Sullair 375 User Manual
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Sullair 375 User Manual

Portable air compressor
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Portable Air Compressor
375, 375H, 400HH, 425, 425H
SAFETY WARNING
Users are required to read the
entire User Manual before han-
dling or using the product.
USER MANUAL
Tier 4 Final
Caterpillar
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
Subject to EAR, ECCN EAR99 and related export control restrictions.
PART NUMBER:
02250223-036 R01
The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
201605010000
and all subsequent serial numbers.
Publication date: 05/27/2016
Copyright © 2016 Sullair, LLC. All rights reserved.

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Summary of Contents for Sullair 375

  • Page 1 Publication date: 05/27/2016 void its warranty. Copyright © 2016 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions.
  • 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 are offered at regular intervals throughout the year at Sullair’s training facility located in Michigan City, Indiana.

  • Page 3: Table Of Contents

    375, 375H, 400HH, 425, 425H T4F User Manual Table of Contents Table of Contents Section 1: Safety.......................1 General....................... 1 Personal protective equipment ..............1 Pressure release ..................1 Fire and explosion ..................2 Moving parts ....................3 Hot surfaces, sharp edges and sharp corners..........4 1.6.1...
  • Page 4 Identification—375D Tier 4 Final DPQ............34 2.17 Identification—375D Tier 4 Final DLQ ............36 Section 3: Specifications..................39 Specifications—375, 375H, 400HH, 425 & 425H Tier 4 Final Caterpillar ... 39 Lubrication guide—compressor ..............41 Lubrication guide—engine ................ 41 Application guide..................41 Section 4: Operation ....................
  • Page 5 375, 375H, 400HH, 425, 425H T4F User Manual Table of Contents 5.11.1 Single Axle Controller warning priority messages ..........60 5.11.2 Single Axle Controller shutdown priority messages..........61 Section 6: Noise Control..................63 Noise emissions warranty................. 63 Tampering with the noise control system is prohibited......63 Noise emissions maintenance and maintenance record log ....
  • Page 6 Table of Contents 375, 375H, 400HH, 425, 425H T4F User Manual Notes: 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 7: Section 1: Safety

    1.1 General protective clothing, protective shields and barriers Sullair designs and manufactures all of its products so they and electrical protective equipment, as well as noise can be operated safely. However, the responsibility for safe...

  • Page 8: Fire And Explosion

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual E. Provide an appropriate flow-limiting valve for each cap completely. Remove radiator filler cap only when additional 75 feet (23 m) of hose in runs of air hose cool enough to touch with a bare hand.

  • Page 9: Moving Parts

    375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety uids or fluid film within the material. DO NOT use P. DO NOT attempt to use ether as a starting aid in gas- flammable solvents for cleaning purposes. oline engines or diesel engines with glow plugs as serious personnel injury or property damage may E.

  • Page 10: Hot Surfaces, Sharp Edges And Sharp Corners

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual C. Wear snug-fitting clothing and confine long hair when Standards 29 CFR 1920 and any other Federal, State working around this compressor, especially when or Local codes or regulations. exposed to hot or moving parts.

  • Page 11: Electrical Shock

    375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety pound to air line anti-icer systems. Keep openings of 1.8 Electrical shock valve or atomizer tube of ether starting aid system A. Keep the towing vehicle or equipment carrier, com- pointed away from yourself and other personnel.

  • Page 12: Entrapment

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual Keep lift operator in constant attendance whenever reservoir tanks. Lockout or tag lines or compressor is suspended. valves. b. Any mechanism under tension or pres- J. Set compressor down only on a level surface capa-...

  • Page 13: Jump Starting

    375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety made to inform him or her that the lock- J. Set the parking brakes of both the compressor (if pro- out or tagout device has been removed. vided) and the starting vehicle or otherwise block both sides of all wheels.

  • Page 14: Towing

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual U. Allow the compressor to warm up. When the com- device or otherwise couple the compressor to the pressor is warm and operating smoothly at normal towing vehicle. idle RPM, disconnect the jumper cable from the...

  • Page 15: Towing

    375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety M. Make sure parking brakes in towing vehicle are set, CAUTION or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided.

  • Page 16: Parking Or Locating Compressor

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual ing forward or backing up, regardless of the terrain CAUTION being traversed. DO NOT permit personnel to ride in or on the com- pressor. Retract the front screw jack only after attaching the compressor to the tow vehicle.

  • Page 17: California Proposition 65

    375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety 1.14 California proposition 65 WARNING California Proposition 65 Warning Diesel engine exhaust and some of its constitu- ents are known to the State of California to cause cancer, birth defects and other reproduc- tive harm.

  • Page 18: Symbols And References

    1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual 1.15 Symbols and references The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable sym- bols. DIESEL FUEL HEARING PROTECTION...
  • Page 19 375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety 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...
  • Page 20 1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual 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...
  • Page 21 375, 375H, 400HH, 425, 425H T4F User Manual 1: Safety DO NOT OPERATE WATER DRAIN WHILE STACKED PRESSURIZED SPRING SEVER (FAN) DO NOT MIX FLUIDS DEF FLUID ONLY AUTO START/STOP FLUID DRAIN LOW FUEL HEST: HIGH EMISSIONS DPF: DIESEL SYSTEM TEMPERATURE...
  • Page 22 1: Safety 375, 375H, 400HH, 425, 425H T4F User Manual Notes: 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 23: Section 2: Description

    As you continue reading this manual and come to learn how the compressor operates and is cared for, you will see how surprisingly easy it is to keep a Sullair compres- sor in top operating condition. Read Section 5: Mainte- nance to keep your compressor in top operating condition.
  • Page 24 13. Moisture separator 7. Battery shut off switch 14. Discharge air filters (optional) Figure 2-2: 375, 475H, 400HH, 425 & 425H Tier 4 Final portable air compressor— Caterpillar standard and aftercooled models 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 25: Sullair Compressor Unit, Functional Description

    375, 375H, 400HH, 425, 425H T4F User Manual 2: Description The engine radiator, charge air cooler, and the compres- sor fluid cooler are next to each other allowing the fan air to push through all three simultaneously. As air passes through the fluid cooler, the heat of compression is removed from the fluid.

  • Page 26: Compressor Discharge System, Functional Description

    2: Description 375, 375H, 400HH, 425, 425H T4F User Manual The fluid leaving the filter flows to the compressor unit a change of direction and reduction of velocity, large where it lubricates, seals and cools the compression droplets of fluid separate and fall to the bottom of the chamber;...

  • Page 27: Capacity Control System, Functional Description

    375, 375H, 400HH, 425, 425H T4F User Manual 2: Description mum receiver pressure of 80 psig (5.5 bar) during all of starting the compressor (the instrument panel annunci- conditions. Keeping this pressure level stable is neces- ator light goes off after 30 seconds) turn the handle of the...
  • Page 28 9. Fluid fill/fluid level sight glass A. Air 10. Discharge air filters (optional) B. Fluid/air 11. Moisture separator (optional) C. Fluid Figure 2-5: Control system with piping and instrumentation—375 & 425 models 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 29 375, 375H, 400HH, 425, 425H T4F User Manual 2: Description 1. Air pressure gauge 14. Compressor air end 2. Idle warm-up control selector valve 15. Fluid fill/fluid level sight glass 3. Low pressure regulator valve 16. Discharge air filters (optional) 4.

  • Page 30: Piping And Instrumentation-Compressor System

    2.7 Piping and instrumentation—compressor system 02250223-497 R00 (sh1)
  • Page 31 2.7 Piping and instrumentation—compressor system Components Key Description Component Description FILTER, AIR COMPR DISCHARGE TEMP (CDT) OPTIONAL GAUGE, FILTER RESTRICTION (OPTONAL) SEPARATOR TANK TEMP (RTT) INLET VALVE DRY SUMP PRESS (GAGE) COMPRESSOR CONTROL PRESS (H AND HH MACHINES ONLY) GAUGE, TEMPERATURE SWITCH, TEMPERATURE SPEED CTRL PRESSURE: VALVE, RELIEF...

  • Page 32: Piping And Instrumentation-Engine System

    2.8 Piping and instrumentation—engine system 02250223-497 R00 (sh2)
  • Page 33 2.8 Piping and instrumentation—engine system Key Description Key Description TURBOCHARGER, COMPRESSOR FILTER, AIR COOLER, AIR TANK, FUEL MUFFLER, ENGINE ENGINE OIL PAN FUEL LEVEL SENDER GAUGE, FILTER RESTRICTION RAIN CAP, EXHAUST SYSTEM TANK, ENGINE COOLANT FUEL FILTER W/ WATER SEPARATOR SENSOR, FLUID LEVEL FUEL TRANSFER PUMP VALVE, DEF COOLANT...

  • Page 34: Shutdown

    2: Description 375, 375H, 400HH, 425, 425H T4F User Manual 2.9 Shutdown 2.11 Instrument panel group, functional description The blowdown valve is normally closed. At shutdown the back pressure in the compressor inlet signals the blow- Refer to Figure 2-8. The instrument panel group consists...
  • Page 35 375, 375H, 400HH, 425, 425H T4F User Manual 2: Description 1. User interface buttons 10. Low fuel lamp 2. Master gauge 11. Emissions malfunction lamp (MIL) 3. Display 12. Compressor warning lamp 4. Regeneration inhibit lamp (not applicable) 13. Engine warning lamp 5.

  • Page 36: Wiring Diagram

    2.12 Wiring diagram 02250218-784 R06 (sh1)
  • Page 37 2.12 Wiring diagram 02250218-784 R06 (sh2)
  • Page 38 2.12 Wiring diagram 02250218-784 R06 (sh3)

  • Page 39: Electrical System, Functional Description

    375, 375H, 400HH, 425, 425H T4F User Manual 2: Description some oil and it should be disposed of properly in accor- 2.13 Electrical system, functional dance with local regulations. description From the moisture separator the air enters the (optional) The electrical system consists of the basic electrical ele- first stage filter.

  • Page 40: Identification-375D Tier 4 Final Dpq

    2.16 Identification—375D Tier 4 Final DPQ 02250216-696 R02...
  • Page 41 2.16 Identification—375D Tier 4 Final DPQ Drawing notes DIMENSIONS ARE IN INCHES. [ ] DIMENSIONS ARE IN MILLIMETERS. ALL DOORS ARE PAD LOCKABLE. REFERENCE: A STANDARD CONTAINER SIZE IS 92" WIDE X 94" TALL X 232" LONG. ENGINE COOLANT DRAIN ENGINE OIL DRAIN COMPRESSOR OIL DRAIN WATER CONDENSATE DRAIN (DO NOT PLUG) (ONLY REQUIRED ON AFTER-COOLED MACHINES)

  • Page 42: Identification-375D Tier 4 Final Dlq

    2.17 Identification—375D Tier 4 Final DLQ 02250219-440 R02...
  • Page 43 2.17 Identification—375D Tier 4 Final DLQ Drawing notes DIMENSIONS ARE IN INCHES. [ ] DIMENSIONS ARE IN MILLIMETERS. ALL DOORS ARE PAD LOCKABLE. REFERENCE: A STANDARD CONTAINER SIZE IS 92" WIDE X 94" TALL X 232" LONG. ENGINE COOLANT DRAIN ENGINE OIL DRAIN COMPRESSOR OIL DRAIN WATER CONDENSATE DRAIN (DO NOT PLUG) (ONLY REQUIRED ON AFTER-COOLED MACHINES)
  • Page 44 2: Description 375, 375H, 400HH, 425, 425H T4F User Manual Notes: 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 45: Section 3: Specifications

    375, 375H, 400HH, 425, 425H T4F User Manual 3: Specifications Section 3 Specifications 3.1 Specifications—375, 375H, 400HH, 425 & 425H Tier 4 Final Caterpillar Table 3-1: Package specifications Model series 375, 375H, 400HH, 425, 425H Package Working weight lbs (kg)
  • Page 46 3: Specifications 375, 375H, 400HH, 425, 425H T4F User Manual Table 3-2: Compressor specifications Model series 375H 400HH 425H Type Rotary screw Actual delivery cfm (L/s) 375 (177) 375 (177) 400 (189) 425 (201) 425 (201) Rated pressure psig (bar) 100 (6.9)

  • Page 47: Lubrication Guide-Compressor

    375, 375H, 400HH, 425, 425H T4F User Manual 3: Specifications 3.2 Lubrication guide—compressor Ambient temperature Change range period, Fluid type hours °F °C ® 1 Sullair AWF 1500 -20 to 120 -29 to 49 Sullair AWF part numbers: 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon/208 liter drum) 3.3 Lubrication guide—engine...
  • Page 48 3: Specifications 375, 375H, 400HH, 425, 425H T4F User Manual Notes: 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 49: Section 4: Operation

    (see Section 3.1: Spec- control and monitor the compressor’s operation and per- ifications—375, 375H, 400HH, 425 & 425H Tier 4 Final formance, operators should learn to recognize indica- Caterpillar on page 39).

  • Page 50: Starting The Compressor

    4: Operation 375, 375H, 400HH, 425, 425H T4F User Manual integrity and safety status. During this pro- Pressure selector valve (H and HH models) cess, the following actions will be per- Sets compressor operation in the LOW range from 80 to formed.

  • Page 51: Troubleshooting

    375, 375H, 400HH, 425, 425H T4F User Manual 4: Operation 4.5 Troubleshooting The following guide contains symptoms and usual message on the LCD, light the compressor shutdown causes for the problems that may occur throughout the panel lamp, shut the system down, and wait for operator compressor system.
  • Page 52 4: Operation 375, 375H, 400HH, 425, 425H T4F User Manual Warning/Shutdown/ Error Message Prevent Startup Description Recommended action Pressure above 10 psi (recent P1 (Dry) pressure is shutdown). Wait for pressure to above setpoint. fall below 10 psi. Shutdown/Prevent High Comp Pres-...
  • Page 53 375, 375H, 400HH, 425, 425H T4F User Manual 4: Operation Warning/Shutdown/ Error Message Prevent Startup Description Recommended action Check connections at sensor on tank. Verify source voltage and ground. Wires possibly reversed. Fuel sensor is defective. Replace. The fuel level sensor sig-...
  • Page 54 4: Operation 375, 375H, 400HH, 425, 425H T4F User Manual Warning/Shutdown/ Error Message Prevent Startup Description Recommended action If problem persists, shut machine down and check for volatiles in the atmosphere. Don’t restart CAT DM1 Message machine until condition is Warning Eng.

  • Page 55: Section 5: Maintenance

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance Section 5 Maintenance immediately. Refer to Section 5.9.3: Air filter 5.1 General maintenance on page 52. After a routine start has been made, it is necessary to WARNING perform an inspection to ensure all operations are per- forming correctly.

  • Page 56: Maintenance After Initial 50 Hours Of Operation

    5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual The engine coolant type should follow these recom- mended specifications: WARNING • Organic acid technology (OAT). • Premixed coolant pH range of 8.0 to 9.5. This engine is fitted with Selective Catalytic •...

  • Page 57: Maintenance Every 100 Hours

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance 5.6 Maintenance every 100 hours 5.9 Part replacement and adjustment procedures • Clean the radiator & cooler exterior surfaces. • Check the Engine Operator’s Manual for ser- 5.9.1 Compressor fluid change procedure vice requirements.

  • Page 58: Air Filter Maintenance

    5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual 1. Remove the old element with a strap wrench. 2. Clean the gasket seating surface. 3. Apply a light coating of fluid to the new gas- ket. 4. Hand tighten the new element (P/N 250025- 525) until the new gasket is seated.

  • Page 59: Setting Speed And Pressure Controls On Portable Compressors Equipped With Poppet Valves

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance arator element which will ensure proper return line flow. 9. Clean the fluid return line strainer and clear the orifice before starting the compressor. 10. After 24 hours of operation, tighten the sump cover bolts to the value given in step 7.

  • Page 60: Bearing Lubrication (American Models)

    5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual 2. With the service valve closed, adjust the pressure regulator setting maintain 115 psig (8 bar) receiver tank pressure. 3. Gradually open the service valve to atmo- sphere until the engine speed increases and the receiver tank pressure stabilizes at 100 psig (6.9 bar).

  • Page 61: First And Second Stage Discharge Air Filter Maintenance-Aftercooled & Filtered Models

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance 1. Remove the rubber cap from the grease The first and second stage filter element should be cap’s end. changed when the pressure drop reaches the red band on the pressure differential gauge.
  • Page 62 5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual 5.9.7.3 Safety—toxic and irritating substances Do not use air from this compressor for respiration (breathing) except in full compliance with OSHA Stan- dards 29 CFR 1920 and any other Federal, State or Local codes or regulations.

  • Page 63: Troubleshooting

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance 5.10 Troubleshooting The following troubleshooting chart is based upon data Always: obtained from factory tests and information from the field. • Check for loose wiring or connections. It lists symptoms, probable causes and remedies. This •...
  • Page 64 5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual Table 5-2: Troubleshooting guide Symptom Probable cause Remedy Check wiring connection to the switch and tighten if necessary Engine coolant temperature switch is open Check switch continuity to ground and...
  • Page 65 375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance Table 5-2: Troubleshooting guide Symptom Probable cause Remedy RUN/START valve not in RUN For compressors with idle warm-up con- position trols, switch valve to RUN for full operation Air demand is excessive...

  • Page 66: Single Axle Controller Priority Messages

    5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual 5.11 Single Axle Controller priority messages 5.11.1 Single Axle Controller warning priority messages Warning message will broadcast over the second line will be removed from the display. Acknowledged active parameter display. Multiple messages will be displayed messages do not re-occur.

  • Page 67: Single Axle Controller Shutdown Priority Messages

    375, 375H, 400HH, 425, 425H T4F User Manual 5: Maintenance 5.11.2 Single Axle Controller shutdown priority messages The single axle controller continuously monitors for play. For more detailed information on engine trouble abnormal shutdown conditions during operation. If pres- codes refer to your engine manual or contact a Caterpil- ent, a textual description of the shutdown condition is lar dealer for technical support.
  • Page 68 5: Maintenance 375, 375H, 400HH, 425, 425H T4F User Manual Notes: 02250223-036 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 69: Section 6: Noise Control

    375, 375H, 400HH, 425, 425H T4F User Manual 6: Noise Control Section 6 Noise Control control prior to its sale or delivery to the ulti- 6.1 Noise emissions warranty mate purchaser or while it is in use. Sullair warrants to the ultimate purchaser and each sub- 2.

  • Page 70: Noise Emissions Maintenance And Maintenance Record Log

    6: Noise Control 375, 375H, 400HH, 425, 425H T4F User Manual 6.3 Noise emissions maintenance and maintenance record log The following instructions and maintenance record log book, for the proper maintenance, use and repair of this com- pressor, is intended to prevent noise emission degradation.
  • Page 71 375, 375H, 400HH, 425, 425H T4F User Manual 6: Noise Control Table 6-3: 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 72 6: Noise Control 375, 375H, 400HH, 425, 425H T4F User Manual Table 6-5: Annual acoustical materials inspection At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material missing or damaged (refer to Parts List). Clean or replace, if necessary. Do not operate compressor with defective acoustical material.
  • Page 73 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 74 Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.

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