Page 2
Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and servicing of Sullair products. Individual courses on Portable compressors are offered at regular intervals throughout the year at Sullair’s training facility located in Michigan City, Indiana and on-site at Sullair distributor locations.
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...
1: Safety 1600H T4F Perkins User Manual E. Provide an appropriate flow-limiting valve for each cap slowly to its stop to relieve any excess pressure additional 75 feet (23 m) of hose in runs of air hose and make sure coolant is not boiling before removing exceeding 1/2″...
1600H T4F Perkins 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.
1: Safety 1600H T4F Perkins 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.
1600H T4F Perkins User Manual 1: Safety valve or atomizer tube of ether starting aid system B. Inspect lifting bail and points of attachment for pointed away from yourself and other personnel. cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or J.
1: Safety 1600H T4F Perkins User Manual trical or other energy source, would cause personal injury 8. Release stored energy and bring the equip- or equipment damage. The power source on any ment to a “zero mechanical state”. machine shall be locked out by each employee doing the 9.
Page 13
1600H T4F Perkins User Manual 1: Safety D. Remove all vent caps (if so equipped) from the bat- ing vehicle is provided with two (2) 12V batteries con- tery or batteries in the compressor. DO NOT permit nected in series, connect the jumper cable to the dirt or foreign matter to enter the open cells.
1: Safety 1600H T4F Perkins User Manual 1.13 Towing attachment on towing vehicle to support the front of drawbar in case it should accidentally become uncoupled. 1.13.1 Preparing to tow F. Make sure that the coupling device and adjacent WARNING...
1600H T4F Perkins User Manual 1: Safety the standard screw jack. Pull the pin connecting the B. DO NOT exceed the towing speeds listed below jack to the drawbar and raise the screw jack to its full under ideal conditions. Reduce your speed according upright position.
1: Safety 1600H T4F Perkins User Manual where the compressor will not be exposed to exces- If a caster wheel is provided on the screw jack, it is sive dust from the work site. part of the screw jack and cannot be removed. Follow the same procedure for stowing away the wheeled D.
1600H T4F Perkins User Manual 1: Safety 1.15 California proposition 65 raised and lowered to encourage flow of liquid to the var- ious drains. WARNING NOTE Breathing diesel engine exhaust exposes you to Never pour any hazardous substance down any chemicals known to the State of California to drain or sewer.
1: Safety 1600H T4F Perkins User Manual 1.17 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 ROTARY COMPRESSOR...
Page 19
1600H T4F Perkins 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 BAR/PSI LOW TEMPERATURE...
Page 20
1: Safety 1600H T4F Perkins 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 AXLE ENGINE RPM LUBRICANT GREASE...
Page 21
1600H T4F Perkins 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 DPF: DIESEL HEST: HIGH EMISSIONS SYSTEM TEMPERATURE PARTICULATE FILTER EMISSIONS DPF REGEN.
Page 22
1: Safety 1600H T4F Perkins User Manual Notes: 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
As you continue reading this manual and come to learn how the compressor operates and is cared for, you will 2.3 Sullair compressor unit, see how surprisingly easy it is to keep a Sullair compres- functional description sor in top operating condition.
Page 24
2: Description 1600H T4F Perkins User Manual 1. Compressor inlet valve 13. Battery disconnect switch 2. Compressor fluid thermal valve 14. Fuel tanks 3. Pressure regulator valve 15. Engine CEM module † 4. Engine coolant fill 16. Discharge air water separator and filters 5.
Refer to Figure 2-3 on page 27. The Sullair compressor perature of the compressor. In addition to the cooler and unit discharges compressed air/fluid mixture into the fan, the system consists of a main filter and thermal receiver tank.
Page 26
2: Description 1600H T4F Perkins User Manual 1. Fluid cooler 4. Oil stop valve 2. Thermal valve 5. Receiver tank 3. Fluid filter 6. Air compressor Figure 2-2: Cooling and lubrication system 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Page 27
1600H T4F Perkins User Manual 2: Description 1. Receiver tank 6. Water separator 2. Minimum pressure check valve 7. Service air valve 3. Pressure relief valve 8. Aftercooler air valve 4. Aftercooler assembly 9. Standard air valve 5. Aftercooled air filters 10.
2: Description 1600H T4F Perkins User Manual Fluid is added to the receiver tank via a capped fluid filler. and opening the blowdown valve. The controller will dis- A fluid level sight glass enables the operator to visually play “STOP INITIATED” and the machine enters a monitor the receiver tank fluid level.
1600H T4F Perkins User Manual 2: Description 2.9 Electrical system, functional (SPN) on the Engine Diagnostics page within the Service menu. description Refer to Section 2.10: Wiring diagram. The electrical sys- NOTE tem is comprised of not only the necessary equipment required to operate the compressor, but also a system to shut it down in the event of a malfunction.
Page 33
2.10 Wiring diagram Drawing notes ALL WIRE TYPES: GXL (MAY REPLACE WITH TXL) ALL WIRE COLORS: WHITE UNLESS OTHERWISE SPECIFIED: e.g BB1.2 AND BB1.3 SEE 02250223-499 WIRE CROSSINGS WITHOUT A DOT ARE DISCONNECTED WIRE CROSSINGS WITH A DOT ARE CONNECTED CN36 AND CN37 MUST HAVE CAN TERMINATING (RESISTOR) MATING CONNECTOR (DT006-3S-P006) 02250226-702.
2: Description 1600H T4F Perkins User Manual 2.14 Aftercooler air system, the Clean Emissions Module (CEM) and Pump Electron- ics Tank Unit (PETU). The CEM is an integrated assem- functional description bly containing the Diesel Particulate Filter (DPF), Diesel Refer to Figure 2-3 on page 27. The purpose of the after-...
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 Refer to the Engine Operator’s Manual for engine oil specifications. 3.4 Application guide Sullair portable air compressors are filled with Sullair ®...
Page 44
3: Specifications 1600H T4F Perkins User Manual Notes: 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
1600H T4F Perkins User Manual 4: Installation Section 4 Installation 4.1 Locating the package Maintain a 6 ft. (1.8 m) minimum separation between the package and any surrounding walls. Position the compressor on a level surface, if possible. If unable to locate the compressor on a level surface, posi-...
Page 46
4: Installation 1600H T4F Perkins User Manual 1. Fuel return 2. Fuel supply Figure 4-1: External fuel connections 1. External tank 2. On-board tank Figure 4-2: Fuel tank selector valve positions 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Before starting your Sullair compressor, read this section thoroughly and familiarize While Sullair has built into this compressor a comprehen- yourself with the controls and indicators—their purpose, sive array of controls and indicators to assure you that it location and use.
5: Operation 1600H T4F Perkins User Manual Control or indicator Purpose Opens the electrical circuit to shut down the compressor when the Receiver Tank Temperature Switch receiver tank temperature reaches 250°F (121°C). Provides an air signal to the inlet valve and engine to close the inlet...
1600H T4F Perkins User Manual 5: Operation • The controller status will display “AIR tems so that the battery is not inadvertently AVAILABLE”. drained after shutdown. 2. At the same time, the service valve should WARNING be opened and set to maintain the desired operating pressure.
Page 50
5: Operation 1600H T4F Perkins User Manual 1. Purge lamp 2. Battery disconnect switch Figure 5-1: Purge lamp location 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
1600H T4F Perkins User Manual 6: Controller Section 6 Controller 6.1 Controller layout Description Function ON/OFF/START switch Used to turn controller on and start or stop machine. Touch screen display. Used to display operating parameters and Display machine information. Also used to access additional machine functions.
6: Controller 1600H T4F Perkins User Manual 6.2 Home display 1. Indicator lamps 5. Diesel exhaust fluid (DEF) level gauges 2. Service pressure gauges 6. Message bar 3. Status bar 7. Diesel fuel level gauges 4. Information bar Figure 6-2: Home display layout 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Page 53
1600H T4F Perkins User Manual 6: Controller Table 6-1: Home display items and functions Description Function Displays status and malfunction indicator lamps. See Section 1.15: Indicator lamps Symbols and references on page 12 for definitions of symbols. Service pressure gauges Displays service (tank) pressure.
6: Controller 1600H T4F Perkins User Manual 6.3 User options Figure 6-3: User options layout User options are accessed via the physical MENU button • FORCED REGEN: This is used to (a) cancel and on the front of the controller. The...
1600H T4F Perkins User Manual 6: Controller 6.4 Service options Figure 6-4: Service options layout Service option sub-menus are accessed via the physical • ENGINE DIAGNOSTICS: Displays any active MENU button on the front of the controller and the SER- engine codes.
6: Controller 1600H T4F Perkins User Manual 6.4.1 Service options: Setup Figure 6-5: Setup options—remote start enabled Figure 6-6: Setup options—auto sleep enabled 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Page 57
1600H T4F Perkins User Manual 6: Controller You can access Setup options by pressing the SETUP restart, the remote start input signal must soft key under the Service Options menu. Pressing the be re-sent. icon next to each setting displays a brief description of •...
6: Controller 1600H T4F Perkins User Manual 6.4.2 Service options: Machine Setup Figure 6-7: Machine Setup options You can access machine setup options by pressing the • Automatic Loading: When set to Disable (the FLEET OPTIONS soft key under the Service Options default setting), the user will need to manually menu.
1600H T4F Perkins User Manual 6: Controller 6.5 Help Figure 6-8: Help display Help menu is accessed via the physical HELP button on 6.5.1.1 Resetting a non-responsive the front of the controller or the HELP soft key in the main touchscreen menu.
Page 60
6: Controller 1600H T4F Perkins User Manual Notes: 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
1600H T4F Perkins User Manual 7: Maintenance Section 7 Maintenance 7.1 General “Excessive Compressor Fluid Consumption” for a probable cause and remedy. A good maintenance program is the key to long compres- sor life. Below is a program that when adhered to, should keep the compressor in top operating condition.
7: Maintenance 1600H T4F Perkins User Manual 7.3 Engine coolant requirements If you are not sure of the coolant that is installed originally or want to change to a different type, the cooling system must be cleaned with a commercial cleaning agent and...
1600H T4F Perkins User Manual 7: Maintenance 7.4 Recommended maintenance • Check the battery level and fill with water if nec- essary. intervals • Check Engine Operator’s Manual for required engine service. 7.4.1 Maintenance after initial 50 hours of operation 7.4.3...
7: Maintenance 1600H T4F Perkins User Manual 7.5 Engine maintenance 7.6.2 Main fluid filter servicing Check Engine Operator’s Manual for required engine service. 7.6 Parts replacement and adjustment procedures 7.6.1 Compressor fluid change procedure Warm-up the compressor for 5 to 10 minutes to warm the fluid.
1600H T4F Perkins User Manual 7: Maintenance 8. Inspect bowl seal and replace if necessary. 3. Remove the primary filter from the housing. 9. Replace bowl. Rotate clockwise and hand- 4. Clean the interior of the housing by using a tighten.
Page 66
7: Maintenance 1600H T4F Perkins User Manual 1. Compressor inlet valve 5. Strainer 2. Pressure regulator 6. Start/run solenoid valve 3. Control pressure transducer 7. System pressure transducer 4. Blowdown valve 8. Discharge temperature switch Figure 7-3: Pneumatic control system 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
7: Maintenance 7.6.5 Separator element replacement CAUTION To assist with the removal of the tank lid, Sullair has provided a jack bolt at the bottom of the lid pivot shaft. Simply jack the lid up and rotate out of the way.
7: Maintenance 1600H T4F Perkins User Manual 2. If equipped, remove the adjusting hole cover for any loose or worn parts, stretched or deformed form the adjusting slot on the bottom of the springs and replace as necessary. brake backing plate.
1600H T4F Perkins User Manual 7: Maintenance 2. Press a section of the widest end of the bear- 7.6.10 Axle bearing adjustment ing into the outer edge of the grease pile clos- 1. Install the bearing and washer into the hub.
All available data concerning the Should your problem persist after making the recom- trouble should be systematically analyzed before undertak- mended check, consult your nearest Sullair representa- ing any repairs or component replacement procedures. tive or Sullair.
Page 71
1600H T4F Perkins User Manual 7: Maintenance Table 7-3: Troubleshooting guide Symptom Probable cause Remedy Check service lines for leaks of open Air demand is too great valves. Set service valve to achieve desired Service valve fully open service pressure.
Page 72
7: Maintenance 1600H T4F Perkins User Manual Table 7-3: Troubleshooting guide Symptom Probable cause Remedy Clogged return line Clean orifice and strainer. Check all pipes, connections and com- Leak in the lubrication system ponents Separator element damaged or not Change separator element.
Sullair warrants to the ultimate purchaser and each sub- 2. The use of the compressor after such device sequent purchaser that this air compressor was...
8: Noise Control 1600H T4F PerkinsUser Manual 8.3 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. Table 8-1: Annual muffler and exhaust system inspection At 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.
Page 75
1600H T4F PerkinsUser Manual 8: Noise Control Table 8-3: 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 76
8: Noise Control 1600H T4F PerkinsUser Manual Table 8-5: 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.
1600H T4F Perkins User Manual A: Acronyms and Abbreviations Appendix A: Acronyms and Abbreviations CEM—Clean Emissions Module DEF—Diesel Exhaust Fluid DOC—Diesel Oxidation Catalyst DPF—Diesel Particulate Filter ECU—Engine Control Unit NOx—Oxides of Nitrous (NO and NO2) PETU—Pump Electronic Tank Unit SCR—Selective Catalytic Reduction 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Page 78
A: Acronyms and Abbreviations 1600H T4F Perkins User Manual Notes: 02250248-733 R03 Subject to EAR, ECCN EAR99 and related export control restrictions.
Page 79
WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside. •...
Page 80
Sullair, LLC 1 Sullair Way 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.
Need help?
Do you have a question about the 1600H T4F Perkins and is the answer not in the manual?
Questions and answers