Sullair 125 User Manual
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Sullair 125 User Manual

Portable air compressor
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USER MANUAL
P
A
C
ORTABLE
IR
OMPRESSOR
125, 130, 49HP
185
AND
C
, D
J
D
ATERPILLAR
EUTZ AND
OHN
EERE
PART NUMBER:
02250174-684 R01
KEEP FOR
FUTURE
WARRANTY NOTICE
REFERENCE
SULLAIR CORPORATION
©
Failure to follow the instructions
The information in this manual is current
and procedures in this manual or,
as of its publication date, and applies to
misuse of this equipment will
compressor serial number:
VOID its warranty!
200803010000
and all subsequent serial numbers.

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Summary of Contents for Sullair 125

  • Page 1 USER MANUAL ORTABLE OMPRESSOR 125, 130, 49HP ATERPILLAR EUTZ AND EERE PART NUMBER: 02250174-684 R01 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current and procedures in this manual or,...
  • Page 2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    PROPOSITION 65 1.14 SYMBOLS AND REFERENCES SECTION 2—DESCRIPTION INTRODUCTION DESCRIPTION OF COMPONENTS SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION- AL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION PIPING AND INSTRUMENTATION—COMPRESSOR SYSTEM PIPING AND INSTRUMENTATION—ENGINE SYSTEM AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 2.10...
  • Page 4 TABLE OF CONTENTS SCRIPTION SECTION 3—SPECIFICATIONS SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR SPECIFICATIONS – 125, 130 AND 185 DEUTZ SPECIFICATIONS—125, 130, 49 HP AND 185 JOHN DEERE LUBRICATION GUIDE – COMPRESSOR APPLICATION GUIDE LUBRICATION GUIDE – ENGINE SECTION 4—GENERAL...

  • Page 5: General

    ENTIRE INSTRUCTION MANUAL. GENERAL CAUTION Sullair Corporation designs and manufactures all of Estimated hose life based on a 5-day 8-hour its products so they can be operated safely. work week is 3 years. These conditions However, the responsibility for safe operation rests exist on an 8-hour shift only.
  • Page 6 SECTION 1 A. Prior to hitching the air compressor to the tow G. If provided, make sure chain length, brake and vehicle, inspect all attachment parts and equip- electrical interconnections provide sufficient ment, checking for (i) signs of excessive wear or slack to prevent strain when cornering and corrosion, (ii) parts that are cracked, bent, maneuvering, yet are supported so they cannot...
  • Page 7 SECTION 1 Make sure tires are in good condition and are the according to posted speed limits, weather, traffic, size (load range) specified and are inflated to the road or terrain conditions: specified pressures. DO NOT change the tire 1. Two axle four-wheel or three axle six-wheel size or type.

  • Page 8: Pressure Release

    SECTION 1 E. Set parking brakes and disconnect breakaway wheeled jack as you would for the standard switch cable and all other interconnecting electri- screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to cal and/or brake connections, if provided.

  • Page 9: Fire And Explosion

    SECTION 1 exceeding 1/2" (13 mm) inside diameter that is to loosen cap slowly to its stop to relieve any be connected to the manifold to reduce pressure excess pressure and make sure coolant is not boiling before removing cap completely. Remove in case of hose failure.

  • Page 10: Moving Parts

    SECTION 1 steam clean as required. If necessary, remove N. DO NOT operate compressor under low over- acoustical material, clean all surfaces and then hanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the replace acoustical material. Any acoustical mate- rial with a protective covering that has been torn compressor in forested areas.

  • Page 11: Hot Surfaces, Sharp Edges And Sharp Corners

    SECTION 1 TOXIC AND IRRITATING when exposed to hot or moving parts inside the SUBSTANCES enclosure. D. Keep access doors closed except when making A. DO NOT use air from this compressor for respi- repairs or adjustments, performing service or ration (breathing) except in full compliance with when starting or stopping the compressor.

  • Page 12: Electrical Shock

    SECTION 1 LIFTING is spilled on skin or clothing, immediately flush with large quantities of water. A. If the compressor is provided with a lifting bail, H. Ethyl ether used in diesel engine ether starting then lift by the bail provided. If no bail is provided, aid systems is toxic, harmful or fatal if swallowed.

  • Page 13: Jump Starting

    SECTION 1 adjustments, inform other personnel before K. Place the starting vehicle in neutral or park, turn doing so, or else secure the access door in the off all non-essential accessory electrical loads and start its engine. open position to avoid the possibility of others closing and possibly latching the door with per- L.

  • Page 14: Implementation Of Lockout/Tagout

    SECTION 1 normal idle RPM, disconnect the jumper cable reservoir tanks. Lockout or tag lines or from the engine block in the compressor, then valves. disconnect the other end of this same cable from b. Any mechanism under tension or pres- the grounded negative (NEG) (-) terminal of the sure, such as springs, should be battery in the starting vehicle.

  • Page 15: California

    SECTION 1 1.13 CALIFORNIA d. ensured that the “Authorized” person is PROPOSITION 65 notified of lock removal before returning to work. 2. Tagout System—Tags are warning devices WARNING affixed at points of power disconnect and are not to be removed by anyone other that the person placing tag on power lockout.
  • Page 16 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. Safety Symbols-1...
  • Page 17 SECTION 1 Safety Symbols-2...
  • Page 18 SECTION 1 Safety Symbols-3...

  • Page 19: Introduction

    125, 130, 49HP AND 185 USER MANUAL Section 2 DESCRIPTION INTRODUCTION DESCRIPTION OF COMPONENTS The Sullair 125, 130, 49HP, and 185 CFM Standard Portable Compressors offer superior Figure 2-1 shows the main components and performance, reliability and require a minimal amount subassemblies of the Sullair 125, 130, 49HP, and of maintenance.
  • Page 20 125, 130, 49HP AND 185 USER MANUAL SECTION 2 Minimum Pressure/Check Valve 8. Compressor Air Filter 2. Radiator/Fluid Cooler Assembly 9. Battery 3. Pressure Regulator & Blowdown Manifold 10. Compressor Unit 4. Service Valves 11. Fluid Fill 5. Fuel Tank 12.

  • Page 21: Sullair Compressor Unit, Functional Description

    125, 130, 49HP AND 185 USER MANUAL COMPRESSOR COOLING The control system can easily be adjusted for AND LUBRICATION pressures from 80 to 125 psig (5.6 to 8.6 bar). The SYSTEM, FUNCTIONAL compressor unit is driven by an industrial diesel DESCRIPTION engine designed to provide enough horsepower to provide an adequate reserve under rated conditions.
  • Page 22 125, 130, 49HP AND 185 USER MANUAL SECTION 2 1. Fluid Cooler 4. Fluid Filter 2. Compressor 5. Receiver/Tank 3. Thermal Valve Figure 2-2: Compressor Cooling and Lubrication System COMPRESSOR DISCHARGE on the element surface, it then flows to the bottom of SYSTEM, FUNCTIONAL the separator.

  • Page 23: Capacity Control System, Functional Description

    SECTION 2 125, 130, 49HP AND 185 USER MANUAL to four distinct phases of operation. They apply to any control system with the exception of those with specified pressures which dependent WARNING pressure requirements. The given values apply to a compressor with an operating pressure range of 100 to 110 psig (6.9 to 7.6 bar).
  • Page 24 125, 130, 49HP AND 185 USER MANUAL SECTION 2 SA_0000023 1. Air Pressure Gauge 10. Fluid Filter 2. Idle Warm-Up Valve 11. Compressor Unit 3. Inlet Valve 12. Air Filter 4. Orifice 13. Fluid Cooler 5. Regulator/Blowdown Valve Manifold 14. Engine Speed Control Cylinder 6.
  • Page 25 BLANK PAGE...

  • Page 26: Piping And Instrumentation—Compressor System

    125, 130, 49HP AND 185 USER MANUAL SECTION 2 PIPING AND INSTRUMENTATION—COMPRESSOR SYSTEM...
  • Page 27 SECTION 2 125, 130, 49HP AND 185 USER MANUAL 1. Filter, Air 17. Orifice 2. Gauge, Filter Restriction (Optional) 18. Valve, Blowdown N.C. 3. Inlet Valve 19. Strainer 4. Compressor 21. Valve, Thermal Bypass 5. Gauge, Temperature 22. Cooler, Oil 6.

  • Page 28: Piping And Instrumentation—Engine System

    125, 130, 49HP AND 185 USER MANUAL SECTION 2 PIPING AND INSTRUMENTATION—ENGINE SYSTEM...
  • Page 29 SECTION 2 125, 130, 49HP AND 185 USER MANUAL 1. Turbocharger, Compressor 20. Engine Thermostat (Integral To Engine) 3. Muffler, Engine 25. Sensor, Coolant Temperature 4. Fuel Level Sender 26. Sensor, Engine Oil Pressure 5. Rain Cap, Exhaust System 29. Jacket Water Heater (Optional) 6.
  • Page 30 125, 130, 49HP AND 185 USER MANUAL SECTION 2 AIR INLET SYSTEM, – 80 (5.6 ORMAL PERATION PSIG FUNCTIONAL DESCRIPTION When the warm-up control selector valve handle is The air inlet system consists of two air filters, a moved to the RUN position, the sump pressure rises compressor air inlet valve and interconnecting piping above 80 psig (5.6 bar).

  • Page 31: Instrument Panel Group, Functional Description

    SECTION 2 125, 130, 49HP AND 185 USER MANUAL 2.10 INSTRUMENT PANEL 8. The optional Engine Oil Pressure Gauge GROUP, FUNCTIONAL monitors the pressure of the lubricating oil in DESCRIPTION the engine. 9. The optional Engine Coolant Temperature Refer to Figure 2-5 for the locations of the following...
  • Page 32 125, 130, 49HP AND 185 USER MANUAL SECTION 2 1. System air pressure 7. Engine voltage (optional) 2. Start stop switch 8. Engine oil pressure (optional) 3. Warm-up control 9. Engine coolant temperature (optional) 4. Shutdown indicator 10. Engine RPM (optional) 5.

  • Page 33: Wiring Diagram—Cat & Jd

    SECTION 2 125, 130, 49HP AND 185 USER MANUAL 2.11 WIRING DIAGRAM—CAT & JD...

  • Page 34: Wiring Diagram—Deutz

    125, 130, 49HP AND 185 USER MANUAL SECTION 2 2.12 WIRING DIAGRAM—DEUTZ...

  • Page 35: Electrical System, Functional Description

    SECTION 2 125, 130, 49HP AND 185 USER MANUAL 2.13 ELECTRICAL SYSTEM, 2.14 COMPRESSOR SHUTDOWN FUNCTIONAL DESCRIPTION & WARNING SYSTEM, FUNCTIONAL DESCRIPTION The electrical system consists of the basic electrical elements required to operate the compressor and The Shutdown System and Annunciator Module...
  • Page 36 BLANK PAGE...

  • Page 37: Section 3-Specifications

    125, 130, 49HP AND 185 USER MANUAL Section 3 SPECIFICATIONS SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR Table 3-1: Overall Specifications—Caterpillar Width Height Weight (wet) Length Model Series 125, 130 and 185 2- 130.8 3322 59.2 1504 53.8 1368 2130...
  • Page 38 125, 130, 49HP AND 185 USER MANUAL SECTION 3 Table 3-3: Engine Specifcations—Caterpillar Engine Type Diesel Diesel Diesel Make Caterpillar Caterpillar Caterpillar Model C2.2 C2.2 C2.2 U.S. EPA Tier 3 U.S. EPA Tier 3 U.S. EPA Tier 3 Emission Level...

  • Page 39: Specifications - 125, 130 And 185 Deutz

    SECTION 3 125, 130, 49HP AND 185 USER MANUAL SPECIFICATIONS – 125, 130 AND 185 DEUTZ Table 3-4: Overall Specifications—Deutz Width Height Weight (wet) Length Model Series 125, 130 and 185 2- 130.8 3322 59.2 1504 53.8 1368 2130 Wheel 125, 130 and 185 Less 69.1...
  • Page 40 125, 130, 49HP AND 185 USER MANUAL SECTION 3 Table 3-6: Engine Specifcations—Deutz Engine Type Diesel Diesel Diesel Make Deutz Deutz Deutz Model TD2009L4 TD2009L4 TD2009L4 U.S. EPA Interim Tier 4 U.S. EPA Interim Tier 4 U.S. EPA Interim Tier 4...

  • Page 41: Specifications-125, 130, 49 Hp And 185 John Deere

    SECTION 3 125, 130, 49HP AND 185 USER MANUAL SPECIFICATIONS—125, 130, 49 HP AND 185 JOHN DEERE Table 3-7: Overall Specifications—John Deere Width Height Weight (wet) Length Model Series 125, 130, 49HP and 130.8 3322 59.2 1504 53.8 1368 2130...

  • Page 42: Lubrication Guide - Compressor

    -20 to 120 (-29 to 49) SAE 10W SE, SF, SG, CD 0 to 100 (-18 to 38) MIL-L-2104E 10W 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)

  • Page 43: Application Guide

    The analysis might indicate a need change intervals different from those recommended in this manual. Sullair Corporation offers a fluid analysis for Sullair AWF. Contact Sullair for details. D-A Lubricant® Company Inc. offers an analysis for users Sullair AWF. Contact...
  • Page 44 BLANK PAGE...

  • Page 45: General

    125, 130, 49HP AND 185 USER MANUAL Section 4 GENERAL GENERAL OMPRESSOR ISCHARGE EMPERATURE WITCH While Sullair has built into this compressor a Opens the electrical circuit to shut down the complete set of controls and indicators that allow the...

  • Page 46: Initial Startup/Shutdown Procedure

    125, 130, 49HP AND 185 USER MANUAL SECTION 4 INITIAL STARTUP/ 2. Press the ENGINE SWITCH to the OFF SHUTDOWN PROCEDURE position after five minutes. RESTART PROCEDURE TARTUP Perform the following actions when starting the After running and shutting down the compressor for...

  • Page 47: General

    125, 130, 49HP AND 185 USER MANUAL Section 5 MAINTENANCE Corrosion to radiator surfaces may occur, thus reducing radiator life expectancy. It is extremely important to WARNING evacuate/purge all air within the cooling system before replacing the radiator cap. DO NOT remove caps. Plugs and/or other...

  • Page 48: Maintenance Every 50 Hours

    125, 130, 49HP AND 185 USER MANUAL SECTION 5 3. Check the Engine Operator’s Manual for ser- 10. Change the fuel filter. (If the filter tends to vice requirements. clog more often than what is expected, change the filter more frequently.) 4.
  • Page 49 SECTION 5 125, 130, 49HP AND 185 USER MANUAL OMPRESSOR LUID ILTER LEMENT ILTER AINTENANCE EPLACEMENT Refer to Figure 5-2. Air filter maintenance should be performed as often as conditions require. If the filters Refer to Figure 5-1. are equipped with optional maintenance indicators, 1.
  • Page 50 125, 130, 49HP AND 185 USER MANUAL SECTION 5 6. Reposition the cover and lock it into the posi- are diagonally opposite each other. Torque tion. the bolts to 60 ft-lbs (81 N•m). 7. Reset the filter restriction indicator (if 8.
  • Page 51 SECTION 5 125, 130, 49HP AND 185 USER MANUAL The following procedure applies to a compressor ROCEDURE ETTING PEED with full-load pressure rating of 100 psig (6.9 bar). RESSURE ONTROLS ORTABLE OMPRESSORS QUIPPED 1. Start the compressor and allow the engine to...
  • Page 52 125, 130, 49HP AND 185 USER MANUAL SECTION 5 4. Gradually open the service valve to atmo- sphere until the engine comes up in speed and sump pressure is held at 100 psig (6.9 WARNING bar). At this point, set the engine high speed...
  • Page 53 SECTION 5 125, 130, 49HP AND 185 USER MANUAL 1. Remove the rubber cap from the grease EARING UBRICATION cap’s end. Refer to Figure 5-5. Proper lubrication of the portable 2. Using a full charged grease gun, place the compressor’s bearing axle is critical to its proper gun onto the grease zerk located on the end function and reduction of wear on this part.

  • Page 54: 5.10 Troubleshooting

    125, 130, 49HP AND 185 USER MANUAL SECTION 5 5.10 TROUBLESHOOTING Always: 1. Check for loose wiring or connections. The following Troubleshooting chart is based upon data obtained from factory tests and information from 2. Check for damaged piping. the field. It lists symptoms, probable causes and 3.
  • Page 55 SECTION 5 125, 130, 49HP AND 185 USER MANUAL Table 5-1: Troubleshooting ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START SYMPTOM PROBABLE CAUSE REMEDY SSAM FLASH CODE: Engine coolant temperature switch is open Check wiring connection to the switch and...
  • Page 56 125, 130, 49HP AND 185 USER MANUAL SECTION 5 Table 5-1: Troubleshooting ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START SYMPTOM PROBABLE CAUSE REMEDY Compressor does not Run/start switch not in run position For compressors with idle warm-up controls,...

  • Page 57: Noise Emissions Warranty

    125, 130, 49HP AND 185 USER MANUAL Section 6 NOISE CONTROL NOISE EMISSIONS control prior to its sale or delivery to the ulti- WARRANTY mate purchaser or while it is in use. 2. The use of the compressor after such device...

  • Page 58: Noise Emissions Maintenance And Maintenance Record Log

    125, 130, 49HP AND 185 USER MANUAL SECTION 6 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD 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.
  • Page 59 SECTION 6 125, 130, 49HP AND 185 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.
  • Page 60 125, 130, 49HP AND 185 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.
  • Page 61 BLANK PAGE...
  • Page 62 ORLDWIDE ALES AND ERVICE SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A. Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82 Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A.

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