ENTIRE INSTRUCTION MANUAL. TOWING GENERAL REPARING TO Sullair designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who WARNING use and maintain these products. The following...
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SECTION 1 engage coupling device or otherwise couple the compressor to the towing vehicle. CAUTION WARNING Retract the front screw jack only after attaching the compressor to the tow vehi- This equipment may be tongue heavy. DO cle. Raise the screw jack to its full up posi- NOT attempt to raise or lower the drawbar tion and pull the pin connecting the jack to by hand if the weight is more than you can...
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SECTION 1 L. Make sure all access doors and tool box covers E. Avoid potholes, rocks and other obstructions, are closed and latched. If the compressor is and soft shoulders or unstable terrain. large enough to hold a man, make sure all per- F.
SECTION 1 chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others. WARNING K. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barri- cades and/or flares (if at night) if compressor is This equipment may be tongue heavy.
SECTION 1 FIRE AND EXPLOSION H. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. WARNING Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or Do not attempt to operate the compressor other component, such as filters and line oilers,...
SECTION 1 H. Keep grounded and/or conductive objects such temperatures above 150 °F (66 °C). Vapors from as tools away from exposed live electrical parts the antifreeze compound are heavier than air. DO NOT store compound or discharge treated such as terminals to avoid arcing which might serve as a source of ignition.
SECTION 1 the engine shut off. When necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut off. If nec- T4 - WARNING essary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment.
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SECTION 1 should be washed with large quantities of clean DANGER water for fifteen minutes. A physician, preferably an eye specialist, should be contacted immedi- ately. INHALATION HAZARD! K. DO NOT store ether cylinders or air line anti-icer Death or serious injury can result from system antifreeze compound in operator’s cabs inhaling compressed air without using or in other similar confined areas.
SECTION 1 ELECTRICAL SHOCK Keep lift operator in constant attendance when- ever compressor is suspended. A. Keep the towing vehicle or equipment carrier, J. Set compressor down only on a level surface capa- compressor hoses, tools and all personnel at ble of supporting at least its net weight plus an least 10 feet (3 m) from power lines and buried additional 10% allowance for the weight of water,...
SECTION 1 G. Cover open cells of all compressor batteries with tery in the starting vehicle. When jump starting clean dampened cloths before attempting to 24V compressors and if the starting vehicle is provided with two (2) 12V batteries connected in jump start.
SECTION 1 and actions and shall be initiated only by Autho- 1. The lock shall removed “Authorized” person who put the lock on the rized Persons and done in the following sequence: energy-isolating device. No one other than 1. Review the equipment or machine to be the person/persons placing padlocks and locked and tagged out.
SECTION 1 1.14 SYMBOLS AND REFERENCES The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols. DIESEL FUEL HEARING PROTECTION ROTARY COMPRESSOR HARD HAT TEST RUN DRAIN SAFETY GLASSES HIGH PRESSURE HEARING PROTECTION SHUT-OFF VALVE...
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SECTION 1 ENGINE START DANGEROUS OUTLET ENGINE ECM REMOTELY CONTROLLED READ/WRITE DATA CORROSIVE INTAKE AIR EXHAUST GAS WARNING FAN GUARD DO NOT MAINTENANCE BELT GUARD BELOW TEMPERATURE DO NOT TOW SERVICE POINT BAR/PSI LOW TEMPERATURE BATTERY STD AIR BATTERY DISCONNECT A/C AIR 24 HOURS RESET...
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SECTION 1 RADIATOR HOUR METER COMPRESSOR AIR AIR-CIRCULATING PRESSURE START AIR-COOLED OIL COOLER CONTROL LIQUID-COOLED OIL COOLER ENGINE PREHEAT LOW TEMP AID LUBRICATION ENGINE WARNING TRAILER TOWING MODE FUEL LEVEL AXEL ENGINE RPM LUBRICANT GREASE ENGINE OIL EXAMINE, CHECK PRESSURE ENGINE COOLANT TEMPERATURE CRUSH/PINCH POINT...
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SECTION 1 DO NOT OPERATE WATER DRAIN WHILE STACKED PRESSURIZED SPRING SEVER (FAN) DO NOT MIX FLUIDS DEF FLUID ONLY AUTO START/STOP SAFETY SYMBOLS 4 FLUID DRAIN...
EPA or CE, and/or only minimal maintenance. any Federal, State, or local noise requirement. The Sullair compressor unit is driven by an industrial The compressor is equipped with a Sullair rotary engine designed to provide enough horsepower at screw compressor unit.
Fluid is used in the system as a coolant and a With a Sullair compressor, there is no lubricant. The fluid is housed in the receiver tank. maintenance or inspection of the internal...
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1600C LP USER MANUAL SECTION 2 Figure 2-2: Cooling and Lubrication System 1. Compressor Fluid Filter 4. Cooler 2. Thermal Valve 5. Receiver Tank 3. Fluid Stop Valve NOTE Arrows indicate direction of fluid flow within the Cooling and Lubrication System.
SECTION 2 1600C LP USER MANUAL CAPACITY CONTROL SYSTEM, bar) reducing regulator opens up the inlet valve and FUNCTIONAL DESCRIPTION the Compass Controller increases the engine speed to full load (1800 rpm). As the demand for air Refer to Figure 2-3 and Figure 2-4. The purpose of decreases, the Compass Controller commands the the control system is to regulate the amount of air engine to reduce speed to idle (1400 rpm) and the...
SECTION 2 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION WARNING Refer to Figure 2-4. The Sullair compressor unit discharges compressed air/fluid mixture into the DO NOT remove caps, plugs, and/or other receiver tank. components when compressor is running The receiver tank has three functions: or pressurized.
SECTION 2 1600C LP USER MANUAL Figure 2-5: Aftercooled Air Systems 1. Receiver Tank 5. Discharge Filters 2. Minimum Pressure Check Valve 6. Standard Air Out 3. Aftercooler 7. Aftercooled Air Out 4. Moisture Separator AIR INLET SYSTEM, Referring to the instrument panel, the engine air filter FUNCTIONAL DESCRIPTION restriction gauge or the compressor air filter restriction gauge will indicate when restriction of the...
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SECTION 2 1600C LP USER MANUAL PIPING & INSTRUMENTATION DIAGRAM - COMPRESSOR DESCRIPTION DESCRIPTION FILTER, AIR VALVE, PRESSURE DIFF. BYPASS GAUGE, AIR FILTER RESTRICTION VALVE, CONTROL PRESSURE REGULATOR INLET VALVE COMPRESSOR MANIFOLD, AIR CONTROL VALVE, RELIEF SWITCH, TEMPERATURE DESCRIPTION SENSOR, TEMPERATURE DRY SIDE PRESSURE SENSOR, PRESSURE CONTROL PRESSURE...
SECTION 2 1600C LP USER MANUAL 2.12 ENGINE CONTROL MODULE, and aid in troubleshooting the compressor. FUNCTIONAL DESCRIPTION NOTE Diagnostic Fault Codes are provided to indicate an electrical or electronic problem has been detected by Only Active diagnostic codes can be read in the ECM (Engine Control Module).
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1600C LP USER MANUAL SECTION 2 Table 2-1: Possible Performance of Active Diagnostic Codes Reduced Flash CID-FMI SPN-FMI Engine Engine Description of Code Engine Code Code Code Misfires Power Shutdown Speed Incorrect crank-without-inject inputs 266-02 266-02 Fuel Temperature open/short to +batt 174-03 174-03 Fuel temperature short to ground...
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545-06 (I) The engine will shut down if both speed/timing sensors are lost. (II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down. CID = Component Identifier SPN = Suspect Parameter Number...
APPLICATION GUIDE ® Contact your D-A Lubricant representative for details. Refer to Figure 3-1. Sullair Air Compressors are supplied with Sullair AWF which is heavy duty multi- viscosity, all-weather fluid. Sullair AWF also allows extended change interval. fluids Lubrication Guidelines Table 3-2 on page 43 can be used.
ID, TANDEM AXLE DESCRIPTION DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS. ALL DOORS REQUIRE 5 FOOT [1524]CLEARANCE. REFERENCE: A STANDARD 40’ CONTAINER SIZE IS 88” WIDE X 89” TALL X 234” LONG. REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’ HIGH CUBE CONTAINER.
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ID, 4-WHEEL DESCRIPTION DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS. ALL DOORS REQUIRE 5 FOOT [1524]CLEARANCE. REFERENCE: A STANDARD 40’ CONTAINER SIZE IS 88” WIDE X 89” TALL X 234” LONG. REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’ HIGH CUBE CONTAINER.
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ID, WITHOUT RUNNING GEAR DESCRIPTION DIMENSIONS ARE IN INCHES [] DIMENSIONS ARE IN MILLIMETERS. ALL DOORS REQUIRE 5 FOOT [1524]CLEARANCE. REFERENCE: A STANDARD 40’ CONTAINER SIZE IS 88” WIDE X 89” TALL X 234” LONG. REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’ HIGH CUBE CONTAINER.
GENERAL for service or indicate the beginning of a malfunction. Before starting your Sullair compressor, read this While Sullair has built into this compressor a section thoroughly and familiarize yourself with the comprehensive array of controls and indicators to controls and indicators—their purpose, location and assure you that it is operating properly, you will want use.
1600C LP USER MANUAL SECTION 4 COMPRESSOR START-UP 2. Turn the OFF/ON/START switch to the PROCEDURE “START” position. You do not have to hold the switch in the “START” position. The LCD 1. Turn the ON/OFF/START switch, located on panel will show the following message: the Compass Controller, to the “ON”...
SECTION 4 1600C LP USER MANUAL SHUTDOWN PROCEDURE The controller will continue to monitor the system pressures and will not power down 1. Close the service valve. until all pressures drop below 10 PSI (0.7 bar). This final process may take 3 to 5 min- 2.
Stop compressor and relieve all internal pressure before doing so. The coolant provided with Sullair portable air compressors is ethylene glycol based, 50/50 mixture, colored green, and should never be mixed with a coolant DAILY OPERATION of a different color such as yellow, orange, or pink.
MAIN FLUID FILTER SERVICING on page 60. the instructions that are provided by the OEM of the product. MAINTENANCE EVERY 600 HOURS When not using Sullair AWF, replace the fluid filter element only. MAIN FLUID FILTER SERVICING on page 60.
2. Repack the wheel bearings on wheel- mounted units. 5.10 MAINTENANCE EVERY 1500 HOURS When using Sullair AWF, change the compressor fluid and replace the fluid filter element. Refer to PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES on page 59. 5.11 PARTS REPLACEMENT AND...
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1600C LP USER MANUAL SECTION 5 When grease is pumped into the zerk, it is channeled spindle. Make sure the grease gun nozzle is to the inner bearing and then flows back to the outer fully engaged on the fitting. bearing and eventually back out of the grease cap 3.
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SECTION 5 1600C LP USER MANUAL 6. Make certain that the mounting surfaces and 8. Center the new elements on filter housing filter heads are clean. head and tighten until the filter gasket makes contact with the filter housing. After gasket 7.
1600C LP USER MANUAL SECTION 5 still closed and the “HIGH/LOW” switch in 8. Replace the receiver tank cover. Install the the “LOW” position, adjust the low-pressure twelve (12) 3/4 x 3”in capscrews and lock- washers in finger-tight, then gradually tighten back-pressure regulator so the service pres- sure is between 100 to 150 psig (6.9 bar to in a criss-cross pattern in 4 to 5 steps.
Replace the air filter element. Engine problems may have developed Refer to Engine Operator’s Manual Instrument panel problems may have developed Refer to Compass Controller Manual. Sullair Part No. 02250167-454. No fuel Check fuel gauge and add fuel if necessary.
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1600C LP USER MANUAL SECTION 5 SYMPTOM PROBABLE CAUSE REMEDY Improper unloading Add fluid to inlet valve spring chamber by with an excessive removing plugs in the top of the spring chamber pressure build-up and filing with compressor fluid. Fluid charge lost from spring chamber on inlet causing pressure valve pressure regulating valve is set too high Some fluid may leak from the control regulator at...
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Engine Warning Count number of flashes. This will flash trouble Determine trouble code and call Caterpillar flashing light code. Service Representative to correct problem. NOTE Additional troubleshooting tips are avail- able in the Compass Controller Manual. Sullair Part No. 02250167-454.
2. The use of the compressor after such device Sullair warrants to the ultimate purchaser and each or element of design has been removed or subsequent purchaser that this air compressor was rendered inoperative by any person.
1600C LP USER MANUAL SECTION 6 NOISE EMISSIONS MAINTENANCE & MAINTENANCE RECORD LOG The following instructions and maintenance record log book, for the proper maintenance, use and repair of this compressor, is intended to prevent noise emission degradation. & M OISE MISSION AINTENANCE...
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SECTION 6 1600C LP USER MANUAL 3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. DO NOT operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbers indicated in Parts List.
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1600C LP USER MANUAL SECTION 6 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.
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WWW.SULLAIR.COM SULLAIR 3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A. Telephone: 1-219-879-5451 Printed in the U.S.A. Specifications subject to change without prior notice. E12EP...