Sullair 02250175-949 R01 User Manual Download

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SECTION 2

1600C LP USER MANUAL

SU_0000204

FLUID

AIR/FLUID

AIR

Figure 2-4: Compressor Flow Diagram - All Models

1. Compressor Air FIlter

11. Fluid Cooler

2. Engine Air FIlter

12. Thermal Valve/Fluid Filter Assembly

3. Engine

13. Receiver Tank

4. Compressor Unit

14. Fluid Level Sight Gauge

5. Service Air (Aftercooled)

15. Final Fluid Separator Element

6. Discharge Air Filters

16. Ball Valve

7. Air Inlet Valve

17. P3 Pressure Transducer

8. Moisture Separator

18. Service Air (Non-Aftercooled)

9. Aftercooler

19. Minimum Pressure Check Valve

10. Relief Valve

20. Temperature Shutdown Switch

Summary of Contents for 02250175-949 R01

Page 1: ...FOR FUTURE REFERENCE USER MANUAL COPYRIGHT 2013 SULLAIR The information in this manual is current as of its publication date and applies to compressor serial number and all subsequent serial numbers 02250175 949 R01 201306100000 PORTABLE AIR COMPRESSOR 1300H A F 1600 A F 1600H A F 1450HH A F A AFTERCOOLED MODELS F FILTERED MODELS CATERPILLAR TIER 3 ...

Page 2: ......

Page 3: ...2 3 SULLAIR COMPRESSOR UNIT FUNCTIONAL DESCRIPTION 23 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTION AL DESCRIPTION 25 2 5 CAPACITY CONTROL SYSTEM FUNCTIONAL DESCRIPTION 28 2 6 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 28 2 7 AFTERCOOLED AIR SYSTEM FUNCTIONAL DESCRIPTION 29 2 8 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION 30 2 9 PIPING INSTRUMENTATION DIAGRAM COMPRESSOR 32 2 10 PIPING ...

Page 4: ...E SECTION 5 MAINTENANCE 57 5 1 GENERAL 57 5 2 DAILY OPERATION 57 5 3 ENGINE COOLANT 58 5 4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 58 5 5 MAINTENANCE EVERY 100 HOURS 58 5 6 MAINTENANCE EVERY 250 HOURS 58 5 7 MAINTENANCE EVERY 300 HOURS 58 5 8 MAINTENANCE EVERY 600 HOURS 59 5 9 MAINTENANCE EVERY 1000 HOURS 59 5 10 MAINTENANCE EVERY 1500 HOURS 59 5 11 PARTS REPLACEMENT AND ADJUSTMENT PROCEDU...

Page 5: ...s or requirements DO NOT modify the compressor except with written factory approval Each day walk around the air compressor and inspect for leaks loose or missing parts damaged parts or parts out of adjustment Perform all recommended daily maintenance Inspect for torn frayed blistered or otherwise deteriorated and degraded hoses Replace as required 1 2 TOWING PREPARING TO TOW A Prior to hitching t...

Page 6: ... range specified and are inflated to the specified pressures DO NOT change the tire size or type Also make sure wheel bolts lugs or nuts are tightened to the specified torques J If provided make sure all dual stop tail direc tional and clearance lights are operating properly and that their lenses are clean and functional Also make sure all reflectors and reflecting sur faces including the slow mov...

Page 7: ...warning U turns especially should be made slowly and carefully D Avoid grades in excess of 15 27 E Avoid potholes rocks and other obstructions and soft shoulders or unstable terrain F Maneuver in a manner that will not exceed the freedom of motion of the compressor s drawbar and or coupling device in or on the towing vehi cle s coupling device and or adjacent structure whether towing forward or ba...

Page 8: ... 1 2 13 mm inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure D Provide an appropriate flow limiting valve for each additional 75 feet 23 m of hose in runs of air hose exceeding 1 2 13 mm inside diameter to reduce pressure in case of hose failure E Flow limiting valves are listed by pipe size and rated CFM Select appropriate valve accordingly F DO NO...

Page 9: ... on the receiver open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air fluid system 1 4 FIRE AND EXPLOSION A Refuel at a service station or from a fuel tank designed for its intended purpose If this is not possible ground the compressor to the dis penser prior to refueling B Clean up spills of lubricant or other combustibl...

Page 10: ... injury may result R Antifreeze compound used in air line anti icer systems contains methanol which is flammable Use systems and refill with compound only in well ventilated areas away from heat open flames or sparks DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150 F 66 C Vapors from the antifreeze compound are heavier than air DO NOT store compound or d...

Page 11: ...s above normal engine exhaust temperatures Gas temperatures during the regeneration period can reach 750 C 1382 F 1 7 TOXIC AND IRRITATING SUBSTANCES A DO NOT use air from this compressor for respi ration breathing except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal State or Local codes or regulations T4 WARNING Increased DPF skin temperature and exhaust gas temperature...

Page 12: ...mpound enters the eyes or if fumes irritate the eyes they should be washed with large quantities of clean water for fifteen minutes A physician preferably an eye specialist should be contacted immedi ately K DO NOT store ether cylinders or air line anti icer system antifreeze compound in operator s cabs or in other similar confined areas L The antifreeze compound used in air line anti freeze syste...

Page 13: ...empt to lift in high winds G Keep all personnel out from under and away from the compressor whenever it is suspended H Lift compressor no higher than necessary I Keep lift operator in constant attendance when ever compressor is suspended J Set compressor down only on a level surface capa ble of supporting at least its net weight plus an additional 10 allowance for the weight of water snow ice mud ...

Page 14: ...nect one end of the other jumper cable to the grounded negative NEG terminal of the bat tery in the starting vehicle When jump starting 24V compressors and if the starting vehicle is provided with two 2 12V batteries connected in series connect the jumper cable to the negative NEG terminal of the grounded battery R Check your connections DO NOT attempt to start a 24V compressor with one 12V batter...

Page 15: ...n affixing tag to power source must be on tag along with date tag was placed on power source 8 Release stored energy and bring the equipment to a zero mechanical state 9 Verify Isolation Before work is started test equipment to ensure power is disconnected B General Security 1 The lock shall be removed by the Authorized person who put the lock on the energy isolating device No one other than the p...

Page 16: ...TECTION DO NOT REMOVE MANUAL DO NOT BREATHE COMPRESSED AIR DO NOT STAND ON SERV VALVE DO NOT OPERATE W DOORS OPEN DO NOT OPEN DO NOT STACK ELECTRICAL SHOCK AIR FLOW HOT SURFACE PRESSURIZED VESSEL PRESSURIZED COMPONENT CLOSED MECHANICAL FUSE LOW PRESSURE READ MANUAL BRAKES ROTARY COMPRESSOR TEST RUN DRAIN HIGH PRESSURE NO ENGINE COMPRESSOR ENGINE OIL ENGINE COOLANT WATER OIL DO NOT SHUT OFF VALVE W...

Page 17: ...ATTERY DISCONNECT OFF ON RESET REMOTELY CONTROLLED DO NOT MAINTENANCE ENGINE START ENGINE ECM READ WRITE DATA INTAKE AIR EXHAUST GAS FAN GUARD BELT GUARD SERVICE POINT LOW TEMPERATURE STD AIR A C AIR 24 HOURS BELTS FILTER STRAINER FORK LIFT HERE DIRECTION OF ROTATION NO FORKLIFT SAFETY SYMBOLS 2 ...

Page 18: ...S VALVE COMPRESSOR OIL HEAT STACKING LIMIT BY NUMBER DRAIN HEATER BATTERY HEATER ENGINE PREHEAT LOW TEMP AID COMPRESSOR AIR PRESSURE AIR CIRCULATING FAN AIR COOLED OIL COOLER LIQUID COOLED OIL COOLER TRAILER TOWING MODE CRUSH PINCH POINT FUNCTIONAL ARROW PRESSURE CONTROL INTERNAL FUEL EXTERNAL FUEL SIDE DOOR T LATCH INLET VALVE SPRING ENGINE INTAKE AIR FILTER LUBRICANT GREASE EXAMINE CHECK SAFETY ...

Page 19: ...SECTION 1 19 DO NOT OPERATE WHILE STACKED DO NOT MIX FLUIDS AUTO START STOP FLUID DRAIN PRESSURIZED SPRING WATER DRAIN SEVER FAN DEF FLUID ONLY RUN SAFETY SYMBOLS 4 ...

Page 20: ...SECTION 1 20 ...

Page 21: ...ng and lubrication system compressor discharge system capacity control system instrument panel and electrical system The machine is also supplied with sound deadening insulation to lower noise emissions to meet EPA or CE and or any Federal State or local noise requirement The Sullair compressor unit is driven by an industrial engine designed to provide enough horsepower at rated conditions Refer t...

Page 22: ...ressor Fluid Filter 2 Thermal Valve 11 Receiver Tank 3 Regulator Valve 12 E Stop 4 Fluid Stop Valve 13 Engine Muffler 5 Engine Coolant Fill 14 Manual Enclosure 6 Fluid Cooler 15 Battery Disconnect Switch 7 Aftercooler 16 Fuel Tank 8 Engine Charge Air Cooler 17 Discharge Air Filters if equipped 9 Engine Radiator ...

Page 23: ...e fluid temperature is cool and routing to the cooler is not required The fluid first enters the thermal valve and then flows on to the compressor unit bypassing the cooler As the compressor continues to operate the temperature of the fluid rises and the thermal valve element begins to shift This forces a portion of the fluid to the fluid cooler The cooler is a radiator type that works in conjunct...

Page 24: ...CTION 2 24 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 ...

Page 25: ... the service valve can now be opened Pressure from the 60 psig 4 1 bar reducing regulator opens up the inlet valve and the Compass Controller increases the engine speed to full load 1800 rpm As the demand for air decreases the Compass Controller commands the engine to reduce speed to idle 1400 rpm and the inlet valve closes where it stabilizes until the air demand is required again If the machine ...

Page 26: ...Manifold All Models 1 Blowdown Valve 8 P1 Pressure Transducer 2 P2 Pressure Transducer 9 Reducing Regulator 3 High Pressure Bypass Regulator 10 RUN START Solenoid 4 Low Pressure Bypass Regulator 11 Start Orifice 5 HI LO Solenoid 12 Check Valve 6 Recirculating Solenoid 13 Run Orifice 7 Recirculating Valve ...

Page 27: ... Engine Air FIlter 12 Thermal Valve Fluid Filter Assembly 3 Engine 13 Receiver Tank 4 Compressor Unit 14 Fluid Level Sight Gauge 5 Service Air Aftercooled 15 Final Fluid Separator Element 6 Discharge Air Filters 16 Ball Valve 7 Air Inlet Valve 17 P3 Pressure Transducer 8 Moisture Separator 18 Service Air Non Aftercooled 9 Aftercooler 19 Minimum Pressure Check Valve 10 Relief Valve 20 Temperature S...

Page 28: ...r is being run in parallel with other compressors tied to a large air system Fluid is added to the receiver tank via a capped fluid filler A fluid level gauge glass enables the operator to visually monitor the receiver tank fluid level 2 7 AFTERCOOLED AIR SYSTEM FUNCTIONAL DESCRIPTION Refer to Figure 2 5 The purpose of the aftercooled air system is to operate the air compressor in conditions when ...

Page 29: ...r filter will be required Referring to the instrument panel the engine air filter restriction gauge or the compressor air filter restriction gauge will indicate when restriction of the air passing through the filter becomes too high At this time change the air filter element Refer to AIR FILTER MAINTENANCE on page 61 These indicators should be checked daily after start up under normal conditions T...

Page 30: ...1600C LP USER MANUAL SECTION 2 30 2 9 PIPING INSTRUMENTATION DIAGRAM COMPRESSOR 02250176 713 R03 S1 ...

Page 31: ...VE BLOWDOWN N C 19 2 STRAINER 20 1 SIGHTGLASS ORIFICE BLOCK 21 1 VALVE THERMAL BYPASS 22 1 COOLER OIL 23 1 FILTER OIL 24 1 VALVE OIL STOP 25 1 VALVE PILOT ACTUATED RECIRC SOL 26 2 VALVE REGULATOR BACK PRESSURE 27 1 GAUGE PRESSURE 28 N A 29 2 VALVE CHECK 30 1 VALVE SOLENOID 3 WAY RUN START 31 2 VALVE SOLENOID 2 WAY ELECT 32 1 SEPARATOR ELEMENT 33 N A 34 N A 35 1 CYLINDER AIR 36 2 VALVE PRESSURE DIF...

Page 32: ...1600C LP USER MANUAL SECTION 2 32 2 10 PIPING INSTRUMENTATION DIAGRAM ENGINE 02250176 713 R03 S2 ...

Page 33: ...1 RADIATOR ENGINE 20 1 ENGINE THERMO INTEGRAL TO ENGINE 21 1 SENSOR INLET AIR PRESS TURBO BOOST 22 1 SWITCH COOLANT LEVEL 23 1 SENSOR FUEL PRESSURE 24 1 SENSOR FUEL TEMPERATURE 25 1 SENSOR COOLANT TEMPERATURE 26 1 SENSOR ENGINE OIL PRESSURE 27 1 SENSOR CAM SPEED TIMING 28 1 SENSOR CRANK SPEED TIMING 29 1 HEATER WATER JACKET OPTIONAL 30 1 OIL LEVEL DIPSTICK 31 1 FILTER AIR 32 1 TANK FUEL 33 1 PAN E...

Page 34: ...UP FUNCTIONAL DESCRIPTION Refer to Compass Controller Manual Sullair Part Number 02250167 454 Figure 2 6 Instrument Panel Group 1 HI LO Switch 2 Diagnostic Service Port 3 Reset Switch 4 Pressure Gauge 5 Temp Tach Fuel Gauge 6 Warning Bank 7 START ON OFF Switch ...

Page 35: ... problem and aid in troubleshooting the compressor Refer to Table 2 1 for possible performance of active diagnostic codes 2 13 ELECTRICAL SYSTEM FUNCTIONAL DESCRIPTION Refer to Section 2 13 and Section 2 14 The electrical system 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 The components of the e...

Page 36: ...mperature open short to batt 110 03 110 03 x x x Engine coolant temperature short to ground 110 04 110 04 x x x 28 Throttle position calibration required 91 13 91 03 x x 32 Throttle position signal abnormal 91 08 91 08 x x 34 Speed timing sensor loss of signal 320 02 190 02 x x I Speed timing sensor mechanical failure 320 11 190 11 x x I Loss of secondary engine speed signal 342 02 723 02 x x I Se...

Page 37: ...re 096 0094 00 64 HIgh inlet temperature derate 025 0172 16 High inlet temperature shutdown 027 0172 05 65 High fuel temperature derate 054 0174 16 High fuel temperature shutdown 055 0174 00 High fuel temperature warning 056 0174 15 72 Injector cylinder 1 fault 1 11 651 11 x x Injector cylinder 2 fault 2 11 652 11 x x 73 Injector cylinder 3 fault 3 11 653 11 x x Injector cylinder 4 fault 4 11 654 ...

Page 38: ... START SOL AIR STOP SWITCH AIR STOP MODULE AIR STOP COMMON BATT BATT BATT BATT DIGITAL SENSOR 8V COOLANT LEVLE SW DIGITAL SENSOR RET ANALOG SENSOR RET ANALOG SENSOR 5V SWITCH BATT DATA LINK DATA LINK DIAGNOSTIC LAMP WARNING LAMP J1939 J1939 J1939 SHIELD UNSWITCH BATT UNSWITCH BATT UNSWITCH BATT UNSWITCH BATT ENGINE ECM AIR STOP RECIRCULATING HI LOW START RUN SEE HARNESS PRINT FOR TWISTED PR WIRE S...

Page 39: ... SWITCH CDT SENSOR RTT SENSOR P3 WETSIDE PRESSURE P2 CONTROL PRESSURE P1 DRYSIDE PRESSURE 5 VOLT DC NOT USED LOUVER NOT USED BATT SWITCH CAT DATA LINK CAT DATA LINK DIANOSTIC LP ENGINE WARNING LAMP ENGINE CAN J1939 CAN J1939 BATT UNSW COMPASS CONTROLLER 12 VOLT BATTERY STARTER RELAY REMOTE START INPUT STARTER STARTER SOLENOID LOUVER SOLENOID ETHER START SOLENOID SEE HARNESS PRINT FOR TWISTED PR WI...

Page 40: ...LED HOUSING NOTE XXXXX TWISTED PAIR AMP 770579 1 8 POS MIN MATE N LOCK AMP TERM 171637 1 9 PIN RECEPTACLE USES PINS 1060 16 0122 SEAL UNUSED POS START ON OFF VCH SWITCH BLOCK W AMP FASTIN FASTON 250 SERIES TERMINALS CONNECTOR 1 14 PIN RECEPTACLE USES PINS 0460 202 16141 SEAL UNUSED POSITIONS RESET HI LOW CONNECTOR 1 02250172 331 R00 LEFT ...

Page 41: ...ERLOCK SOCKETS TOGETHER IN THIS ORDER RELAY SWITCH POWER RELAY ENGINE CRANK RELAY HI LOW RELAY START RUN AMP 770024 1 2 POS MATE N LOK PIN S NOT CRUCIAL USES AMP 770008 3 15A 24V CIRCUIT BREAKER 3 PLACES USES AMP 2 34161 1 OR EQUIVALENT 10 RING TERMINAL CONNECTOR 2 CONNECTOR 2 29 PIN RECEPTACLE 02250172 331 R00 RIGHT ...

Page 42: ...42 NOTES ...

Page 43: ... Wet Weight lbs kg 16350 7416 16020 7267 15250 6917 Track width in mm 81 2050 78 1981 n a Tire Size ST235 80R16 E 8 25R15R G w tube n a Tire Pressure psi bar 65 4 5 105 7 2 n a Wheel Size 16 15 n a Lug Nut Torque ft lbs Nm 105 140 105 140 n a Max Towing Speed mph km h 55 89 15 24 n a Axle Rating lbs kg 6000 2720 12000 5443 n a Aftercooled models add 500 lbs 227 kg Table 3 2 Lubrication Guidelines ...

Page 44: ...d Com pressor Fluid Lubricating Compressor Fluid See Lubrication Guide See Lubrication Guide See Lubrication Guide See Lubrication Guide See Lubrication Guide See Lubrication Guide Receiver Tank Capacity 23 US gallons 87 liters 23 US gallons 87 liters 23 US gallons 87 liters 23 US gallons 87 liters 23 US gallons 87 liters 23 US gallons 87 liters Electrical System Engine 24 Volt Engine 24 Volt Engi...

Page 45: ...r if conditions warrant use of other extended life lubricants contact Sullair for recommendations Sullair encourages the user to participate in a fluid analysis program This could result in a fluid change interval differing from that stated in the manual Sullair Corporation offers a fluid analysis program for Sullair AWF Contact your local Sullair representative for details D A Lubricant Company I...

Page 46: ...1600C LP USER MANUAL SECTION 3 46 3 6 ID TANDEM AXLE 02250175 070 r00 ...

Page 47: ... FIT IN A 40 HIGH CUBE CONTAINER A5 ENGINE COOLANT DRAIN A6 ENGINE OIL DRAIN A7 COMPRESSOR OIL DRAIN A8 DRAIN PLUG 9 A9 TIEDOWN 4 A10 100 SPILL CONTAINMENT FRAME A11 LIFTING BAIL A12 AIR CONTROL DOOR A13 INSTRUMENT PANEL DOOR COMPASS A14 E STOP A15 OVERALL HEIGHT A16 ENGINE EXHAUST AIR OUT A17 ENGINE COOLANT PORT ACCESS COVER A18 ENGINE AIR INTAKE A19 UNIT AIR INTAKE A20 3 NPT STANDARD AIR DISCHAR...

Page 48: ...1600C LP USER MANUAL SECTION 3 48 3 8 ID 4 WHEEL 02250175 073 r00 ...

Page 49: ...IT IN A 40 HIGH CUBE CONTAINER A5 ENGINE COOLANT DRAIN A6 ENGINE OIL DRAIN A7 COMPRESSOR OIL DRAIN A8 DRAIN PLUG 9 A9 TIEDOWN 4 A10 100 SPILL CONTAINMENT FRAME A11 LIFTING BAIL A12 AIR CONTROL DOOR A13 INSTRUMENT PANEL DOOR COMPASS A14 E STOP A15 OVERALL HEIGHT A16 ENGINE EXHAUST AIR OUT A17 ENGINE COOLANT PORT ACCESS COVER A18 ENGINE AIR INTAKE A19 UNIT AIR INTAKE A20 3 NPT STANDARD AIR DISCHARGE...

Page 50: ...1600C LP USER MANUAL SECTION 3 50 3 9 ID WITHOUT RUNNING GEAR 02250175 075 r01 ...

Page 51: ...S CAN FIT IN A 40 HIGH CUBE CONTAINER A5 ENGINE COOLANT DRAIN A6 ENGINE OIL DRAIN A7 COMPRESSOR OIL DRAIN A8 DRAIN PLUG 9 A9 TIEDOWN 4 A10 100 SPILL CONTAINMENT FRAME A11 LIFTING BAIL A12 AIR CONTROL DOOR A13 INSTRUMENT PANEL DOOR COMPASS A14 E STOP A15 OVERALL HEIGHT A16 ENGINE EXHAUST AIR OUT A17 ENGINE COOLANT PORT ACCESS COVER A18 ENGINE AIR INTAKE A19 UNIT AIR INTAKE A20 3 NPT STANDARD AIR DI...

Page 52: ...NOTES 52 ...

Page 53: ...emperature Gauge Monitors the temperature of the engine coolant The normal operating temperature should read approximately 160 F to 210 F 71 C to 99 C Compass Controller Depicts system related diagnostics Can be used for system performance monitoring Compressor Discharge Temperature Gauge Monitors the temperature of the air fluid mixture leaving the compressor unit The normal reading should be app...

Page 54: ...following message will be displayed on the LCD Graphic Display 2 Turn the OFF ON START switch to the START position You do not have to hold the switch in the START position The LCD panel will show the following message Once the compressor has started the unit will enter a warm up phase At this point the unit is not producing usable compressed air and the service valve should still be closed The fo...

Page 55: ...isconnect power to all systems so that the battery is not inadvertently drained after shutdown However the engine ECM continues to draw minimal power even when the controls are powered down If the machine is not intended to be operated within the course of a week the battery dis connect should be disengaged or a charger should be installed to maintain the batteries SU_0000048 Stop Initiated Servic...

Page 56: ...NOTES 56 ...

Page 57: ...r the correct readings for their particular phase of operation 2 After the compressor has warmed up it is recommended that a general check on the overall compressor and instrument panel be made to assure that the compressor is run ning properly 3 Check the air filter restriction gauges Should they indicate restriction replace the ele ments immediately Refer to AIR FILTER MAINTENANCE on page 61 5 3...

Page 58: ...y 3 Check Engine Operator s Manual for required service 5 7 MAINTENANCE EVERY 300 HOURS When not using Sullair AWF change the compressor fluid and replace the fluid filter element Refer to MAIN FLUID FILTER SERVICING on page 60 5 8 MAINTENANCE EVERY 600 HOURS When not using Sullair AWF replace the fluid filter element only MAIN FLUID FILTER SERVICING on page 60 CAUTION The radiator and engine cool...

Page 59: ...luid filter in this section Fill the receiver tank with fluid according to Lubrication Compressor on page 43 RUNNING GEAR LUBRICATION Refer to Figure 5 1 An inspection of the running gear should be made on a routine basis On four wheel steerable running gear models front axle pivot joints and rod ends are fitted with grease zerks which should be lubricated every six months WHEEL BEARING LUBRICATIO...

Page 60: ...rease is observed remove the grease gun wipe off any excess and replace the rubber plug in the cap MAIN FLUID FILTER SERVICING Refer to Figure 5 3 The main fluid filters are located schematically in the coolant line between the receiver tank and the compressor unit The main filter elements are replaceable For installation of the filter elements follow the procedure explained below 1 The compressor...

Page 61: ...ary element change DO NOT reconnect the secondary element once it is removed ELEMENT REMOVAL 1 Clean the exterior of the air filter housing 2 Remove the cover element assembly by loosening the wingnut securing the cover element assembly 3 Remove the cover element assembly from the housing by unscrewing the wingnut 4 Clean the interior of the housing by using a damp cloth DO NOT blow out dirt with ...

Page 62: ... has been installed inspect and tighten all air inlet connections prior to resuming operation PRIMARY ELEMENT REPLACEMENT 1 Place the element in position over the sec ondary element 2 Install the cover with clean out port pointing down Clamp in place using all latches located on canister Figure 5 4 Air Filter Assembly 1 Housing 4 Primary Element 2 Secondary Element 5 Sealing Washer 3 Dust Collecto...

Page 63: ... a machine with any other operating range except for the stated operating pressure For high pressure machines adjustment pressures are shown in parenthesis 1 Start the machine and let it warm up and enter full RUN mode 2 Open service valve slightly until engine tries to speed up Slowly close the service valve With service valve closed check and adjust the pressure at the reducing regulator to a mi...

Page 64: ...s of 10 psig 0 7 bar separator element replacement is necessary Follow the procedure explained below 1 Remove all piping connected to the receiver tank cover to allow removal return line ser vice line etc 2 Remove the fluid return line from the fitting in the cover 3 Remove the twelve 12 3 4 x 3 in capscrews and lockwashers and lift the cover from the receiver tank with the minimum pressure check ...

Page 65: ...ent 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 Compressor shuts down with air demand present No fuel Check fuel gauge and add fuel if necessary Compressor discharge temperature switch is open Cooling air flow is insufficient clean cooler and check for proper ventil...

Page 66: ...ged air fluid separator Replace separator element and also change compressor fluid and fluid filter at this time Defective pressure regulator Adjust or repair Engine speed too low Readjust engine speed Control air cylinder defective Replace cylinder Excessive compressor fluid consumption Clogged return line Clear orifice Leak in the lubrication system Check all pipes connections and components Sep...

Page 67: ...light Replace the switch Check engine light Engine safety switch low coolant fault Replace the switch Caterpillar part Engine Warning flashing light Count number of flashes This will flash trouble code Determine trouble code and call Caterpillar Service Representative to correct problem SYMPTOM PROBABLE CAUSE REMEDY NOTE Additional troubleshooting tips are avail able in the Compass Controller Manu...

Page 68: ...68 NOTES ...

Page 69: ... or the causing thereof 1 The removal or rendering inoperative by any persons other than for purposes of mainte nance repair or replacement of any device or element of design incorporated into any new compressor for the purpose of noise control prior to its sale or delivery to the ulti mate purchaser or while it is in use 2 The use of the compressor after such device or element of design has been ...

Page 70: ...tem Remove and replace any defective parts by ordering with part numbers indicated in the Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date 2 ANNUAL AIR FILTER S AND AIR INLET SYSTEM INSPECTION In addition to the instructions in the Maintenance section of the Operator s Manual the air filter s and entire air inlet system should be inspected at least annually ...

Page 71: ...sing or deformed members including all hinged doors covers and their fastening devices DO NOT operate compressor with defective frame canopy and parts Remove and replace defective parts by ordering with part numbers indicated in Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date 5 ANNUAL ACOUSTICAL MATERIALS INSPECTION At least annually inspect all acoustical ...

Page 72: ...t 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 Repair or adjust per instructions in Operator s Manual as required Maintenance Performed By Location Date Maintenance Performed By Location Date ...

Page 73: ...NOTES ...

Page 74: ...Printed in the U S A Specifications subject to change without prior notice E12EP SULLAIR 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 219 879 5451 WWW SULLAIR COM ...

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