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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.
CALIFORNIA 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 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION AFTERCOOLED AIR SYSTEM, FUNCTIONAL DESCRIPTION AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR...
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...
600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL Section 2 DESCRIPTION INTRODUCTION As you continue reading this manual and come to learn how the compressor operates and is cared for, Sullair Portable Air Compressor models offer you will see how surprisingly easy it is to keep a superior performance and reliability while requiring Sullair compressor in top operating condition.
SECTION 2 600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL air cooler). As air passes through the aftercooler heat water separator then to your service line while the is removed which was introduced by the engine’s fluid is being cooled in preparation for reinjection.
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600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL SECTION 2 Fluid SU_0000144 Figure 2-3: Compressor Oil, Cooling and Lubrication - All Models 3. RECEIVER TANK 5. THERMAL VALVE 4. FLUID COOLER 6. FLUID FILTER CAPACITY CONTROL “START” position and start the engine using the SYSTEM, FUNCTIONAL START/STOP switch.
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SECTION 2 600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL COMPRESSOR DISCHARGE - 80 (5.5 RESSURE PSIG SYSTEM, FUNCTIONAL DESCRIPTION With the HIGH/LOW valve in the “LOW” position, and the START/RUN valve in the “RUN” position, the The Sullair compressor unit discharges compressed service valve can now be opened.
600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL SECTION 2 which is drawn through the aftercooler by the engine fan, cools the compressed air as it passes through the aftercooler core. Cooled air enters the moisture WARNING separator where condensation is removed from the cooler air and discharged.
SECTION 2 600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL AIR INLET SYSTEM, Referring to the engine air filter restriction gauge or FUNCTIONAL DESCRIPTION the compressor air filter restriction gauge will indicate when restriction of the air passing through the filter Refer to Figure 2-5.
PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR 02250201-490-R01S-1...
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PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR DESCRIPTION DESCRIPTION FILTER, AIR VALVE, PRESSURE DIFF. BYPASS GAUGE, AIR FILTER RESTRICTION SEPARATOR, ELEMENT INLET VALVE MANIFOLD, OIL CONTROL COMPRESSOR MANIFOLD, AIR CONTROL VALVE, RELIEF VALVE, SHUTTLE SWITCH, TEMPERATURE VALVE, RECIRCULATING SENSOR, TEMPERATURE CHART SENSOR, PRESSURE DESCRIPTION VALVE, BACK PRESSURE REGULATOR DRY SIDE PRESSURE...
2.10 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE 02250201-490-R01-2...
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2.10 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE DESCRIPTION DESCRIPTION TURBOCHARGER, ENGINE HEATER, WATER JACKET (OPTIONAL) COOLER, CHARGE AIR OIL LEVEL (DIPSTICK) MUFFLER, SCR ENGINE FILTER, AIR SENDER, FUEL LEVEL TANK, FUEL RAIN CAP, EXHAUST SYSTEM PAN, ENGINE OIL FILTER, FUEL W/ WATER SEPARATOR GAUGE, FILTER RESTRICTION PUMP, FUEL (INTERNAL TO ENGINE) SENSOR, INLET AIR TEMPERATURE...
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DESCRIPTION NOTES: AIR INTAKE AND EXHAUST SYSTEM FUEL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM DEF SYSTEM CHART DESCRIPTION COOLANT LEVEL FUEL LEVEL OIL LEVEL (DIPSTICK) DEF FLUID LEVEL INLET MANIFOLD AIR PRESSURE FUEL PRESSURE OIL PRESSURE EXHAUST TEMPERATURE INLET AIR TEMPERATURE COOLANT TEMPERATURE NOX SENSOR...
0 to 100 (-18 to 38) MIL-L-2104E 10W 0 to 100 (-18 to 38) (I) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5gallons/18.9 liters), 250030-758 (55 gallons,208 liter drum) APPLICATION GUIDE Refer to Figure 3-1. Sullair Air Compressors are drained from the receiver tank periodically.
SECTION 3 600H, 750, 750H, 750HH, 825, 900, 900H, USER MANUAL changed if this condition develops. CAUTION DO NOT mix types of fluids. Combinations of different fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging.
IDENTIFICATION, LESS RUNNING GEAR (DLQ) 02250204-061-r00...
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IDENTIFICATION, LESS RUNNING GEAR (DLQ) NOTES NOTES DIMENSIONS ARE IN INCHES A15: AUX. FUEL PORTS [ ] DIMENSIONS ARE IN MILLIMETERS. A16: LIFTING BAIL ALL DOORS REQUIRE 5 FOOT [1524] A17: COOLING AIR EXHAUST (3) CLEARANCE. A18: AIR CONTROL DOOR REAR DOOR ACCESS BATTERIES AND A19: INSTRUMENT PANEL DOOR...
IDENTIFICATION, TANDEM AXLE (DTQ) 02250204-062-R00...
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IDENTIFICATION, TANDEM AXLE (DTQ) NOTES NOTES DIMENSIONS ARE IN INCHES A19: HYDRAULIC SURGE BRAKE (OPTIONAL) [] DIMENSIONS ARE IN MILLIMETERS. A20: AIR CONTROL DOOR ALL DOORS REQUIRE 5 FOOT [1524] A21: INSTRUMENT PANEL DOOR CLEARANCE. A22: E-STOP REAR DOOR ACCESS BATTERIES AND A23: DOOR (4) COOLERS.
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IDENTIFICATION, 4-WHEEL (DWQ) NOTES NOTES DIMENSIONS ARE IN INCHES A16: LIFTING BAIL [ ] DIMENSIONS ARE IN MILLIMETERS. A17: COOLING AIR EXHAUST (3) ALL DOORS REQUIRE 5 FOOT [1524] A18: AIR CONTROL DOOR CLEARANCE. A19: INSTRUMENT PANEL DOOR REAR DOOR ACCESS BATTERIES AND A20: E-STOP COOLERS.
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600H, 750, 750H, 750HH, 825, 900H USER MANUAL Section 4 OPERATION GENERAL for service or indicate the beginning of a malfunction. While Sullair has built into this compressor a Before starting your Sullair compressor, read this comprehensive array of controls and indicators to...
600H, 750, 750H, 750HH, 825, 900H USER MANUAL SECTION 4 CONTROL OR INDICATOR PURPOSE Air Inlet Valve Regulates the amount of air allowed to enter the air inlet. This regulation is determined by the amount of air being used at the service line.
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600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL Section 5 MAINTENANCE GENERAL After a routine start has been made, it is necessary to perform an inspection to ensure all operations are A good maintenance program is the key to long performing correctly.
600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5 • Protects all standard metals within the cool- 1. Clean the return line orifice and strainer. ing system (i.e. brass, copper, steel, solder, 2. Change compressor fluid filter cast iron, and aluminum.) 3.
SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL 5.10 MAINTENANCE EVERY 1500 all internal pressure before proceeding. Drain the HOURS fluid by opening the appropriate drain valve located in the frame at the front of the machine. Close the When using Sullair AWF, change the compressor valve when draining is complete.
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600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5 SU_0000076 Figure 5-2: Typical E-Z Lube Axle 1. RUBBER PLUG 4. GREASE FLOW 2. OUTER BEARING 5. GREASE FITTING 3. INNER BEARING 6. METAL END CAP 7. SPRING-LOADED DOUBLE LIP SEAL 3.
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SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL 7. Apply a light film of clean fluid to each ele- ILTER AINTENANCE ment gasket surface. Refer to Figure 5-4. Air filter maintenance should be 8. Center the new elements on filter housing...
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600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5 LEMENT EMOVAL LEMENT NSPECTION 1. Clean the exterior of the air filter housing. 1. Place a bright light inside the element to inspect for damage or leak holes. Concen- 2.
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SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL on the instrument panel. If not, repeat step, ONTROL YSTEM DJUSTMENT but adjust the unload service pressure up or Refer to Figure 5-5. Prior to adjusting the control down as needed until 100 psig (6.9 bar) is system, it is necessary to determine the desired maintained when engine speed is 1800 rpm.
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SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL capscrews to 112 to 127 ft.lbs (151 to 172 EPARATOR LEMENT EPLACEMENT N·m). Refer to Figure 5-6. When fluid carry-over is evident 9. Reconnect all piping. The fluid return line...
600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5 5.12 TROUBLESHOOTING GUIDE • Check for loose wiring. • Check for damaged piping. The following Troubleshooting Chart is based on • Check for parts damaged by heat or an electrical...
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SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SYMPTOM PROBABLE CAUSE REMEDY Improper unloading with Fluid charge lost from spring chamber Add fluid to inlet valve spring chamber by an excessive pressure on inlet valve pressure regulating valve...
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600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5 SYMPTOM PROBABLE CAUSE REMEDY Engine overheating Loose or broken fan belt Tighten or change belt. Dirty radiator core Clean thoroughly. Dirty oil cooler Clean thoroughly. Low water level Refill.
600H, 750, 750H, 750HH, 825, 900, 900H 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...
600H, 750, 750H, 750HH, 825, 900, 900H 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.
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SECTION 6 600H, 750, 750H, 750HH, 825, 900, 900H 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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600H, 750, 750H, 750HH, 825, 900, 900H 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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Always air. Always there. WWW.SULLAIR.COM SULLAIR 3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A. Telephone: 1-219-879-5451 Printed in the U.S.A. Specifications subject to change without prior notice. E12EP...
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