678 kg) 3700 lbs. (1678 kg)Sound Level (US EPA) 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m


36

Table 3-3: Engine Specifcations—Caterpillar

Engine 125 130 185Type Diesel Diesel DieselMake Caterpillar Caterpillar CaterpillarModel C2.2 C2.2 C2.2

Emission Level U.S. EPA Tier 3European Stage IIIA

U.S. EPA Tier 3European Stage IIIA

U.S. EPA Tier 3European Stage IIIA

Displacement 134 cu-in (2.2 L) 134 cu-in (2.2 L) 134 cu-in (2.2 L)Cylinders 4 4 4

Bore x Stroke 3.30 x 3.90 in(84.0 x 100.0 mm)

3.30 x 3.90 in(84.0 x 100.0 mm)

3.30 x 3.90 in(84.0 x 100.0 mm)

Rated Speed 2550 RPM 2650 RPM 2800 RPMRated Power 60 HP (44.8 kW) 60 HP (44.8 kW) 60 HP (44.8 kW)

Type of Motor Oil See Engine Operator Manual

See Engine Operator Manual


Fuel Tank Capacity 20 Gallons (76 liters) 20 Gallons (76 liters) 20 Gallons (76 liters)Radiator Capacity 2.5 US Gallons (9.5 liters) 2.5 US Gallons (9.5 liters) 2.5 US Gallons (9.5 liters)Engine Water Temperature Shutdown 225°F (107°C) Shutdown 225°F (107°C) Shutdown 225°F (107°C)

Minimum Idle Speed 2550 RPM1 2650 RPM1 2200 RPM1

Alternator Rating 65 amp 65 amp 65 amp1 DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.


37

3.2 SPECIFICATIONS – 125, 130 AND 185 DEUTZ

Table 3-4: Overall Specifications—Deutz


125, 130 and 185 2-Wheel 130.8 3322 59.2 1504 53.8 1368 2130 966

125, 130 and 185 Less Running Gear 69.1 1765 40.9 1040 41.7 1060 1885 855

1Length over drawbar for 2 – wheel version

Table 3-5: Compressor Specifications—Deutz

Compressor 125 130 185Type Rotary Screw Rotary Screw Rotary ScrewMaximum Operating Pressure 125 psig (8.6 bar) 125 psig (8.6 bar) 125 psig (8.6 bar)




Rated Pressure 100 psig (6.9 bar) 100 psig (6.9 bar) 100 psig (6.9 bar)




Lubricating Compressor Fluid See Section 3.4 See Section 3.4 See Section 3.4




Track Width 50.9” (1294 mm) 50.9” (1294 mm) 50.9” (1294 mm)Tire Size (Load Range) ST175/80D13 ST175/80D13 ST175/80D13Tire Pressure 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)Wheel Size 13 x 4.5 13 x 4.5 13 x 4.5Lug Nut Torque 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm)Operating Tilt (maximum) 15° 15° 15°Electrical System 12 volt 12 volt 12 voltCompressor Discharge Temperature Shutdown 250°F (121°C) 250°F (121°C) 250°F (121°C)

Service Valves (2) 3/4” (2) 3/4” (2) 3/4”Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)Axle Rating 3700 lbs. (1678 kg) 3700 lbs. (1678 kg) 3700 lbs. (1678 kg)Sound Level (US EPA) 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m


38

Table 3-6: Engine Specifcations—Deutz

Engine 125 130 185Type Diesel Diesel DieselMake Deutz Deutz DeutzModel TD2009L4 TD2009L4 TD2009L4

Emission Level U.S. EPA Interim Tier 4European Stage IIIA

U.S. EPA Interim Tier 4European Stage IIIA

U.S. EPA Interim Tier 4European Stage IIIA

Displacement 140 cu-in (2.29 L) 140 cu-in (2.29 L) 140 cu-in (2.29 L)Cylinders 4 4 4


3.54 x 3.54 in(90.0 x 90.0 mm)

3.54 x 3.54 in(90.0 x 90.0 mm)

Rated Speed 2550 RPM 2650 RPM 2800 RPMRated Power 67 HP (50.0 kW) 67 HP (50.0 kW) 67 HP (50.0 kW)




Fuel Tank Capacity 20 Gallons (76 liters) 20 Gallons (76 liters) 20 Gallons (76 liters)Radiator Capacity 2.5 US Gallons (9.5 liters) 2.5 US Gallons (9.5 liters) 2.5 US Gallons (9.5 liters)Engine Water Temperature Shutdown 225°F (107°C) 225°F (107°C) 225°F (107°C)

Minimum Idle Speed 2550 RPM1 2650 RPM1 2200 RPM1

Alternator Rating 50 amp 50 amp 50 amp1 DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.


39

3.3 SPECIFICATIONS—125, 130, 49 HP AND 185 JOHN DEERE

Table 3-7: Overall Specifications—John Deere


125, 130, 49HP and 185 2-Wheel 130.8 3322 59.2 1504 53.8 1368 2130 966

125, 130, 49HP and 185 Less Running

Gear69.1 1765 40.9 1040 41.7 1060 1885 855

1 Length over drawbar for 2 – wheel version

Table 3-8: Compressor Specifications—John Deere

Compressor 125 130 49HP 185Type Rotary Screw Rotary Screw Rotary Screw Rotary ScrewMaximum Operating Pressure 125 psig (8.6 bar) 125 psig (8.6 bar) 125 psig (8.6 bar) 125 psig (8.6 bar)



160 Free CFM (75 L/S)


Rated Pressure 100 psig (6.9 bar) 100 psig (6.9 bar) 100 psig (6.9 bar) 100 psig (6.9 bar)





Lubricating Compressor Fluid See Section 3.4 See Section 3.4 See Section 3.4 See Section 3.4





Track Width 50.9” (1294 mm) 50.9” (1294 mm) 50.9” (1294 mm) 50.9” (1294 mm)Tire Size (Load Range) ST175/80D13 ST175/80D13 ST175/80D13 ST175/80D13

Tire Pressure 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar) 50 psig (3.5 bar)Wheel Size 13 x 4.5 13 x 4.5 13 x 4.5 13 x 4.5Lug Nut Torque 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm)Operating Tilt (maximum) 15° 15° 15° 15°

Electrical System 12 volt 12 volt 12 volt 12 voltCompressor Discharge Temperature

Shutdown 250°F (121°C)




Service Valves (2) 3/4” (2) 3/4” (2) 3/4” (2) 3/4”Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph) 55 mph (88 kmph)

Axle Rating 3700 lbs. (1678 kg) 3700 lbs. (1678 kg) 3700 lbs. (1678 kg) 3700 lbs. (1678 kg)Sound Level (US EPA) 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m


40

3.4 LUBRICATION GUIDE – COMPRESSOR

Table 3-9: Engine Specifcations—John Deere

Engine 125 130 49HP 185Type Diesel Diesel Diesel DieselMake John Deere John Deere John Deere John DeereModel 4024TF270 4024TF270 4024TF281 4024TF270

Emission Level U.S. EPS Tier 2European Stage II

U.S. EPS Tier 2European Stage II

U.S. EPA Interim Tier 4 European Stage IIIA

U.S. EPS Tier 2European Stage II

Displacement 149 cu-in (2.44 L) 149 cu-in (2.44 L) 149 cu-in (2.44 L) 149 cu-in (2.44 L)Cylinders 4 4 4 4


3.40 x 4.10 in(86.0 x 104.0 mm)

3.40 x 4.10 in(86.0 x 104.0 mm)

3.40 x 4.10 in(86.0 x 104.0 mm)

Rated Speed 2550 RPM 2650 RPM 2650 RPM 2800 RPMRated Power 60.0 HP (44.8 kW) 60.0 HP (44.8 kW) 49.0 HP (36. kW) 60.0 HP (44.8 kW)





Fuel Tank Capacity 20 Gallons (76 liters)

20 Gallons (76 liters)



Radiator Capacity 2.5 US Gallons (9.5 liters)

2.5 US Gallons (9.5 liters)



Engine Water Temperature Shutdown 225°F (107°C) 225°F (107°C) 225°F (107°C) 225°F (107°C)

Minimum Idle Speed 2000 RPM1 2000 RPM1 2000 RPM1 2000 RPM1

Alternator Rating 70 amp 70 amp 70 amp 70 amp1 DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/or coupling damage will occur. The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm.

FLUID TYPE CHANGE PERIOD/HOURS AMBIENT TEMPERATURE RANGE °F (°C)

Sullair AWF (I) 1500 -20 to 120 (-29 to 49)SAE 10W SE, SF, SG, CD 250 0 to 100 (-18 to 38)

MIL-L-2104E 10W 250 0 to 100 (-18 to 38)(l) Sullair part numbers for Sullair AWF are 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon drum/280 liters)


41

3.5 APPLICATION GUIDESullair air compressors are supplied with Sullair AWFwhich is a heavy duty multi-viscosity, all weather fluidwhich provides an extended change interval whencompared to other fluids. Detergent motor oils (SAE10W Class SE, SF, SG, or CD) can also be used.Any of these oils are suitable under conditions wheresevere oil oxidation can occur.

Water must be drained from the receiver tankperiodically. In high ambient temperature andhumidity conditions, condensed moisture canemulsify with the oil forming a “milky” color. SAE10W is especially prone to this condition. The fluidshould be changed if this condition develops. DONOT mix different fluids. Combinations of differentfluids can lead to operational problems such asfoaming, plugged filters, blocked orifices or lines.

When ambient conditions exceed the recommendedranges, or if other conditions warrant the use of otherextended life lubricants, contact your local Sullairrepresentative for recommendations.

Sullair encourages users to participate in a fluidanalysis program. The analysis might indicate a needfor change intervals different from thoserecommended in this manual. Sullair Corporationoffers a fluid analysis for Sullair AWF. Contact Sullairfor details.

D-A Lubricant® Company Inc. offers an analysis forusers of Sullair AWF. Contact your Sullairrepresentative for details.

3.6 LUBRICATION GUIDE – ENGINE

Refer to the Engine Operator’s Manual for oilspecifications.

1. Receiver/Tank2. Sight Glass3. Fluid Fill Port

Figure 3-1: Receiver Tank

NOTEProper compressor fluid level visible half-way in fluid sight glass when checked on a level surface with the compressor not running.

42

BLANK PAGE

Section 4

43


GENERAL4.1 GENERALWhile Sullair has built into this compressor acomplete set of controls and indicators that allow theoperator to control and monitor the compressor’soperation and performance. Operators should learnto recognize indications which identify a servicerequirement or conditions that could lead to (or show)a (current) malfunction. Before starting thecompressor, read this section thoroughly to gainfamiliarity with the controls and indicators – theirfunction and location.

4.2 PURPOSE OF CONTROLSCONTROL OR INDICATOR PURPOSEENGINE SWITCHPress this switch to the ON (ignition) position toenergize the electrical system of the compressor.Press the switch to the START position tomomentarily engage the starter and start thecompressor. Press the switch to the OFF position toshut the compressor down. This switch is located onthe instrument panel.

COLD WEATHER STARTING AID BUTTONPush this button, prior to compressor start-up, toallow the engine to pre-heat for easier starting.

HOURMETERIndicates the accumulated hours of operation. Usefulfor planning and logging service schedules.

AIR PRESSURE GAUGEContinuously monitors the pressure inside thereceiver tank at various load and unload conditions.

FLUID SIGHT LEVEL GLASSIndicates the fluid level in the receiver tank. Properlevel is marked halfway up the sight glass. Check thelevel when the compressor is shutdown and on levelground.

COMPRESSOR DISCHARGE TEMPERATURE SWITCH

Opens the electrical circuit to shut down thecompressor when the discharge temperaturereaches a specific value (See Specifications on page35).

THERMAL VALVEFunctions as a temperature regulator by directing thecompressor fluid either to the cooler or to thecompressor unit.

MINIMUM PRESSURE DEVICEMaintains the minimum of 80 psig (5.6 bar) in thecompressor sump.

PRESSURE RELIEF VALVE Vents sump pressure to the atmosphere if pressureinside the sump exceeds 200 psig (13.8 bar).

AIR INLET VALVERegulates the amount of air allowed to enter the aircompressor inlet. Regulation is determined by asignal from the pressure regulator(s).

PRESSURE REGULATORAllows the pressure signal to reach the engine speedcontrol and the air inlet valve to control air deliveryaccording to demand.

SHUTDOWN SYSTEM/ANNUNCIATOR MODULE (SSAM)

Monitors the compressor safety system forconditions requiring shutdown. The annunciator onthe instrument control will flash the applicableshutdown code.

BLOWDOWN VALVE Vents sump pressure to the atmosphere atshutdown.

IDLE WARM-UP CONTROL Keeps the compressor inlet valve closed for reducedcompressor load at start-up. When the compressor iswarmed-up, the handle is turned from the START tothe RUN position for full operation.


44

4.3 INITIAL STARTUP/SHUTDOWN PROCEDURE

STARTUP

Perform the following actions when starting thecompressor for the first time:

1. Ensure that the compressor is on a level sur-face. (If the compressor is on an uneven sur-face, the fluid sight gauge readings will notbe accurate, and it will not be possible todetermine if fluid levels are too low.)

2. Ensure that a minimum clearance of 3 feet isprovided all the way around the machine toallow exhaust gas to ventilate before operat-ing the machine. Failure to ventilate hotexhaust gas can result in improper function-ing of machine and the heat build-up canresult in melting of rubber and/or plasticcomponents.

3. Check the oil and fluid levels in the engineand compressor: add oil and/or fluid if neces-sary.

4. Fill the fuel tank and drain any water from thefuel/ water separator.

5. Crack open one service line.

6. Place the WARM-UP control in the STARTposition.

7. Press the ENGINE SWITCH to the ON posi-tion.

8. In cold weather, press the cold weather start-ing aid button. Hold button for 10 to 30 sec-onds and then release.

9. Momentarily press the ENGINE SWITCH tothe START position to engage the starter:release the switch when the engine starts.

10. After 30 seconds (the annunciator light willgo off after 30 seconds) Turn the IDLEWARM-UP SWITCH from START to RUN toput the compressor in full operation.

11. Close all doors to maintain proper noiselevel.

SHUTDOWN

1. Close the service valves and run the com-pressor for approximately five minutes toallow the compressor to cool down.

2. Press the ENGINE SWITCH to the OFFposition after five minutes.

4.4 RESTART PROCEDUREAfter running and shutting down the compressor forthe first time, perform the following actions whenrestarting the compressor:

1. Check engine oil, engine coolant, and fuellevels.

2. Check the compressor fluid level (sightglass) and drain any water from the fuel/water separator.

3. Check the dust collectors and clean if neces-sary.

4. Crack open the service valve.

5. Place the WARM-UP control in the STARTposition.

6. Press the ENGINE SWITCH to the ON posi-tion.

7. In cold weather, press the cold weather start-ing aid button. Hold button for 10 to 30 sec-onds and then release.

8. Momentarily press the ENGINE SWITCH tothe START position to engage the starter:release the switch when the engine starts.

9. After 30 seconds (the annunciator light willgo off after 30 seconds) Turn the IDLEWARM-UP SWITCH from START to RUN toput the compressor in full operation.

10. To shut down the compressor, see Shutdownprocedure on previous page.

WARNINGDO NOT us aerosol types of starting aids such as ether.

Such use could result in an explosion and personal injury.

If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again.

Section 5

45


MAINTENANCE

5.1 GENERALConsistent and correctly performed maintenance willensure the compressor’s performance and extend itsoperational life. See Part Replacement AndAdjustment Procedures on page 46 for a detaileddescription of specific compressor components.Before performing maintenance actions, read theCIMA Safety Manual, if applicable. For enginemaintenance requirements and procedures, refer tothe Engine Operator’s Manual.

5.2 ENGINE COOLANT REQUIREMENT FOR RADIATORS

The coolant provided with Sullair portable aircompressors is ethylene glycol based, 50/50 mixture,and should never be mixed with a different coolant type,color or brand. If radiator coolant is to be added, for anyreason, be sure that the coolant added is the same aswhat is in the cooling system, as well as what isrecommended. Refer to the Maintenance Section of theEngine Operator’s Manual for proper engine coolantspecifications and instructions. Ensure that the propercoolant is used when adding engine coolant to themachine. If you are not sure of the coolant that isinstalled originally or want to change to a different type,the cooling system must be cleaned with a commercialcleaning agent and completely flushed and filled withdistilled water several times to remove all traces of oldcoolant. Then, fill the system with the recommendedcoolant using only one brand/type. Cross contaminationwhich is caused by adding different types of enginecoolants may result in the coolant additives to deplete(dropout); thus leaving radiator surfaces unprotected.

Corrosion to radiator surfaces may occur, thus reducingradiator life expectancy. It is extremely important toevacuate/purge all air within the cooling systembefore replacing the radiator cap.

5.3 DAILY MAINTENANCESee Initial Startup Shutdown/Procedure for generaloperation.

5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

After the initial 50 hours of operation, the followingmaintenance actions are required to eliminatecontaminants from the system:

1. Clean the return line orifice and change thestrainer.

2. Change the compressor fluid filter.

WARNINGDO NOT remove caps. Plugs and/or other components when the compressor is run-ning or pressurized. Shutdown the com-pressor before removing any components.

CAUTIONThe radiator and engine cooling system must be drained and flushed periodically. Refer to the OEM Engine Manual for more information. Replace the coolant with a solution of 50% ethylene glycol and 50% water or as required for your geographic location. DO NOT use a leak sealing type of antifreeze. Should a 100% water solution be used, a non-chromate rust inhibitor must be added. DO NOT mix coolant types.

NOTEDispose of fluids in accordance with applicable federal, state and local regula-tions.


46

3. Check the Engine Operator’s Manual for ser-vice requirements.

4. Check the fuel filter for water.

5. Confirm that the receiver tank cover bolts aretightened to 60 lb-ft (81N•m).

5.5 MAINTENANCE EVERY 50 HOURS

1. Inspect air filter elements and replace if nec-essary.

2. Check the fuel filter for water.


1. Clean the radiator and cooler exterior sur-faces.



1. Check fan belt tension.

2. Clean the radiator and cooler exterior sur-faces. (Where dust and other atmosphericcontaminants are present, it might be neces-sary to clean these parts more frequently.)


4. Change the engine oil and filter.

5. Change the compressor fluid if it is not Sul-lair AWF.

6. Clean or replace the return line strainer.

7. Change the air filter primary elements.

8. Change the compressor fluid filter.

9. Clean the return line orifice.

10. Change the fuel filter. (If the filter tends toclog more often than what is expected,change the filter more frequently.)

11. Change the engine fuel/water separator.

12. Check the engine rpm idle speed. The idlespeed should be at the specified minimumidle speed listed in Section 3.


1. If the compressor fluid is Sullair AWF,change the fluid and replace the fluid filterelement. (See Compressor Fluid Filter Ele-ment Replacement on page 47.)

2. Service the engine cooling system.

3. Lubricate axle bearings on wheel-mountedunits.

5.9 PART REPLACEMENT AND ADJUSTMENT PROCEDURES

COMPRESSOR FLUID CHANGE PROCEDURE

1. Run the compressor five to ten minutes towarm the fluid.

2. Shut the compressor down and relieve allinternal pressure.

3. Drain the fluid sump by removing the plug, oropening the valve at the bottom of the sumptank.

4. Change the compressor fluid and replace thefluid filter element (For element replacementsee the filter servicing procedure in this Sec-tion.)

5. Fill the sump with fluid in accordance withthe specifications in Section 3.

NOTEThe fluid change period varies by fluid brand. Refer to Section 3.4.

WARNINGOperating the compressor below its mini-mum specified idle speed will damage the compressor. Operating the compressor in this condition will cause coupling and/or compressor failure.


47

COMPRESSOR FLUID FILTER ELEMENT REPLACEMENT

Refer to Figure 5-1.

1. Remove the old element with a strapwrench.

2. Clean the gasket seating surface.

3. Apply a light coating of fluid to the new gas-ket.

4. Hand tighten the new element until the newgasket is seated.

5. Continue tightening the element by hand anadditional 1⁄2 to 3⁄4 turn.

6. Restart the compressor and check for leaks.

AIR FILTER MAINTENANCE Refer to Figure 5-2. Air filter maintenance should beperformed as often as conditions require. If the filtersare equipped with optional maintenance indicators,change the filters every time the indicators show achange is necessary.

AIR FILTER REPLACEMENT

1. Loosen and remove the air filter and cover.

2. Remove the primary and optional secondaryelements.

3. Clean the body, inside and out, with a dampcloth.

4. Reinstall (if clean) or replace the secondaryelement if installed.

5. Replace the new primary filter element.

1. Compressor Unit2. Thermal Valve Manifold3. Fluid Filter Element

P/N 250028-032

1. Filter Body

2. Filter Cover

3. Primary Element

4. Optional Safety Element

Replacement Primary Element

P/N 02250102-158

Optional Replacement Safety Element

P/N 02250102-160

Figure 5-2: Air Filter


48

6. Reposition the cover and lock it into the posi-tion.

7. Reset the filter restriction indicator (ifequipped).

ELEMENT INSPECTION

1. Insert a bright light source into the elementand look for any light leaks which indicatethe presence of damage (holes, cracks, etc.)

2. Inspect all gaskets and gasket contact sur-faces of the housing and replace any dam-aged ones.

3. Store clean elements for later use in a cleancontainer.

4. After installing the element, inspect andtighten all air inlet connections before operat-ing the compressor.

SEPARATOR ELEMENT REPLACEMENT

Refer to Figure 5-3. When compressor fluidcarryover is evident, after replacing or inspecting thefluid return line strainer and orifice, and theblowdown valve; and all are in satisfactory condition,the separator element must be replaced with Kitnumber 250034-112 (element for air/fluid separator).

1. Disconnect all sump cover piping connec-tions to permit removal (return line, serviceline, etc.).

2. Remove the fluid return line from the fittingon the cover.

3. Remove the eight (8) cover bolts and wash-ers and lift the cover off the sump.

4. Remove the separator element.

5. Scrape the old gasket material from thecover and the flange on the sump. Do notallow the scrapings to fall into the tank.

6. Install the new element.

7. Replace the sump cover and bolts. Lightlytighten all the bolts and then graduallytighten them alternating between bolts which

are diagonally opposite each other. Torquethe bolts to 60 ft-lbs (81 N•m).

8. Reconnect all piping. The fluid return linetube should extend to the bottom of the sep-arator element which will ensure properreturn line flow.

9. Clean the fluid return line strainer and clearthe orifice before starting the compressor.

10. After 24 hours of operation, tighten the sumpcover bolts to the value given in step 7.

1

2

3

4

5

SU_0000670

1. Capscrew2. Washer3. Cover4. Separator Element with Gaskets5. Receiver Tank

Air/Fluid Separator Element

P/N 250034-112

Figure 5-3: Air/Fluid Separator


49

PROCEDURE FOR SETTING SPEED AND PRESSURE CONTROLS ON PORTABLE COMPRESSORS EQUIPPED WITH POPPET VALVES

Refer to Figure 5-4. Before adjusting thecompressor’s control system, the rated full-loadpressure and the high/low rpm settings must bedetermined. This information is provided in Section 3or can be obtained by contacting a Sullairrepresentative.

The following procedure applies to a compressorwith full-load pressure rating of 100 psig (6.9 bar).

1. Start the compressor and allow the engine towarm-up to its normal operating temperaturewith the service valve closed.

2. With the service valve closed, set the enginelow speed (idle) to its specified setting withthe idle stop screw on the engine injectorpump.

1. Receiver Tank2. Compressor Unit3. Engine Speed Control Cylinder4. Pressure Regulator/Blowdown

Manifold5. Warm-up Control Valve6. Air Pressure Gauge

A. .25 OD White

B. .38 OD Blue

C. .25 OD Black

D. .38 OD Green

E. .38 OD Orange

F. .38 Yellow

G. .38 OD Red

H. .31 OD White (To fitting at unit air filter)

Figure 5-4: Control System Adjustment -– Standard Pressure


50

3. Adjust the pressure regulator so that thecompressor maintains 115 psig (8 bar).

4. Gradually open the service valve to atmo-sphere until the engine comes up in speedand sump pressure is held at 100 psig (6.9bar). At this point, set the engine high speedto its specified setting by adjusting the highidle threaded rod located on the enginespeed control. To raise or lower the speed,lengthen or shorten the rod respectively.

5. Open the service valve to 100 psig (6.9 bar)(rated full load pressure) and recheck topengine speed and control response. Closethe service valve and allow the compressorto cycle and re-check low engine speed(idle).

WARNINGOperating the compressor below its mini-mum specified idle speed will damage the compressor. Operating the compressor in this condition will cause coupling and/or compressor failure.


51

BEARING LUBRICATION

Refer to Figure 5-5. Proper lubrication of the portablecompressor’s bearing axle is critical to its properfunction and reduction of wear on this part. Wheelbearings should be lubricated at least every 12months, or more, to ensure proper performance andminimize wear. Use a wheel bearing grease thatconforms to MILSPEC MIL-G-10924 or a hightemperature one such as lithium complex NLGIconsistency #2.

Axles with the E-Z Lube feature can be periodicallylubricated without removing the hubs from the axle.This feature consists of axle spindles that have beenfitted with a grease zerk in their ends. When greaseis pumped into the zerk, it is channeled to the innerbearing and then flows back to the outer bearing, andthen back out of the grease cap hold (see Figure 5-5).

1. Remove the rubber cap from the greasecap’s end.

2. Using a full charged grease gun, place thegun onto the grease zerk located on the endof the spindle. Make sure the nozzle is fullyengaged on the fitting.

3. Pump grease into the zerk. The old greasewill be displaced and flow out of the caparound the grease gun nozzle.

4. When the new grease starts flowing out ofthe cap, disengage the gun and wipe off anyexcess off the cap; and replace the rubberplug.

SU_0000671

1

2

4

5

6

7

3

1. Rubber Plug2. Outer Bearing3. Grease Flow4. Grease Fitting

5. Metal End Cap6. Inner Bearing7. Spring Loaded Double Lip Seal

Figure 5-5: Typical E-Z Lube Axle


52

5.10 TROUBLESHOOTINGThe following Troubleshooting chart is based upondata obtained from factory tests and information fromthe field. It lists symptoms, probable causes andremedies. This chart does not cover all possiblemalfunctions or cases of abnormal operation. Beforeundertaking repairs or replacement actions, analyzeall of the available data.

Performing a detailed visual inspection in all casescan prevent additional damage or abnormaloperation.

Always:

1. Check for loose wiring or connections.

2. Check for damaged piping.

3. Check for heat damage to parts (electricalshort circuits can cause heat damage) whichcan appear as discolorations or the presenceof a burnt odor.

If the troubleshooting remedy does not work, or themalfunction is not covered in this Troubleshootingchart, contact your nearest Sullair representative orSullair for technical assistance.

Table 5-1: Troubleshooting

ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START

SYMPTOM PROBABLE CAUSE REMEDY

NO SSAM FLASH CODE Low voltage or battery disconnected Check battery cables and tighten if loose

Check ground wire for proper attachment to frame. Tighten if required.

Recharge or replace battery if required.

Blown fuse in wiring harness Remove and inspect fuse. Replace if necessary.

Instrument panel connectors loose or disconnected.

Check instrument panel connectors and reattach if required

Check instrument panel wires for broken connections or corrosion. Clean and/or replace if damaged.

Faulty SSAM module Replace the module

SSAM FLASH CODE: ONE FLASH

Compressor temperature switch is open Check wiring connection to the switch and tighten if loose

Check switch continuity to ground and replace if necessary

Low receiver tank fluid level Add fluid to receiver tank as required

Loose or broken fan belt Tighten or replace belt

Cooling air flow is insufficient, dirty fluid cooler core

Clean core thoroughly and check for proper ventilation

Clogged compressor fluid filter Change fluid filter element

Faulty fluid thermostat Change fluid thermostat element

Plugged fluid cooler tube (internal) Replace cooler


53

SSAM FLASH CODE: TWO FLASHES

Engine coolant temperature switch is open Check wiring connection to the switch and tighten if necessary

Check switch continuity to ground and replace if necessary

Cooling air flow is insufficient Clean cooler and check for proper ventilation

Loose or broken fan belt Tighten or replace belt

Low engine coolant Fill with proper water/glycol mixture as required

Faulty water pump Change pump

Defective engine thermostat Change thermostat element

Engine problems might be present Refer to the Engine Operator’s Manual

SSAM FLASH CODE: THREE FLASHES

Engine oil pressure switch is open Check wiring connection to switch and tighten if necessary

Install gauge in parallel with the switch. Replace the switch if the pressure exceeds 15 psig and stays open. If the pressure is less than 15 psig, refer to the Engine Operator’s Manual.

SSAM FLASH CODE:FOUR FLASHES

Did not start compressor within the 30 seconds from turning the ignition switch to the ON position

"After turning the ignition switch to the ON position, press the switch to the START position within 30 seconds"

Low battery voltage Check the battery cables and tighten if necessary

Recharge or replace battery if necessary

No fuel Refuel

Water or dirt in the fuel and/or filter Drain water from the fuel/water separators on the fuel filters. Siphon water from the fuel tank and clean the tank if necessary

Plugged air filter Clean and replace if necessary

Plugged fuel filter Replace the fuel filter

Engine problems Turn the compressor OFF. See the Engine Warning/Shutdown Table for probable causes

Starter solenoid relay does not engage Check wiring and tighten all connectorsReplace relay

No input frequency from alternator Check alternator “W” terminal (7.5 ± 2.50 VAC greater than 300 HZ)

SSAM FLASH CODE: FIVE FLASHES

No fuel Check fuel level and fill tank if empty

Defective fuel switch Replace switch





54

Compressor does not achieve full discharge pressure

Run/start switch not in run position For compressors with idle warm-up controls, switch toggle to RUN for full operation

Air demand is excessive Check service lines for leaks or open valves

Dirty air filter Check the filter and change the element if required

Defective pressure regulator Check the diaphragm and replace with kit if necessary

Defective idle warm-up control Replace control

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

Pressure regulating valve is set too high Readjust

Control system leak causing loss of pressure signal

Check control lines

Defective pressure regulating valve. Repair valve (kit available)

Inlet valve jammed Free or replace valve

Restriction in the control system Check all control lines and components. Ice and/or other contaminants could be the cause

Defective pressure relief valve opens when pressure is too low

Replace the pressure relief valve

Defective pressure regulator Check the diaphragm and replace with kit if necessary

Insufficient air delivery Run/start switch not in run position For compressors with idle warm-up controls, switch toggle to RUN for full operation

Plugged air filter Replace

Defective idle warm-up control Replace control

Plugged air/fluid separator Replace separator element and also change compressor fluid and fluid filter

Defective pressure regulator Adjust or repair

Engine speed too low Readjust engine speed

Excessive compressor fluid consumption

Clogged return line Clear orifice and return line strainer

Lubrication system leak "Check all pipes, connections and components"

Separator element damaged or malfunctioning

Change separator element




Section 6

55


NOISE CONTROL6.1 NOISE EMISSIONS

WARRANTYSullair Corporation warrants to the ultimatepurchaser and each subsequent purchaser that thisair compressor was designed, built and equipped toconform at the time of sale to the first retailpurchaser, with all applicable noise controlregulations.

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

6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED

U.S. Law prohibits the following acts or the causingthereof:

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

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

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

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

1. Removal or rendering inoperative any of thefollowing:

a. Engine exhaust system or parts thereof

b. Compressor air intake system or part thereof

c. Enclosure of part thereof

2. Removal of any of the following:

a. Vibration isolators

b. Control silencer

c. Floor panel

d. Fan shroud

e. Acoustical materials including fiberglassfoam or foam tape

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


56

6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

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

NOISE EMISSION MAINTENANCE AND MAINTENANCE RECORD LOG1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTIONAt 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 INSPECTIONIn 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


57

3. ANNUAL ENGINE VIBRATION MOUNT INSPECTIONAt 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 INSPECTIONAt 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 INSPECTIONAt 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


58

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

59

BLANK PAGE

WORLDWIDE SALES AND SERVICE

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

change without prior notice.E07EP

SULLAIR ASIA, LTD.Sullair Road, No. 1

Chiwan, ShekuoShenzen, Gunagdong PRV.PRC POST CODE 518068Telephone: 755-6851686

Fax: 755-6853473www.sullair-asia.com

Champion Compressors, LTD.Princess Highway

Hallam, Victoria 3803Australia

Telephone: 61-3-9796-4000Fax: 61-3-9703-8053

www.championcompressors.com.au

SULLAIR CORPORATION3700 East Michigan Boulevard

Michigan City, Indiana, 46360 U.S.A.www.sullair.com

Telephone: 1-800-SULLAIR (U.S.A. only)Fax: 219-874-1273

CUSTOMER CAREfor PARTS and Service

1-888-SULLAIR (7855247)219-874-1835

SULLAIR EUROPE, S.A.Zone Des Granges BP 8242602 Montbrison, FranceTelephone: 33-477968470

Fax: 33-477968499www.sullaireurope.com

Sullair 185cfm Compressor Operator Manual - Sunflower · PDF file©SULLAIR CORPORATION The...

Documents

Transcript of Sullair 185cfm Compressor Operator Manual - Sunflower · PDF file©SULLAIR CORPORATION The...