OPEN FRAME AIR COMPRESSOR

900XH - 1350XH
and Aftercooled Models

350 PSIG CATERPILLAR

OPERATORS MANUAL AND PARTS LIST
KEEP FOR FUTURE REFERENCE
Part Number

02250166-434
Sullair Corporation
The information in this document is correct at the time of printing for Portable Compressor Serial Number

200601080007
and all subsequent Serial Numbers.

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Portable compressors are presented at regular intervals throughout the year at a dedicated training facility at the Sullair corporate headquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for rental house and Contractor Maintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Corporate Training Department 1-888-SULLAIR or 219-879-5451 (ext. 5363)

www.sullair.com
- Or Write Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department

TABLE OF CONTENTS

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL

Section 1

PAGE 1 1 4 4 5 6 6 7 7 7 7 1.1 GENERAL 1.2 TOWING 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT 1.11 JUMP STARTING

SAFETY

Section 2

DESCRIPTION
9 9 10 10 11 14 15 15 18 19 20 2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION 2.9 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION 2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION 2.11 AFTERCOOLER AIR SYSTEM, SYSTEM, FUNCTIONAL DESCRIPTION

Continued...

TABLE OF CONTENTS
Section 3

SPECIFICATIONS

25 26 26 26

3.1 SPECIFICATIONS 3.2 LUBRICATION GUIDE - COMPRESSOR 3.3 APPLICATION GUIDE 3.4 LUBRICATION GUIDE - ENGINE

Section 4

OPERATION

29 29 30 30 31

4.1 GENERAL 4.2 PURPOSE OF CONTROLS 4.3 INITIAL START-UP PROCEDURE 4.4 SUBSEQUENT START-UP PROCEDURE 4.5 SHUTDOWN PROCEDURE

Section 5

MAINTENANCE

33 33 33 33 33 33 33 33 34 34 34 34 36 37 37 38

5.1 GENERAL 5.2 DAILY OPERATION 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 5.4 MAINTENANCE EVERY 100 HOURS 5.5 MAINTENANCE EVERY 250 HOURS 5.6 MAINTENANCE EVERY 300 HOURS 5.7 MAINTENANCE EVERY 500 HOURS 5.8 MAINTENANCE EVERY 1000 HOURS 5.9 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES COMPRESSOR FLUID CHANGE PROCEDURE SERVICING THE MAIN FLUID FILTER AIR FILTER MAINTENANCE CONTROL SYSTEM ADJUSTMENT SEPARATOR ELEMENT REPLACEMENT 5.10 TROUBLESHOOTING 5.11 TROUBLESHOOTING GUIDE

Section 6

NOISE CONTROL

41 41 41

6.1 NOISE EMISSIONS WARRANTY 6.2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED 35 6.3 NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG

Continued...

TABLE OF CONTENTS
Section 7

ILLUSTRATIONS AND PARTS LIST

45 46 48 52 56 58 62 66 68 70 72 74 76 78 80 82 84 86 88 94 100 104 108 108 110 112 114 116 120 122 130

7.1 PROCEDURE FOR ORDERING PARTS 7.2 RECOMMENDED SPARE PARTS LIST 7.3 ENGINE AND COMPRESSOR MOUNTING 7.4 AIR INLET SYSTEM - ALL MODELS 7.5 EXHAUST SYSTEM - ALL MODELS 7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM 7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM AFTERCOOLED 7.7 ENGINE RADIATOR ASSEMBLY - ALL MODELS 7.8 AFTERCOOLER MOUNTING - ALL MODELS 7.9 CONTROL SYSTEM HOSE ROUTING - ALL MODELS 7.10 SPEED CONTROL CYLINDER AND PARTS ALL MODELS 7.11 AIR CONTROL MANIFOLD ASSEMBLY - ALL MODELS 7.12A INLET VALVE AND PARTS (6.5) - 900XH 7.12B INLET VALVE AND PARTS (8) - 1150XH AND 1350XH 7.13A INLET VALVE PARTS - 6.5 - 900XH 7.13B INLET VALVE PARTS - 8 - 1150XH AND 1350XH 7.14A DISCHARGE SYSTEM - 900XH AND 1150XH 7.14B DISCHARGE SYSTEM - 900XH AND 1150XH AFTERCOOLED 7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED 7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED 7.15B RECEIVER AND PARTS - 1350XH STANDARD AND AFTERCOOLED 7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY 7.17 SUB-ASSEMBLY - HGIH PRESSURE FILTER / CHECK VALVE / ORIFICE 7.18 DISCHARGE / CHECK VALVE ASSEMBLY 7.19 MINIMUM PRESSURE / CHECK VALVE 7.20 FUEL SYSTEM AND PARTS - ALL MODELS 7.21 ELECTRICAL PARTS - ALL MODELS 7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS 7.23 FRAME AND PARTS 7.24 DECAL GROUP 7.25 DECAL LOCATIONS

Section 1

SAFETY
1.1 GENERAL Sullair Corporation designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. Read the CIMA Safety Manual prior to compressor operation and towing, if applicable in your area. The air compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operators Manual. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries. NEVER start the air compressor unless it is safe to do so. DO NOT attempt to operate the air compressor with a known unsafe condition. Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to operate it until the condition is corrected. Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes 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.

NOTE (cont.)

tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operators Manual, and review its instructions and other requirements for safe towing. A. PREPARING TO TOW 1. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment, checking for (i) signs of excessive wear or corrosion, (ii) parts that are cracked, bent, dented or otherwise deformed or degraded, and (iii) loose nuts, bolts or other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected. 2. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor. 3. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not, raise drawbar to engage coupling device or otherwise couple the compressor to the towing vehicle.

WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands. 4. Make sure the coupling device is fully engaged, closed and locked. 5. If chains are provided, pass each chain through its point of attachment on the towing vehicle; then hook each chain to itself by passing the grab hook over (not through) a link. Cross chains under front of drawbar before passing them through points of attachment on towing vehicle to support front of drawbar in case it should accidentally become uncoupled. 6. Make sure that the coupling device and adjacent structures on the towing vehicle (and also, if uti-

NOTE
Estimated hose life based on a 5-day 8hour work week is 3 years. These conditions exist on an 8-hour shift only. Any other operation of the equipment other than 8-hour shifts would shorten the hose life based on hours of operation. 1.2 TOWING (I)

NOTE
DO NOT tow the compressor should its weight exceed the rated limit of the
continued

(I) While not towed in the usual sense of the word, many of these instructions are directly applicable to skid-mounted portable air compressors as well.

Section 1

SAFETY
lized, chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain. 7. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render them inoperative. and reinsert the pin. Make sure the jack is secured in place prior to towing. 9. Make sure tires are in good condition and are the size (load 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. 10. If provided, make sure all dual stop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional. 11. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided. 12. Make sure all access doors and tool box covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors. 13. Make sure parking brakes in towing vehicle are set, or that its wheel are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided. 14. Make sure the compressor wheels are not chocked or blocked, and that all tie-downs, if any, are free. 15. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when conditions prevail. 16. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor. 17. DO NOT load this equipment with accessories or tools such that it is unbalanced from side to side or front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result. B. TOWING 1. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed). 2. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions. a. Two axle four-wheel steerable models: 15MPH (24KMPH).

WARNING
Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. 8. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar,

Section 1

SAFETY
b. All other models: 55 MPH (88KMPH). 3. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, Uturns, or other maneuvers. Such maneuvers can cause the compressor to tip, roll over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without warning. U-turns especially should be made slowly and carefully. 4. Avoid grades in excess of 15 (27%). 5. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain. 6. Maneuver in a manner that will not exceed the freedom of motion of the compressors drawbar and/or coupling device, in or on the towing vehicles coupling device and/or adjacent structure whether towing forward or backing up, regardless of the terrain being traversed. 7. DO NOT permit personnel to ride in or on the compressor. 8. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction. 9. DO NOT permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle. C. PARKING OR LOCATING COMPRESSOR 1. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade so the compressor does not tend to roll downhill. DO NOT park or locate compressor on grades exceeding 15 (27%). 2. Make sure compressor is parked or located on a firm surface than can support its weight. 3. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to excessive dust from the work site. 4. On four-wheel models, park compressor with front wheels in straight ahead position. 5. Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake connections, if provided. 6. Block or chock both sides of all wheels. 7. If provided, unhook chains and remove them from the points of chain attachment on the towing vehicle, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting. 8. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has sufficient load bearing capability to support the weight of the compressor.

WARNING
Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

WARNING
This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle. 9. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing. 10. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the

Section 1

SAFETY
drawbar or if hinged, to raise it to the upright position, by hand, if the weight is more than you can safely handle. Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others. 11. When possible, stow hinged drawbar in the vertical upright position. Make certain it is securely latched in the vertical upright position. Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from your hands or otherwise fall to the ground. 12. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is parked on or adjacent to public roads. Park so as not to interfere with traffic. 1.3 PRESSURE RELEASE A. Open the pressure relief valve at least weekly to make sure it is not blocked, closed, obstructed or otherwise disabled. B. Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throttle) valve, when an air hose exceeding 1/2 (13mm) inside diameter is to be connected to shutoff (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302 (b) (7) or any applicable Federal, State and Local codes, standards and regulations. C. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2 (13mm) 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 meters) of hose in runs of air hose exceeding 1/2 (13mm) 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 NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturers rated safe operating pressures for these items. G. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. 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. I. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound. J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge. K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes, standards and regulations. L. DO NOT engage in horseplay with air hoses as death or serious injury may result. M. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure. N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure. O. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand. P. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty. Q. If a manual blowdown valve is provided on the receiver, open the valve to insure 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 dispenser prior

Section 1

SAFETY
to refueling. B. Clean up spills of fuel, fluid, battery electrolyte or coolant immediately if such spills occur. C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, or when checking or adding electrolyte to batteries, or when checking or adding fluid, or when checking diesel engine ether starting aid systems or replacing cylinders, or when refilling air line anti-icer systems antifreeze compound. D. DO NOT permit liquids, including air line anti-icer system antifreeze compound or fluid film to accumulate on bottom covers or on, under or around acoustical material, or on any external or internal surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes. E. Disconnect the grounded (negative) battery connection prior to attempting any repairs or cleaning inside the enclosure. Tag the battery connections so others will not unexpectedly reconnect it. F. Keep electrical wiring, including the battery terminals and other terminals, in good condition. Replace any wiring that has cracked, cut abraded or otherwise degraded insulation or terminals that are worn, discolored or corroded. Keep all terminals clean and tight. G. Turn off battery charger before making or breaking connections to the battery. H. Keep grounded conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made. J. Remove any acoustical material or other material that may be damaged by heat or that may support combustion prior to attempting weld repairs. Remove diesel engine ether starting aid cylinders and air line anti-icer system components containing antifreeze compound, prior to attempting weld repairs in any place other than the fuel system. DO NOT weld on or near the fuel system. K. Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine. N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas. O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160F (71C). Remove ether cylinder from the compressor when operating in ambient temperatures above 60F (16C). P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result. Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the compressor or personal 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 wellventilated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150F (66C). Vapors from the antifreeze compound are heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas. DO NOT store containers or antifreeze compound in direct sunlight. S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression systems and detectors if so equipped. 1.5 MOVING PARTS A. Keep hands, arms and other parts of the body and also clothing away from belts, pulleys and other

Section 1

SAFETY
moving parts. B. DO NOT attempt to operate the compressor with the fan or other guards removed. C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts inside the enclosure. D. Keep access doors closed except when making repairs or adjustments, performing service or when starting or stopping the compressor. E. Make sure all personnel are out of and clear of the compressor prior to attempting to start or operate it. F. Shut off engine before adding fuel, fluid, coolant lubricants, air line antifreeze compound or battery electrolyte, or before replacing ether starting aid cylinders. G. Disconnect the grounded negative battery connection to prevent accidental engine operation prior to attempting repairs or adjustments. Tag the battery connection so others will not unexpectedly reconnect it. H. When adjusting the controls, it may require operation of the equipment during adjustment. DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM. Make all other adjustments with the engine shut off. When necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment. I. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, antifreeze or other liquids to minimize possibility of slips and falls. 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases. C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A. DO NOT use air from this compressor for respiration (breathing) except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal, State or Local codes or regulations.

DANGER
Death or serious injury may occur from inhaling compressed air without using proper safety equipment. See OSHA standards, and/or any Federal, State or Local codes or regulations on safety equipment. B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or wellventilated areas. D. If the compressor is operated indoors, discharge engine exhaust fumes outdoors. E. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of any portable or stationary compressor. F. Fuels, fluids, coolants, lubricants and battery electrolyte used in the compressor are typical of the industry. Care should be taken to avoid accidental ingestions and/or skin contact. In the event of ingestion seek medical treatment promptly. DO NOT induce vomiting if fuel is ingested. Wash with soap and water in the event of skin contact. G. Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, immediately flush with large quantities of water. H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting, but call a physician immediately. I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze compound to air line anti-icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourself and other personnel. J. If ethyl ether or air line anti-icer system

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SAFETY
antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for 15 minutes. A physician, preferably any eye specialist, should be contacted immediately. K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operators cabs or in other similar confined areas. L. The antifreeze compound used in air line antiicer systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, induce vomiting by administering a tablespoon of salt in each glass of clean warm water until vomit is clear, then administer two tablespoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. 1.8 ELECTRICAL SHOCK A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10 feet (3 meters) from power lines and buried cables. B. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. C. Attempt repairs only in clean, dry and well- lighted and ventilated areas. D. Stay clear of the compressor during electrical storms! It can attract lightning. 1.9 LIFTING A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local, State, Military and Federal regulations that may apply. B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight of snow, ice, mud or stored tools and equipment. If your are unsure of the weight, then weigh compressor before lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F. DO NOT attempt 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 whenever compressor is suspended. J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional 10% allowance for the weight of snow, ice, mud or stored tools and equipment. K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disengaging the lifting hook. 1.10 ENTRAPMENT A. Make sure all personnel are out compressor before closing and latching enclosure doors. B. If the compressor is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. 1.11 JUMP STARTING A. Observe all safety precautions mentioned elsewhere in this manual. B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other sources of ignition away. C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any contacted areas thoroughly with water immediately. Always wear an acid-resistant apron and face shield when attempting to jump start the compressor. D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells.

Section 1

SAFETY
E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance-free batteries). F. DO NOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60F (16C) before attempting to jump start or it may explode. G. Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start. H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result. I. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle. J. Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block both sides of all wheels. K. Place the starting vehicle in neutral or park, turn off all non-essential accessory electrical loads and start its engine. L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current. M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which might serve as a source of ignition. N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign. O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal 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 positive (POS) (+) terminal of the ungrounded battery. P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor, or when jump starting 24V compressor, to the positive (POS) (+) terminal of the ungrounded battery in the compressor. Q. Connect one end of the other jumper cable to the grounded negative (NEG) (-) terminal of the battery 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 battery in the starting vehicle. DO NOT apply 24V to one 12V battery in the compressor. S. Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening and the battery. T. Start the compressor in accordance with normal procedure. Avoid prolonged cranking. U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two (2) 12V batteries connected in series. V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps.

Section 2

DESCRIPTION
2.1 INTRODUCTION The Sullair 900XH-1350XH Open Frame Air Compressor models offer superior performance and reliability while requiring only minimal maintenance. The compressor is equipped with a Sullair rotary screw compressor unit. Compared to other compressors, the Sullair is unique in mechanical reliability and compressor durability. No inspection is required of the working parts within the compressor unit. 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 compressor in top operating condition. Read Section 5 (Maintenance) to keep your compressor in top operating condition. Should any problem or question arise which cannot be answered in this text, contact your nearest Sullair representative or the Sullair Corporation Service Department. 2.2 DESCRIPTION OF COMPONENTS Refer to Figure 2-1. The components and assem-

Figure 2-1 Sullair Rotary Screw Open Frame Air Compressor - Typical Main Component Locations

Section 2

DESCRIPTION
blies of the Sullair 900XH-1350XH Open Frame Air Compressors models are clearly shown. The package includes a compressor unit, diesel engine, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical system. The Sullair compressor unit is driven by an industrial engine designed to provide enough horsepower for more than adequate reserve at rated conditions. Refer to Engine Operator's Manual for a more detailed description of the engine. The engine cooling system is comprised of a radiator, high capacity fan and thermostats. The high capacity fan draws air through the radiator, keeping the engine at the proper operating temperature. The same fan also cools the fluid in the compressor cooling and lubrication system. Prior to passing through the radiator, the fan air also passes through the compressor fluid cooler (which is mounted adjacent to the radiator). As air passes through the cooler, the heat of compression is removed from the fluid. The same fan also cools the engines intake air supply. Prior to passing through the radiator and oil cooler, the fan air passes through an air to air aftercooler. As air passes through the air to air aftercooler heat is removed which was introduced by the engine's turbo charger. The engine is coupled to the compressor unit with a non-lubricated vulcanized rubber disc and drive flange-type coupling. On open frame compressors supplied without fuel tanks, the customer is responsible for providing fuel supply. 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION Sullair compressors feature the Sullair compressor unit, a two-stage, positive displacement, flood lubricated-type compressor. This unit provides continuous compression to meet your needs. With a Sullair compressor, no maintenance or inspection of the internal parts of the compressor unit is required with the warranty. Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three basic functions: 1. As coolant, it controls the rise of air temperature normally associated with the heat of compression. 2. Seals the leakage paths between the rotors and the stator and also between the rotors themselves. 3. Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler. After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows to your service line and the fluid is cooled in preparation for re-injection. 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-2 and 2-3A (Standard) or 2-3B (Aftercooled). The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. In addition to the cooler and fan, the system consists of a main filter, fluid stop valve and thermal valve. Fluid is used in the system as a coolant and a lubricant. The fluid is housed in the receiver/sump which from this time on will be referred to as the sump. Upon start-up, the temperature of the fluid is cool and routing to the fluid cooler is not necessary. The fluid, taking the path of least resistance, flows to the thermal valve. The thermal valve has two entrance ports and two exit ports. The entrance ports will be referred to as Port A and Port B. Port A accepts fluid from the sump and Port B accepts fluid from the cooler. The exit ports will be referred to as Port C and Port D. Port C routes fluid to the cooler and Port D routes fluid to the compressor. As previously stated, upon start-up, the fluid temperature is cool, and routing to the cooler is not required. The fluid first enters the thermal valve through Port A and then flows on to the compressor unit through Port D, 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 through Port C. The cooler is a radiator-type that works in conjunction with the engine fan. The fan draws air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve, entering at Port B. Before the temperature of the fluid becomes high enough that Port A is completely shifted, cooled fluid entering at Port B is mixed with warmer fluid entering at Port A. When the temperature of the fluid entering at Port A reaches 210F (99C), the thermal element shifts complete-

10

Section 2

DESCRIPTION
Figure 2-2 Compressor Cooling and Lubrication System

ly causing all fluid to flow to the cooler. The thermal valve incorporates a pressure relief valve, which allows fluid to bypass the cooler, if the cooler becomes plugged or frozen. This helps assure that fluid will continue to be provided to the compressor for lubrication. After the fluid passes through the thermal valve it is then directed through the main fluid filter. There the fluid is filtered in preparation for injection into the compression chamber and bearings of the compressor unit. The filter has a replaceable element and a built-in bypass valve which allows the fluid to flow even when the filter element becomes plugged and requires changing or when the viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it then flows on to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and gears. The fluid stop valve functions on shutdown when it

shuts off the fluid supply to the compressor unit. The fluid stop valve is held open by a pressure signal from the compressor discharge. At shutdown, the pressure signal is lost and the fluid stop valve closes, isolating the compressor unit form the cooling system. 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-2, 2-3A or 2-3B. The Sullair compressor unit discharges compressed air/fluid mixture into the sump. The sump has three functions: 1. It acts as a primary fluid separator. 2. Serves as the compressor fluid sump. 3. Houses the air/fluid separator. The compressed air/fluid mixture enters the sump and is directed against the side wall. By change of direction and reduction of velocity, large droplets of 11

Section 2

DESCRIPTION
Figure 2-3A Control System - 900XH, 1150XH and 1350XH Models

12

Section 2

DESCRIPTION
Figure 2-3B Control System - Aftercooled Models

13

Section 2

DESCRIPTION
fluid separate and fall to the bottom of the sump. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid collects on the element's surface, the fluid descends to the bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator element is returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet. An orifice (protected by a strainer) is included in this return line to help assure proper flow. The sump is ASME code rated at 400 psig (27.6 bar) working pressure. A minimum pressure/check valve, located downstream from the separator, helps assure a minimum receiver pressure of 140 psig (9.6 bar) during all conditions. This pressure is necessary for proper air/fluid separation and proper fluid circulation. A minimum pressure/check valve at the outlet of the receiver is installed to prevent compressed air in the service line from bleeding back into the receiver on shutdown when the compressor is being run in parallel with other compressors tied to a large air system. A pressure relief valve (located on the wet side of the separator) is set to open if the sump pressure exceeds 400 psig ( 27.6 bar). A temperature switch will shut down the compressor if the discharge temperature reaches 265F (129C) or 250F (121C) for the interstage. The compressor unit discharges compressed air/fluid mixture through a discharge check valve into the sump. The discharge valve is located on the rear of the compressor unit at the end opposite the drive shaft. The discharge check valve prevents discharged air from returning to the compression chamber after shutdown. Fluid is added to the sump via a capped fluid filler. A fluid level gauge glass enables the operator to visually monitor the sump fluid level. 2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-3A or 2-3B. The purpose of the control system is to regulate the amount of air intake in accordance with the amount of compressed air demand. The control system consist of an inlet valve, the high and low pressure regulators, the pressure reducing regulator, the blowdown/running blowdown valve, the engine speed control cylinder, a start-run selector valve, and the high-low selector valve. START MODE - 0 TO 200 PSIG (0 TO 13.8 BAR) When starting the compressor, the start-run valve should be in the start position with the high-low selector valve in low position. In the START position, the inlet valve is held closed by the springs in the inlet valve. The valve is cracked open by vacuum in the compressor and is allowed to build up to 200 psig. The reason for keeping the valve closed during start is to allow the engine to warm up without being loaded by the compressor. Air pressure is contained in the receiver tank by the minimum pressure valve which has a set point of 200 psig. (13.8 bar), At this point the valve opens allowing the air to pass to the service valve. After engine has warmed up the run-start selector valve can be switched to the run position. LOW PRESSURE MODE - 200 PSIG (13.8 BAR) With the high-low valve in the low position, the startrun valve can now be switched to the run position. With the service valve open, pressure from the 60 psig (4.1 bar) reducing regulator opens up the inlet valve and increases the engine speed to full load (1800 rpm). As the demand for air decreases the speed cylinder retracts, the engine rpm returns to idle (1400 rpm) and the inlet valve closes, where it stabilizes until the air demand is required. HIGH PRESSURE MODE - 350 PSIG (24.1 BAR) When the selector valve is switched to the high pressure position the low pressure regulator is blocked off allowing the high pressure regulator to take over control of the machine. The 60 psi (4.1 bar) reducing regulator fully opens the inlet valve and strokes the speed cylinder for maximum rpm. As the pressure reaches the set point of the system the high pressure regulator cracks open and closes the inlet valve and allows the speed cylinder to return the engine back to idle, until the demand for air is seen. SHUTDOWN The blowdown valve is normally closed. When the compressor is shutdown, system pressure backs up

NOTE
DO NOT remove caps, plugs, and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal pressure before doing so.

14

Section 2

DESCRIPTION
Figure 2-4 Control System Diagram

02250077-331R03

to the inlet valve causing the check spring in the inlet valve to close the air inlet valve. This sends a pressure signal to the blowdown valve causing it to open and vent the pressure in the system. After the pressure is vented, the blowdown valve spring returns the blowdown valve to the closed position. 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION The compressor inlet system consists of two air filters, a compressor air inlet valve and interconnecting piping to the engine and compressor. Also, nylon tubing from air filter restriction indicator gauges on instrument panel are provided. The air filters are 2-stage units with a safety element dry element-type filter. This filter is capable of cleaning extremely dirty air. However, in such cases, frequent checks of the air 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. See 2.8

Section 5 for Air Filter Maintenance Procedures. These indicators should be checked daily, after start-up under normal conditions. The compressor air inlet valve controls the amount of air intake of the compressor in response to the air demand. INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION Refer to Figure 2-5A. The instrument panel group consists of an EMS (Engine Monitoring System). On the EMS unit there are ten warning lamps available for system related diagnostics. These diagnostics can be used for system performance monitoring. They are located on the main EMS unit in two rows of five: coolant temperature, intake manifold temperature, fuel temperature, battery voltage, accessory temperature, engine oil pressure, fuel pressure, coolant level, engine derate, and accessory pressure. See Figure 2-5A for functional lamps. Beneath the warning lamps is a digital LCD display to scroll through different engine and machine parameters. Digital readouts are as follows:

15

Section 2

DESCRIPTION
Figure 2-5A EMS (Engine Monitoring System) Unit

engine speed:

intake manifold temperature:

SPd
engine oil pressure:

L Air
fuel temperature:

GA -1
coolant temperature:

FUEL
accessory pressure (not used):

GA -2
not used:

ACCR P
accessory temperature (not used):

GA -3
fuel pressure (not used):

ACCR
fuel rate:

GA -4
engine boost:

FUEL
engine running hours:

boos

HRS

16

Section 2

DESCRIPTION
Figure 2-5B Instrument Panel Group Description). The air pressure gauge continually monitors the sump pressure at various load and/or unload conditions. The voltmeter monitors the condition of the batteries and the charging circuit. The normal reading is 24 to 28 volts. The compressor discharge temperature gauge monitors the temperature of the air/fluid mixture leaving the compressor unit. The normal reading should be approximately 200F to 230F (93C to 110C). The engine switch is used both to energize the compressor's electrical system and engage the engine/starter. The knob-type switch works similar to an automotive key switch; it turns in a clockwise direction with "off" being the first position, "ignition" the second and "start" being the third position. It also has a built-in anti-restart device that protects the starter from engaging while the engine is running. The switch must be turned back to the "off" position before the engine can be re-started.

percent engine load:

LOAd
Refer to Figure 2-5B for locations of the following indicators and controls: The warning lamp is on or flashing when an engine operation problem had been detected by the engine electronics. This usually does not indicate an electronic malfunction. This light can be used along with the EMS lights to determine malfunction. Consult Table 1 - Engine to Warning Lamp Actions for engine to warning lamp actions. Time To Shutdown is defined as the time before the engine will shut down following initial activation of the diagnostic code. It is assumed the engine has been running for at least 30 seconds before diagnostic code activation. Start/Restart Time is defined as the time before a shutdown occurs if conditions causing the diagnostic code(s) are present at start up. The check engine lamp is used to flash diagnostic fault codes (See Section 2.9, Engine Control Module, Functional

NOTE
When re-starting the compressor, make sure receiver tank pressure has blown down to 10 psig (0.7 bar) or less. More than 10 psig (0.7 bar) can put extra load on the starter. The warm-up control valve is provided for cold weather starting. When placed in the "start" position, the warm-up control valve cuts off the pressure signal to the pressure regulating valve causing the inlet valve to remain closed. It will allow the engine to run unloaded until it is properly warmed up at which time the valve should be set in the "run" position. The engine air filter restriction gauge is provided to monitor engine air filter condition. A reading over 20 inches of water or in red zone indicates time to service the air filter. The compressor air filter restriction gauge is provided to monitor the unit air filter condition. A reading over 20 inches of water or in red zone indicates time to serv-

17

Section 2

DESCRIPTION
Table 1 - Engine to Warning Lamp Actions CID-FMI 100 - 01 100 - 11 105 - 00 105 - 11 110 - 00 110 - 11 111 - 01 111 - 11 Description Low Fluid Pressure Warning Very Low Fluid Pressure High Inlet Manifold Air Temperature Warning Very High Inlet Manifold Air Temperature High Coolant Temperature Warning Very High Coolant Temperature Low Coolant Level Warning Very Low Coolant Level Warning Warning Lamp ON Flashing ON ON Flashing Flashing On Flashing Time to Shutdown No 30 Seconds No No No 20 Seconds No 30 Seconds Start/Restart Time No 18 Seconds No No No 60 Seconds No 80 Seconds

ice the air filter. The sump tank separator element restriction gauge is provided to monitor sump tank separator element restriction. A reading over 10 psid (0.7 bar) or in red zone, indicates time to service the element. The scroll switch toggled to the left will indicate gauges pertaining to the engine. Toggled to the right will convert reading from Metric to English. Check engine and warning lamp for further engine diagnostics. See Section 2.9 and Table 2, Possible Performance Effect of Active Diagnostic Codes. The compressor discharge high temperature light or the low fuel level light will remain on, indicating the specific problem, until the rotary switch (engine switch) is turned to "OFF" position. When the starter switch is initially turned on, the lights will come on to check bulb function. The lights should go out after 15 seconds. The low fuel lamp indicates a low fuel shutdown or open circuit. The compressor high temperature lamp indicates a receiver or discharge high temperature shutdown. Could also indicate an open circuit. HI/LO selector valve; HI position allows machine to operate at rated pressure (350 psig [24.1 bar]). The LO position forces machine to run at ( 175 psig [ 12.1 bar]) rated speed.

NOTE
An open in any safety circuit will not allow machine to start. 2.9 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION Diagnostic Fault Codes are provided to indicate an electrical or electronic problem has been detected by the ECM (Engine Control Module). In some cases the engine performance can be affected when the condition causing the code exists. More frequently, however, the operator cannot detect any difference in the engine performance. If the operator indicates a performance problem occurs whenever the Check Engine Lamp is flashing, the diagnostic code may indicate the cause of the problem, and should be corrected. If the operator does not indicate a problem with the engine performance and a diagnostic code is logged by the ECM, it indicates the ECM detected an abnormal condition, but it did not affect performance. If this is the case, unless there are several occurrences of the code in a very short period of time, or, the ECM is indicating an Active Code at the present time, there is most likely nothing wrong with the system. The diagnostic FLASH CODE may be retrieved using this lamp. The lamp is not required for engine operation, however it can be useful to determine Active diagnostic codes. The lamp will illuminate (ON) at initial ECM

18

Section 2

DESCRIPTION
power-up to test the lamp operation (self test). The lamp will begin to flash (ON, then OFF, ON...) after the five second self test. The sequence of flashes represent the Flash Code diagnostic message. Count the first sequence of flashes to determine the first digit. After a two second pause, count the second sequence of flashes to determine the second digit. Any additional flash code diagnostics will follow (after a pause) and will be displayed in the same manner. Diagnostic Codes. 2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-7. 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 electrical system are an engine starter (with an integral solenoid), battery, an alternator with a built-in voltage regulator, a compressor discharge temperature switch (which will shut down the compressor should the compressor temperature exceed 265F [130C]), a low coolant shutdown switch and a low fuel shutdown switch. This compressor also incorporates an engine coolant level detector. This device is located in the top tank on the engine radiator. It will shut the compressor down or prevent it from being started if the engine coolant level drops too low. In addition, there is a starter protection relay which prevents accidental starter engagement after the engine is running or whenever there is pressure in

NOTE
Only Active diagnostic codes can be read in this manner. Logged diagnostic codes must be retrieved with an Electronic Service Tool. See Table 2, Possible Performance Effect of Active Diagnostic Codes, for possible effect of Active

Figure 2-6 Aftercooled Compressed Air Discharge System

19

Section 2

DESCRIPTION
the receiver/sump. Also, should fuel supply level drop near bottom of the fuel tank, a switch will shut down the machine before the engine actually runs out of fuel. 2.11 AFTERCOOLER AIR SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-3B and 2-6. The purpose for the aftercooled system is to operate the air compressor in conditions when compressed air temperatures required to be 10-25F (5 to 13C) over ambient temperature.Two discharge valves are provided on all 900XH -1350XH compressor models. One valve is labeled standard air and one valve is labeled aftercooled air. Closing the standard air (non-aftercooled) valve completely forces the air flow the from receiver tank to the aftercooler. The ambient air, 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 separator where condensation is removed from the cooler air and discharged. This condensate does carry some oil and it should be disposed of properly in accordance with local regulations. From the moisture separator the compressed air goes to the compressor service valve.

NOTE
After-cooler system should not be operated in ambient conditions below 32 F (0C). If it is necessary to operate in these conditions, Sullair can supply optional equipment to accommodate this requirement. To operate in the non-aftercooled mode close the aftercooler service valve completely and open non-aftercooler valve.

20

Section 2

DESCRIPTION
Table 2 - Possible Performance of Active Diagnostic Codes
Flash Code 12 13 Description of Code Incorrect Crank-without-inject inputs Fuel Temperature open/short to +batt Fuel Temperature short to ground 5 Volt Sensor DC Power Supply short to +batt 21 5 Volt Sensor DC Power Suppy short to ground Digital Sensor Supply short to +batt Digital Sensor Supply short to ground Engine Oil Pressure open/short to +batt 24 Engine Oil Pressure open/short to ground Turbo Outlet Pressure above normal Turbo Outlet Pressure open/short to +batt Turbo Outlet Pressure short to ground 26 27 28 32 Atmospheric Pressure open/short to +batt Atmospheric Pressure short to ground Engine Coolant Temperature open/short to +batt Engine Coolant Temperature short to ground Throttle Position calibration required Throttle Position signal abnormal Speed/Timing Sensor Loss of Signal 34 Speed/Timing Sensor mechanical failure Loss of Secondary Engine Speed signal Secondary Engine Speed Sensor mechanical failure Engine Overspeed Shutdown Engine Overspeed Warning Fuel Pressure open/short to +batt 37 Fuel Pressure short to ground Engine Oil Temperature open/short to +batt Engine Oil Temperature short to ground Intake Manifold Air Temp open/short to +batt Intake Manifold Air Temp short to ground Engine Timing calbiration required Low Engine Oil Pressure Warning 46 51 53 56 Low Engine Oil Pressure Derate Low Engine Oil Pressure Shutdown System voltage intermittent/erratic Electronic Control Module Error Personality Module mismatch Check Prgrammable Paramters CID-FMI SPN-FMI Engine Low Code Code Misfires Power 266-02 174-03 174-04 262-03 262-04 263-03 263-04 100-03 100-04 273-00 273-03 273-04 274-03 274-04 110-03 110-04 91-13 91-08 320-02 320-11 342-02 342-11 004 190 94-03 94-04 175-03 175-04 172-03 172-04 261-13 100 039 040 168-02 254-12 253-02 268-02 266-02 174-03 174-04 620-03 620-04 678-03 678-04 100-03 100-04 102-00 102-03 102-04 108-03 108-04 110-03 110-04 91-03 91-08 190-02 190-11 723-02 723-11 0190-16 0190-00 94-03 94-04 175-03 175-04 172-03 172-04 228-13 0100-17 0100-18 0100-01 168-02 no code 234-02 111-02 X X X (I) X X X X (I) X X X (I) X X X (II) X X X X X X X Reduced Engine Engine Shutdown Speed

25

X X

X X X X

X X X X X (I) X (I) X (I) X (I)

35

38 42

X X X

X X X

X X X

(I) The engine will shut down if both speed/timing sensors are lost. (II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down. CID = Component Identifier SPN = Suspect Paramater Number FMI = Failure Mode Identifier

Continued... 21

Section 2

DESCRIPTION
Table 2 - Possible Performance of Active Diagnostic Codes (continued)
Flash Code 58 61 Description of Code J1939 Data Link communications High Engine Coolant Temperature Derate High Engine Coolant Temperature Shutdown High Engine Coolant Warning Low Engine Coolant Level Derate Low Engine Coolant Level Shutdown Low Engine Coolant Level Warning CID-FMI SPN-FMI Engine Low Code Code Misfires Power 247-09 015 016 017 057 058 059 639-09 0110-16 0110-00 0110-15 0111-018 0111-01 0111-17 Reduced Engine Engine Shutdown Speed

62

63

Fuel Filter Restriction Derate Fuel Filter Restriction Shutdown Fuel Filter Restriction Warning High Fuel Pressure High Inlet Temperature Derate High Inlet Temperature Warning High Fuel Temperature Derate High Fuel Temperature Shutdown High Fuel Temperature Warning Injector Cylinder #1 Fault Injector Cylinder #2 Fault Injector Cylinder #3 Fault Injector Cylinder #4 Fault Injector Cylinder #5 Fault Injector Cylinder #6 Fault Ether Start Relay open/short to +batt Either Start Relay short to ground

005 006 095 096 025 027 054 055 056 1-11 2-11 3-11 4-11 5-11 6-11 545-05 545-06

0094-15 0094-16 0094-00 0094-00 0172-16 0172-15 0174-16 0174-00 0174-15 651-11 652-11 653-11 654-11 655-11 656-11 545-05 545-06 X X X X X X X X X X X X

64

65

72 73 74 00

CID = Component Identifier

SPN = Suspect Paramater Number

FMI = Failure Mode Identifier

22

Section 2

DESCRIPTION
Figure 2-7 Wiring Diagram

02250145-161R01

23

NOTES

24

Section 3

SPECIFICATIONS
3.1 SPECIFICATIONS Model Series in 900XH, 1150XH & 1350XH OPEN FRAME Length mm 44498 Width in 87.5 mm 2222 in 89 Height mm 2261 Weight (wet) (I) lb kg 12500 5670

177.1

(I) Aftercooled add 500 lbs / 227 kg

COMPRESSOR : Type : Maximum Operating Pressure : Rated Pressure : Delivery at 350 psig (34.5 bar) : Cooling : Lubricating Compressor : Sump Capacity : Operating Tilt (maximum) : Electrical System : Battery (2) : Alternator : Service Valves : ENGINE : Make : Type : Rated Speed : Horsepower, SAE : Cylinders : Cycles : Bore x Stroke : Displacement : Lubricating System : Type of Motor Oil: Radiator Capacity : Idle Speed : 900XH MODELS Rotary Screw 350 psig (24.1 bar) 350 psig (24.1 bar) 900 Free CFM (25.5 M3/min) Pressurized Compressor Fluid Consult Lubrication Guide 58 U.S. Gallons (219.6 liters) 15 Engine - 24 Volt Instrument System - 24 Volt 1400cca @ 32F (0C) (8D) 1125cca @ 0F (-18C) 45 amp 2 npt 900XH MODELS Caterpillar Cat C15 ATAAC TIER II (I) 1800 RPM 450 HP (336 kw) 6 4-cycle 5.4 x 6.5 inches (137 x 165 mm) 893 cubic inches (14.6 liters) Full Pressure Fluid See Engine Operators Manual 30 U.S. gallons (113 liters) 1400 RPM 1150XH MODELS Rotary Screw 350 psig (24.1 bar) 350 psig (24.1 bar) 1150 Free CFM (32.6 M3/min) Pressurized Compressor Fluid Consult Lubrication Guide 58 U.S. Gallons (219.6 liters) 15 Engine - 24 Volt Instrument System - 24 Volt 1400cca @ 32F (0C) (8D) 1125cca @ 0F (-18C) 45 amp 2 npt 1150XH MODELS Caterpillar Cat C16 ATAAC TIER II (I) 1800 RPM 525 HP (392 kw) 6 4-cycle 5.4 x 6.5 inches (137 x 165 mm) 893 cubic inches (14.6 liters) Full Pressure Fluid See Engine Operators Manual 30 U.S. gallons (113 liters) 1400 RPM 1350XH MODELS Rotary Screw 350 psig (24.1 bar) 350 psig (24.1 bar) 1350 Free CFM (38.2 M3/min) Pressurized Compressor Fluid Consult Lubrication Guide 58 U.S. Gallons (219.6 liters) 15 Engine - 24 Volt Instrument System - 24 Volt 1400cca @ 32F (0C) (8D) 1125cca @ 0F (-18C) 45 amp 2 npt 1350XH MODELS Caterpillar Cat C16 ATAAC TIER II (I) 1800 RPM 630 HP (470 kw) 6 4-cycle 5.5 x 6.75 inches (140 x 171 mm) 964 cubic inches (15.8 liters) Full Pressure Fluid See Engine Operators Manual 30 U.S. gallons (113 liters) 1400 RPM

(I) Air to air aftercooled.

25

Section 3

SPECIFICATIONS
3.2 LUBRICATION GUIDE - COMPRESSOR FLUID TYPE CHANGE PERIOD, HOURS Sullair AWF (I) Mobil Rarus SHC 1026 Mobil Rarus SHC 1024 500 800 1000 AMBIENT TEMPERATURE RANGE F (C) -20 to 120 (-29 to 49) 50 to 125 (10 to 52) -20 to 100 (-29 to 38)

(I) Sullair part numbers for multi-viscosity lubricants are 250030-757 for 5 gallon / 20 liter container, and 250030-758 for 55 gallon / 208 liter container. 3.3 APPLICATION GUIDE Refer to Figure 3-1. Sullair Air Compressors are supplied with Sullair AWF which is heavy duty multiviscosity, all-weather fluid. Sullair AWF also allows an extended change interval. Detergent motor oils (SAE 10W Class SE, SF, SG or CD) can also be used. Any of these oils are suitable under conditions where severe oil oxidations can occur. Water must be drained from the receiver periodically. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a milky color. SAE 10W is especially prone to this condition. The fluid should be changed if this condition develops. When ambient conditions exceed those noted or 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 Inc. offers an analysis program for users of D-A products and Sullair AWF. Contact your D-A lubricant supplier or Sullair representative for details. 3.4 LUBRICATION GUIDE - ENGINE For engine oil specifications, refer to the Engine Operators Manual.

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.

Figure 3-1 Fluid and Fuel Fill Port Locations - Typical Locations

NOTE
When performing a fluid change or topping off the fill, the proper level should be at half of the sight glass, with the machine off.

26

Section 3

SPECIFICATIONS
Figure 3-2 Identification - Compressor Assembly

02250135-977R03

27

NOTES

28

Section 4

OPERATION
4.1 GENERAL While Sullair has built into this compressor a comprehensive array of controls and indicators to assure you that it is operating properly, you will want to recognize and interpret the reading which
4.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR ENGINE SWITCH PURPOSE

will call for service or indicate the beginning of a malfunction. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators - their purpose, location and use.

The engine switch is used to both energize the compressors electrical system and engage the engine/starter. The rotary type switch works similar to an automotive key switch; it turns in a clockwise direction with off being the first position, ignition the second and start being the third position. It also has a built-in anti-restart device that protects the starter fromengaging while the engine is running. The switch must be turned back to the off position before the engine can be re-started. NOTE When re-starting the compressor,make sure receiver tank pressure has blown down to (10 psig 0.7 bar) or less. More than 0.7 bar (10 psig ) can put extra load on the starter.

VOLTMETER

Monitors the condition of the batteries and the charging circuit. The normal reading is 24 to 28 volts. Continually monitors the pressure inside the receiver tank at various load and unload conditions. Monitors the temperature of the engine water. The normal operating temperature should read approximately 160F to 210F (71C to 99C ). Depicts system-related diagnostics. Can be used for system performance monitoring. Monitors the temperature of the air/fluid mixture leaving the compressor unit. The normal reading should be approximately 200F to 230F (93C to 110C). Prevents starter engagement when the air system is pressurized. Monitors the fluid level in the sump. Proper level is always visible in the sight glass. Check the level when the compressor is shut down. Opens the electrical circuit to shut down the compressor when the discharge temperature reaches 265F (124C) or 250F (121C) for interstage. Provides regulated air pressure to the inlet valve and engine speed control to open the inlet valve and move engine governor to full speed with warm-up valve in therun position. Provides an air signal to the inlet valve and engine speed cylinder to close the inlet valve and reduce engine speed to control air delivery according to demand. Continued on page 30 29

AIR PRESSURE GAUGE ENGINE WATER TEMPERATURE GAUGE

EMS (ENGINE MONITORING SYSTEM) COMPRESSOR DISCHARGE TEMPERATURE GAUGE SYSTEM PRESSURE SWITCH FLUID LEVEL SIGHT GLASS

COMPRESSOR DISCHARGE TEMPERATURE

REDUCING REGULATOR VALVE

BACK PRESSURE REGULATING VALVE

Section 4

OPERATION
4.2 PURPOSE OF CONTROLS (CONTINUED) CONTROL OR INDICATOR PURPOSE

MINIMUM PRESSURE / CHECK VALVE

Maintains a minimum of 200 psig (13.8 bar) in the compressor sump. This valve restricts receiver air discharge from receiver/sump when pressure falls to 200 psig (13.8 bar). Also prevents back flow into the sump during unload conditions and after shutdown. Select high pressure (350 psig) or low pressure (200 psig) at instrument panel to correspond to operators needs. Opens sump pressure to the atmosphere should pressure inside the sump exceed 400 psig (27.6 bar). Regulates the amount of air allowed to enter the air inlet valve. This regulation is determined by the amount of air being used at the service line. Vents sump pressure to the atmosphere at shutdown. Regulates flow of fluid to and around the fluid cooler. Designed to maintain a minimum operating temperature; used for fast warm-up at start-up and to eliminate condensation during operation. Allows the engine to run at unload speed (lower pressure) until properly warmed up. Vents surplus sump pressure to the atmosphere during operation. 10. Turn engine switch to the ignition position. 11. Turn engine switch to start position and hold until engine starts (maximum 15 seconds). 12. When engine coolant temperature reaches 110F (43C), turn arrow on start-run valve handle to RUN position. Compressor is now ready for full load operation. 13. After the initial run, shut the compressor down and refill the radiator and compressor fluid sump as required. Tighten any loose fittings and check fan belt tension. 4.4 SUBSEQUENT START-UP PROCEDURE On subsequent starts, follow the procedure explained below: 1. Position compressor on level ground so fluid level can be read accurately. Check fluid level and add as needed. 2. Close and latch all doors except instrument panel door. 3. Close all service valves and turn arrow on startrun valve handle down to start position.

HI/LO SELECTOR VALVE PRESSURE RELIEF VALVE AIR INLET VALVE

BLOWDOWN VALVE THERMAL VALVE

START/RUN CONTROL VALVE BLOWDOWN VALVE

4.3 INITIAL START-UP PROCEDURE The following procedure should be used to make the initial start-up of your compressor: 1. Position the compressor on a level surface so that proper amounts of liquid can be added if necessary. (I) 2. If needed, add a water and ethylene glycol solution to the engine radiator. Engine cooling system capacity is 30 gallons (113 liters). 3. Fill compressor fluid sump with fluid as recommended in Section 3, Specifications. System capacity is 58 gallons (220 liters). 4. Check engine oil level and add if necessary. 5. Check the fuel supply. 6. Fill the battery with electrolyte, if necessary. 7. Close and latch all doors except instrument panel door. 8. Close all service valves and turn arrow on startrun valve handle down to start position. 9. Below 40F (4C) use starting aid (per instructions printed on starting aid device).

(I) The radiator is filled with a 50/50 mixture of ethylene glycol and water at the factory before shipment.

30

Section 5

MAINTENANCE
4. Below 40F (4C) use starting aid (per instructions printed on starting aid device). 5. Turn engine switch to the ignition position. 6. Turn engine switch to start position and hold until engine starts (maximum 15 seconds). 7. When engine coolant temperature reaches 110F (43C), turn arrow on start-run valve handle upward to RUN position. 8. Compressor is now ready for full load operation. 4.5 SHUTDOWN PROCEDURE To shut the compressor down, close the service valves and turn the start/run control valve to the start position. Run compressor for approximately 5 minutes; then turn the on/off switch to the off position. In case of emergency where immediate shutdown is required, this procedure is not necessary. The on/off switch should be put in the off position immediately.

31

NOTES

32

Section 5

MAINTENANCE
5.1 GENERAL A good maintenance program is the key to long compressor life. Below is a program that when adhered to, should keep the compressor in top operating condition. For engine maintenance requirements, refer to the Engine Operator's Manual for a detailed description of service instructions. See Parts Replacement and Adjustment Procedures for a detailed description of specific compressor system components. Prior to performing maintenance, read the CIMA Safety Manual, if applicable. Also check the air filter restriction gauges. Should they indicate restriction, replace the elements immediately (see Air Filter Maintenance in Section 5.10). 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation, a few simple maintenance routines can rid the system of any possible foreign materials, if any. Perform the following maintenance operations to prevent unnecessary problems. 1. Clean the return line orifice and strainer. 2. Change compressor fluid filter. 3. Check Engine Operator's Manual for required service. 5.4 MAINTENANCE EVERY 100 HOURS After 100 hours of operation, it will be necessary to perform the following: 1. Check the battery level and fill with water if necessary. 5.5 MAINTENANCE EVERY 250 HOURS Perform the following after every 250 hours of operation: 1. Check fan belt tension. 2. Clean the radiator and cooler exterior. Depending on how contaminated the atmosphere may be, more frequent cooler and radiator cleaning may be necessary. To clean between fluid cooler and radiator, the three (3) bolts securing the top of the fluid cooler to the top mounting bracket should be removed, allowing the fluid cooler to swing down on its lower hinge. This will allow easier access to clean between the fluid cooler and radiator cores. 3. Check Engine Operator's Manual for required service. 4. Change the engine oil and oil filter. This is best done when the engine is hot. 5.6 MAINTENANCE EVERY 300 HOURS When using fluids other than Sullair AWF, change the compressor fluid and replace the fluid filter element (See maintenance procedure in Section 5.10). 5.7 MAINTENANCE EVERY 500 HOURS When using Sullair AWF, replace the fluid filter element and change compressor fluid. (See maintenance procedures in Section 5.10). 5.8 MAINTENANCE EVERY 1000 HOURS Perform the following after every 1000 hours of operation:

WARNING
DO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal pressure before doing so. Stop compressor and relieve all internal pressure before doing so. 5.2 DAILY OPERATION Prior to starting the compressor, it is necessary to check the fluid level in the sump. Should the level be low, simply add the necessary amount. If the addition of fluid becomes too frequent, a simple problem has developed which is causing this excessive loss. See the Troubleshooting Section (5.11) under Excessive Fluid Consumption for a probable cause and remedy. Also check the engine oil level and the radiator coolant level prior to starting.

NOTE
The radiator and engine cooling system must be drained and flushed every two (2) years. Replace the coolant with a solution of 50% ethylene glycol and 50% water or as required for your geographic location. DO NOT use a leak sealing type of anti-freeze. Should a 100% water solution be used, a nonchromate rust inhibitor must be added. After a routine start has been made, observe the instrument panel gauges and be sure they monitor the correct readings for their particular phase of operation. 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 running properly.

33

Section 5 MAINTENANCE
1. Clean the return line orifice and strainer. 5.9 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES COMPRESSOR FLUID CHANGE PROCEDURE Warm-up the compressor for 5 to 10 minutes to warm the fluid. Shut the compressor off and relieve all internal pressure before proceeding. Drain the fluid sump by removing the plug at the bottom of the sump tank. Change the compressor fluid and replace the fluid filter element. For element replacement see procedure for servicing the fluid filter in this section. Fill the sump with fluid according to specifications in Section 3. SERVICING THE MAIN FLUID FILTER Refer to Figure 5-1. The main fluid filter (P/N 02250111-592) is located schematically in the coolant line between the receiver/sump and the compressor unit. The main filter element is replaceable. For installation of the filter element and o-ring kit (P/N 250031-850), follow the procedure explained below. 1. The compressor MUST be shut off and system pressure MUST be relieved. 2. Drain by removing drain plug at bottom of bowl and catching drainage in a container. 3. Rotate bowl counterclockwise and remove. 4. Remove element and o-ring from housing and discard. This element is NOT cleanable. 5. Make sure mounting surface of filter head is Figure 5-1 Main Filter (P/N 02250111-592) clean. 6. Apply a light film of fluid to o-ring and place it in its proper position. 7. Place new, clean element in housing, centering it on location in the head. 8. Inspect bowl seal and replace if necessary. 9. Replace bowl. Rotate clockwise and hand-tighten. 10. Replace drain plug. Torque to 15-20 ft.-lbs. (2027 Nm). AIR FILTER MAINTENANCE Refer to Figure 5-2. Air filter (P/N 02250049-036 [engine]) (P/N 02250053-402 [compressor]) maintenance should be performed when indicated on instrument panel by the engine air filter restriction gauge. The air filters are both equipped with a primary element and secondary element each.

NOTE
DO NOT strike elements against any hard surface to dislodge dust. This will damage the sealing surfaces and possibly rupture the elements. The secondary element must be replaced after every third primary element change. DO NOT reconnect the secondary element once it is removed.

*Repair Kit P/N 250031-850

34

Section 5

MAINTENANCE
Figure 5-2 Air Filter (P/N 02250049-036 [engine] and P/N 02250053-402 [compressor])

*Primary Replacement Filter Element P/N 02250051-238 **Secondary Replacement Filter Element P/N 02250051-239 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 compressed air as this may introduce dust downstream of the filter. 5. When it becomes necessary to remove the secondary element, pull the element out of the housing. 6. Install the new secondary element over the rod. 7. With the secondary element in place, replace the primary element. ELEMENT INSPECTION 1. Place a bright light inside the element to inspect for damage or leak holes. Concentrated light will shine through the element and disclose any holes. 2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident, correct the condition immediately. 3. If the clean element is to be stored for later use, it must be stored in a clean container. 4. After the element 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 threaded rod and tighten the wingnut. 2. Install the cover, replace the clamp and tighten the wingscrew.

35

Section 5 MAINTENANCE
Figure 5-3 Control System Components

CONTROL SYSTEM ADJUSTMENT Refer to Figure 5-3, or control schematic (Figure 23). Prior to adjusting the control system, it is necessary to determine the desired operating pressure range as well as the maximum pressure at which the machine is to operate. This pressure must not exceed the maximum operating pressure which is stamped on the machine serial number plate. The following explanation applies to a typical machine with a desired operating range of 200 to 350 psig (13.8 to 24.1 bar). This information will apply to 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 with warmup valve in "start" position. Check for leaks around connections.

2. Open service valve slightly and turn the warm-up valve to "run" position. Slowly close the service valve, watching the pressure gauge to insure the unload pressure does not exceed 350 psig (24.1 bar) . If it does, the control regulator set screw must be backed out until the compressor will unload. With service valve closed, check and adjust the pressure at the reducing regulator for a 60 psig (4.1 bar) setting. With service valve still closed, adjust the high pressure back pressure regulator on 350 psig [25.5 bar] machines to maintain a discharge pressure of 350 psig (24.1 bar) . Machine speed must be 1400 RPM, check instrument panel. Open the service valve to load the compressor to maintain 350 psig (24.1 bar) discharge pressure. Operating speed should be 1800 RPM on the instrument panel. 3. For 200 psig (13.8 bar) machines turn the pres-

36

Section 5

MAINTENANCE
sure selector valve to "low" position. Close the service valve and set the low pressure back pressure regulator to maintain 210 psig (14.5 bar) discharge pressure. Open the service valve to maintain 200 psig (13.8 bar) and check for 1800 RPM full load speed. If lower speed is observed, raise the setting of the low pressure control regulator until rated speed is achieved. SEPARATOR ELEMENT REPLACEMENT Refer to Figure 5-4. When the need for a separator element replacement is indicated by the maintenance indicator (usually mounted to the air receiver/separator tank but can also be remote mounted), use the following procedure for separator replacement. 1. Remove the air receiver/separator tank lid by removing the twelve (12) hex head capscrews. 2. Remove the 3/4"-10 jam nut and sealing hex nut from the 3/4"-10 separator hold down rod. 3. Remove the round separator cover plate from the top of the separator element. 4. Remove the old separator element and discard. 5. Scrape the old gasket material from the tank lid mounting surface and the flanges mounting surface on the tank. Be sure to keep all scrapings from falling back inside of the tank. 6. Before installing the new separator element, make sure to lubricate both sealing o-rings on the element with a lubricating compound (i.e. Silglyde). Then install the new separator element, the cover plate, the new 3/4"-10 sealing hex nut, and the 3/4"-10 jam hex nut. Torque the sealing hex nut to 85 to 90 ft.-lbs. (115 to 122 Nm). DO NOT over-tighten, as damage to separator element can result. 7. Next, install the tank flange gasket that is provided. Before installing, lubricate both sides of the gasket (i.e. Silglyde). Reinstall the tank lid. Install the capscrews finger tight, then gradually tighten in a crisscross pattern in 4 to 5 steps. Always tighten the capscrews alternately at opposite sides of the cover. Torque lubricated capscrews to 280ft.-lbs. (380 Nm). 8. Clean or replace fluid return line strainer. 9. Clean the fluid return line orifice installed in the side of the compressor unit air end. 5.10 TROUBLESHOOTING The following Troubleshooting Chart is based on both the data obtained from actual tests conducted at our factory and real applied situations. It contains symptoms and usual causes for the described problems. However, DO NOT assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. Check for loose wiring. Check for damaged piping. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation.

NOTE
To assist with the removal of the tank lid, Sullair has provided a 1"-8 nut to the top lid so it can be removed by a 1"8 eye bolt (which is available from Sullair) or a similar type of lifting device.

Figure 5-4 Separator Element

*Repair Kit P/N 250028-244

37

Section 5 MAINTENANCE
5.11 TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Check fuel level and add fuel if necessary. Replace the element. Check electrolyte level and add distilled water and recharge if necessary. Loose battery cables; tighten cables. Dirty battery cables; clean thoroughly. Plugged Air Filter Engine Problems May Have Developed Tripped Circuit Breaker on Instrument Panel COMPRESSOR SHUTS No Fuel DOWNWITH AIR DEMAND Compressor Discharge PRESENT Temperature Switch is Open Replace the element. Refer to Engine Operators Manual. Check and reset if necessary. Check fuel gauge and add fuel if necessary. Cooling air flow is insufficient; clean cooler and check for proper ventilation. Low fluid sump level; add fluid. Dirty compressor fluid filter; change element. Thermostatic element is not functioning properly; change the thermostatic element. Defective discharge temperature switch; check for a short or open circuit to the engine fuel solenoid. Should this check out normal, it could be possible that the temperature switch itself is defective. Tripped Circuit Breaker on Instrument Panel COMPRESSOR WILL NOT Air Demand is Too Great BUILD UP FULL DISDirty Air Filter CHARGE PRESSURE Pressure Regulator Out of Adjustment Defective Pressure Regulator Defective Air Inlet Cylinder IMPROPER UNLOADING WITH AN EXCESSIVE PRESSURE BUILD-UP CAUSING PRESSURE RELIEF VALVE TO OPEN Fluid Charge Lost from Spring Chamber on Inlet Valve Check and reset if necessary. Check service lines for leaks or open valves. Check the filter gauges on instrument panel and change element if required. Adjust regulator according to control adjustment instructions in the Maintenance section. Check diaphragm and replace if necessary (kit available). Replace cylinder. Add fluid to inlet valve spring chamber by removing plugs (Fig. 5-3) in the top of the spring chamber and filling with compressor fluid. Some fluid may leak from the control regulator at first but will stop leaking when fluid level in the spring chamber equalizes. Readjust. Continued ... 38 COMPRESSOR WILL NOT No Fuel START Plugged Fuel Filter Low Battery Voltage

Pressure Regulating Valve is Set Too High

Section 5

MAINTENANCE
5.11 TROUBLESHOOTING GUIDE SYMPTOM MPROPER UNLOADING WITH AN EXCESSIVE PRESSURE BUILD-UP CAUSING PRESSURE RELIEF VALVE TO OPEN (CONTINUED) PROBABLE CAUSE Running Blowdown Valve Pressure Regulating Valve Set Too High Leak in Control System Causing Loss of Pressure Signal Readjust. Check control lines. Worn seals in inlet valve. Replace seals (kit available). Defective pressure regulating valves; repair valves (kits available). Inlet Valve Jammed Restriction in the Control System Free or replace valve. Check all control lines and components. Ice and other contaminants could cause restrictions. Replace pressure relief valve. Replace. Replace separator element and also change compressor fluid and fluid filter at this time. Adjust or repair. Readjust engine speed. Replace cylinder. REMEDY

Defective Pressure Relief Valve INSUFFICIENT AIR DELIVERY Plugged Air Filter Plugged Air/Fluid Separator Defective Pressure Regulator Engine Speed Too Low Control Air Cylinder Defective

EXCESSIVE COMPRESCheck all pipes, connections and SOR FLUID CONSUMP- Leak in the Lubrication System components. TION Separator Element Damaged or Not Change separator element. Functioning Properly Defective Minimum Pressure/ Check Valve Fluid Sump Overfilled COMPRESSOR OVERHEATING Loose or Broken Fan Belt Dirty Fluid Cooler Core Dirty Aftercooler Dirty Radiator Core Faulty Thermostat Element Plugged Fluid Cooler Tube (Internal) Low Sump Fluid Level Plugged Compressor Fluid Filter ENGINE OVERHEATING Loose or Broken Fan Belt Dirty Radiator Core Dirty Fluid Cooler Low Water Level Repair or replace. Drain to proper level. Tighten or change belt. Clean core thoroughly. Clean core thoroughly. Clean core thoroughly. Change thermostat element. Clean tube thoroughly. Fill. Change element. Tighten or change belt. Clean thoroughly. Clean thoroughly. Refill. Continued on page 40 39

Section 5 MAINTENANCE
5.11 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE Clean thoroughly. Refill. Change pump. Clean and flush thoroughly. Replace engine thermostat. Replace the switch. REMEDY

ENGINE OVERHEATING Dirty Aftercooler (CONTINUED) Low Fluid Level Faulty Water Pump Plugged Radiator Defective Engine Thermostat SHUTDOWN PANEL LIGHTS CHECK ENGINE LIGHT ENGINE WARNING FLASHING LIGHT Faulty Switch Indicated by Light

Engine Safety Switch (Low Coolant) Replace the swtich (Caterpilliar part). Fault Count Number of Flashes. This Will Determine trouble code and call Caterpillar Flash Trouble Code Service Representative to correct problem.

40

Section 6 NOISE CONTROL

6.1 NOISE EMISSIONS WARRANTY Sullair Corporation warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed, built and equipped to conform at the time of sale to the first retail purchaser, with all applicable U.S. E.P.A. and/or any Federal, State or Local noise control regulations. This warranty is not limited to any particular part, component, or system of the air compressor. Defects in the design, assembly, or in any part, component, or system of the compressor which, at the time of sale to the first retail purchaser, caused noise emissions to exceed Federal standards are covered by this warranty for the life of the air compressor. 6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal Law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any persons, other than for purposes of maintenance, 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 ultimate purchaser or while it is in use. 2. The use of the compressor after such device or element of design has been removed or rendered inoperative by any person. Among those acts included in the prohibition against tampering are the acts listed below: 1. Removal or rendering inoperative any of the following: a. Engine exhaust system or parts thereof b. Compressor air intake system or part thereof c. Enclosure of part thereof 2. Removal of any of the following: a. Vibration isolators b. Control silencer c. Floor panel d. Fan shroud e. Acoustical materials including fiberglass foam or foam tape 3. Operation with canopy doors open for any purpose other than starting, stopping, adjustment, repair, replacement of parts or maintenance. 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 compressor, is intended to prevent noise emission degradation (refer to Figure 6-1).

Figure 6-1 Noise Emission Maintenance and Maintenance Record Log 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. DO NOT operate compressor with defective exhaust system. 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

41

Section 6 NOISE CONTROL

2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION In addition to the instructions in the Maintenance section of the Operators Manual, the air filter(s) and entire air inlet system should be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight, that there are no other leaks in the system, and that the filter element(s) are intact. DO NOT operate compressor with defective air inlet system. Remove and replace defective parts by ordering with part numbers indicated in the Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date

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. Maintenance Performed By Location Date Maintenance Performed By Location Date

42

Section 6 NOISE CONTROL

4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any missing 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 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. Remove and replace defective parts by ordering with part numbers indicated in the Parts List. Maintenance Performed By Location Date Maintenance Performed By Location Date

43

Section 6 NOISE CONTROL

6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS In addition to other instructions in the Operators 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. Repair or adjust, per instructions in Operators Manual, as required. Maintenance Performed By Location Date Maintenance Performed By Location Date

44

Section 7 ILLUSTRATIONS AND PARTS

7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, websites, telephone or fax numbers below. When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor (see Figure 7-1). Figure 7-1 Serial Number Plate Location

NOTE: For future convenience, write the machine serial number below: Serial Number ___________________________________________________________

SULLAIR CORPORATION
3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. www.sullair.com : 1-800-SULLAIR (U.S.A. Only) or 1-219-879-5451 Fax: (219) 874-1273

CUSTOMER CARE for PARTS and SERVICE

: 1-888-SULLAIR (7855247) or 219-874-1835

SULLAIR ASIA, LTD.

Sullair Road, No. 1 Chiwan, Shekou Shenzhen, Guangdong PRV. PRC POST CODE 518068 : 755-6851686 Fax: 755-6853473 www.sullair-asia.com

CHAMPION COMPRESSORS, LTD.

Princes Highway Hallam, Victoria 3803 Australia : 1800-810-015 (for Australia -wide Branch Network Only) : 61-3-9796-4000 Fax: 61-3-9703-8053 www.championcompressors.com.au

SULLAIR EUROPE, S.A.

Zone Des Granges BP 82 42602 Montbrison Cedex, France : 33-477968470 Fax: 33-477968499 www.sullaireurope.com

45

Section 7 ILLUSTRATIONS AND PARTS

7.2 SPARE PARTS LIST
LIST DESCRIPTION REFERENCE ELEMENTS 1 2 3 4 7 8 9 10 11 12 13 14 KITS 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 repair kit for blowdown valve 02250069-820 repair kit for blowdown valve 02250120-888 repair kit for air/fluid separator 02250148-253 repair kit for fluid stop valve 250041-069 replacement kit for moisture separator 02250111-923 repair kit for thermal/bypass valve 02250142-938 repair kit for reducing regulator valve 048354 repair kit for control regulator 048059 repair kit for control cylinder 02250112-029 repair kit for shaft seal repair kit for inlet valve (6.5 in) 02250054-763 replacement gasket (exterior) for 02250054-763 repair kit for inlet valve (8 in) 02250045-626 replacement gasket (exterior) for 02250045-626 repair kit for discharge/check valve 02250081-044 replacement gasket (exterior) for 02250081-044 repair kit for minimum pressure valve 02250164-871 repair kit for strainer 02250044-281 replacement assembly for filter assembly 02250117-782 02250077-469 02250120-889 02250148-260 02250051-747 02250111-924 02250142-940 048410 048409 02250112-030 001811A 02250073-277 040690 02250112-531 040422 606208-001 046053 02250166-761 02250044-282 02250117-782 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 replacement element for air filter 02250049-036 (primary) replacement element for air filter 02250049-036 (secondary) replacement element for air filter 02250053-402 (primary) replacement element for air filter 02250053-402 (secondary) replacement element for separator 409805-007 (900-1150) replacement element for separator 02250148-253 (1350) replacement element for drive coupling 02250069-601 replacement element for main fluid filter 02250111-592 replacement element for main fluid filter 250031-849 replacement oil filter for Cat engine replacement fuel filter (primary) for Cat engine replacement fuel filter (secondary) for Cat engine 02250051-238 02250051-239 02250051-238 02250051-239 250028-244 02250148-260 02250137-653 250031-850 250031-850 02250154-063 02250154-066 02250154-065 1 1 1 1 1 1 1 1 1 1 1 1 ORDER KIT NUMBER QTY

Continued on next page

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

46

Section 7 ILLUSTRATIONS AND PARTS

7.2 SPARE PARTS LIST (CONTINUED)
LIST REFERENCE DESCRIPTION ORDER KIT NUMBER QTY

KITS (continued) 31 32 LUBRICATION 33 34 lubricant, multi-vis (55 gallons/208 liters) lubricant, multi-vis (5 gallons/20 liters) 250030-758 250030-757 1 1 replacement kit for moisture separator 02250058-442 replacement handle for 3-way valve 044205 02250058-441 Consult Factory 1 1

MICELLANEOUS 35 manual, CIMA Safety 250023-146 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

47

Section 7 ILLUSTRATIONS AND PARTS

7.3 ENGINE AND COMPRESSOR MOUNTING

02250127-622R08

48

Section 7 ILLUSTRATIONS AND PARTS

7.3 ENGINE AND COMPRESSOR MOUNTING key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 part number 02250043-374 02250043-377 02250069-226 02250069-601 02250081-044 02250117-891 02250121-879 02250128-894 02250133-590 040343 040513 041063 045641 046053 222607 231811 242257 249604-019 250010-330 250030-568 250031-046 250040-099 250041-069 407749 820330-040 821110-300 825512-382 825516-513 826502-228 827908-200 827910-175 827912-150 Continued on page 51 (I) For maintenance on coupling, order replacement element no. 02250137-653. (II) For maintenance on sub-assembly valve no. 02250081-044, order repair kit no. 606208-001. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 49

description spacer, eng mnt cat 3406 1 support, unit/eng h900/350 bushing, taper lock 4040 w/2.75 bore coupling, drive act-6 1350/350 (I) sub assembly, vlv assy 2.5 npt x 2.5 4bsf disch (II) panel, heat shield belt, set cat 4n-6423 (.57:1) tube, radiator upper 900xh-1900 spacer, fan cat c15 49.63 fan clamp, hose 3 clamp, hose 13/16 to 1-1/2 draincock, 1/2 switch, temp-265f 54 los nc gasket, 2-1/2 flange washer, snubbing 1 bolt adapter, eng/compr 900xh switch, temperature nc 250deg f hose, med press .25 x 30 lg isolator, vibration 500 lb. capacity support, front engine mnt 3408 dita valve, drain 1-1/8-12unf washer, .500 hardened valve, oil stop 2 sae code 61 hose, rad upper 2-1/2 x 6 flange, thrd 2 1/2 300# rf key, square cl1 5/8 x 3 nut, hex locking 3/4-10 nut, hex locking 1-8 o-ring, viton 2 1/4 x 1/8 capscrew, hex gr8 1/2-13 x 2 capscrew, hex gr8 5/8-11 x 1 3/4 capscrew, hex gr8 3/4-10 x 1 1/2

quantity 1 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 2 1 1 6 1 2 1 1 2 2 1 8 4 2

Section 7 ILLUSTRATIONS AND PARTS

7.3 ENGINE AND COMPRESSOR MOUNTING

02250127-622R08

50

Section 7 ILLUSTRATIONS AND PARTS

7.3 ENGINE AND COMPRESSOR MOUNTING (CONTINUED) key number 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 A1 part number 827912-225 827912-250 829107-300 829108-100 829108-350 829116-550 837807-109 837808-125 837810-156 837812-188 838212-112 842115-062 860204-025 860404-025 866440-050 866900-020 867101-010 867308-175 869015-010 -

description capscrew, hex gr8 3/4-10 x 2 1/4 capscrew, hex gr8 3/4-10 x 2 1/2 capscrew, hex gr5 7/16-14 x 3 capscrew, hex gr5 1/2-13 x 1 capscrew, hex gr5 1/2-13 x 3 1/2 capscrew, hex gr5 1-8 x 5 1/2 washer, spr lock reg pltd 7/16 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 3/4 hose, heater 5/8 elbow, 37fl 90m 1/4 x 1/4 nipple, pipe-hex 1/4 x 1/4 nipple, pipe-xs plt 2 1/2 x 5 plug, pipe 1/2 3000# stl plt bushing, red pltd 3/8 x 1/4 capscrew, ferry head hd pltd 1/2-13 x 1 3/4 coupling, pipe 1/4 150# plt engine, generic diesel cat3406e tier ii (III) (VI) fan, cat 3406e (IV) compressor, unit and parts (V) (VII)

quantity 1 2 24 4 6 4 24 12 4 2 2 1 ft. 3 1 1 1 1 12 1 1 1 1

Sightglass assembly: refer to Section 7.17 Sub-assembly - High Pressure Filter / Check Valve / Orifice. Engine (III) 02250125-778 02250124-731 02250142-622 Fan (IV) 02250092-462 02250136-317 02250136-317 Unit (V) 02250091-756 02250104-038 02250119-215

Machine Size (CFM / PSI) 900 / 350 1150 / 350 1350 / 350

(VI) For maintenance on Caterpillar engine oil filter, order replacement filter no. 02250154-063. For maintenance on Caterpillar engine fuel filter, order primary replacement filter no. 02250154-066, and secondary replacement filter no. 02250154-065. For in-depth coverage of the engine, consult the Engine Operators Manual. (VII) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies. For shaft seal repairs order shaft seal repair kit no. 001811A. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 51

Section 7 ILLUSTRATIONS AND PARTS

7.4 AIR INLET SYSTEM - ALL MODELS

02250136-060R02

52

Section 7 ILLUSTRATIONS AND PARTS

7.4 AIR INLET SYSTEM - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 02250043-705 02250049-036 02250053-402 02250054-763 02250054-861 02250084-842 02250085-092 02250085-094 02250086-250 02250115-907 02250125-075 02250125-212 02250134-182 02250135-594 02250135-595 02250135-596 02250135-707 02250149-376 028111 029097 040303 040304 040305 041910 041992 043406

description tube, alum air inlet 8"od x 5"lg filter, air 18" dia 1600 cfm (I) filter, air 18" dia 6" outlet 1600 cfm (II) valve, assembly inlet 6.50" (III) tube, nylon .25"od x .04w black clamp, t-bolt ss band 4.50"id elbow, chrg air clr 4" id x 45 deg hose, hump chrg air 4" id x 6" lg tube, 10"od x .063"alum x 4"lg hose, hump 7" short tube, alum stl 4" beaded ss ii tube, alum stl 4" od 90 beaded tube, alum air inlet 8"od x 6"lg tube, air inlet 10"od x 53"lg tube, alum air inlet 10"od x 59"lg adapter, 10"od tube rubber clamp, 10" dia tube clamp, hose t-bolt 10.25 - 10.75 ss tube, alum air inlet 6"od x 5"lg tube, alum air inlet 7"od x 4"lg elbow, rubber 6" id x 45 deg elbow, rubber 6" id x 90 deg clamp, hose 6 1/2" elbow, air inlet 90 rubber 10" clamp, hose 7" elbow, air inlet 90 rubber

quantity 1 1 1 1 10 ft. 8 1 3 2 1 1 1 1 1 1 4 2 12 1 1 1 3 8 2 3 4

Continued on page 55 (I) For maintenance on air filter no. 02250049-036, order primary replacement element no. 02250051238, and secondary replacement element no. 02250051-239. (II) For maintenance on air filter no. 02250053-402, order primary replacement element no. 02250051238, and secondary replacement element no. 02250051-239. (III) For complete breakdown of 6.5 inlet valve assembly, refer to Section 7.13A Inlet Valve Parts - 6.5 - 900XH. For complete breakdown of 8 inlet valve assembly, refer to Section 7.13B Inlet Valve Parts - 8 - 1150XH-1350XH. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

53

Section 7 ILLUSTRATIONS AND PARTS

7.4 AIR INLET SYSTEM - ALL MODELS

02250136-060R02

54

Section 7 ILLUSTRATIONS AND PARTS

7.4 AIR INLET SYSTEM - ALL MODELS (CONTINUED) key number 27 28 29 30 31 32 33 34 35 36 37 38 part number 043598 233298 245796 250006-651 250041-286 825206-337 825306-347 829106-125 829706-100 837806-094 838206-071 868706-125

description clamp, hose 8" tube, alum air inlet 6"od x 20"lg elbow, rubber 90deg red. 8 x 7" tube, alum air inlet 8"od x 12"lg elbow, 90d 1/4" tube x 1/8"fnpt nut, hex pltd 3/8-16 nut, hex f pltd 3/8-16 capscrew, hex gr5 3/8-16 x 1 1/4 screw, hex ser washer 3/8-16 x 1 washer, spr lock reg pltd 3/8 washer, pl-b reg pltd 3/8 washer, bevel 3/8 plt

quantity 8 2 1 1 2 8 4 8 4 8 16 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

55

Section 7 ILLUSTRATIONS AND PARTS

7.5 EXHAUST SYSTEM - ALL MODELS

02250136-062R02

56

Section 7 ILLUSTRATIONS AND PARTS

7.5 EXHAUST SYSTEM - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 part number 02250046-851 02250051-589 02250061-795 02250061-796 02250091-543 02250093-529 02250125-074 02250135-706 02250135-709 02250135-710 02250137-188 02250137-189 02250140-520 040125 241260 250008-152 250011-537 825305-283 825504-145 825505-166 825506-198 829106-100 829106-125 829704-075 829705-075 838204-071 838205-071 838206-071 839105-112

description door, instr panel 750 rain-cap, exhaust 5.75 to 6.35 dia pipe supt, ptech filter assy 1200 ac support, muffler 1200-1500 ac capscr, button head 5/16-18 x 3/4 muffler, exhaust 19 x 5 inlet tube, exh w/half marmn 3406e ii brace, muffler support h enclosure, instrument panel cover, instrument panel backing supt, instr box 900 xh open frame supt, 900xh open frame supt, baffle 1150xha tier ii grommet, rubber clamp, seal 5 hinge, instrument panel door washer, nylon 5/16 nut, hex f pltd 5/16-18 nut, hex locking 1/4-20 nut, hex locking 5/16-18 nut, hex locking 3/8-16 capscr, hex gr5 3/8-16 x 1 capscr, hex gr5 3/8-16 x 1 1/4 screw, hex ser washer 1/4-20 x 3/4 screw, hex ser washer 5/16-18 x 3/4 washer, pl-b reg pltd 1/4 washer, pl-b reg pltd 5/16 washer, pl-b reg pltd 3/8 eyebolt, 5/16 -18 x 1 1/8 pltd

quantity 1 1 1 1 5 1 1 1 1 1 1 1 1 2 1 1 2 8 1 6 21 13 8 13 8 1 1 30 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

57

Section 7 ILLUSTRATIONS AND PARTS

7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM

02250127-635R02

58

Section 7 ILLUSTRATIONS AND PARTS

7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24 25 part number 02250052-613 02250053-495 02250078-197 02250095-736 02250117-235 02250117-236 02250117-237 02250117-607 02250117-890 02250123-111 02250127-628 02250127-634 02250127-668 250016-435 250031-849 408300-010 824208-448 824212-665 825205-273 825305-283 828405-100 828608-125 828608-150 828612-150 829105-075

description guard, fan 48 rh 900h/350-1600 guard, fan 48 lh 900h/350-1600 channel, ext rub u 3/32 tube, adapter 2 90deg 4bsf hose, hi-pressure 2 x 173 lg hose, hi-pressure 2 x 168 lg hose, hi-pressure 2 x 65 lg support, bracket oil filter 900xh support, bracket oil filter 900xh support, cooler oil/air 1600h-1900 sub assembly, cooler air/oil assy 900xh sub assembly, radiator 900xh tier ii (I) sub assembly, receiver & parts 900xh tier ii (II) flange, kit sae splt 2 filter, asm parker 80cnz (III) compr model, 20-12stretch unit (IV) clamp, hose 2 3/8 i.d. nut, hex unfin 1/2-13 nut, hex unfin 3/4-10 nut, hex pltd 5/16-18 nut, hex f pltd 5/16-18 capscrew, ferry head hd 5/16-18 x 1 capscrew, hex gr5 1/2-13 x 1 1/4 capscrew, hex gr5 1/2-13 x 1 1/2 capscrew, hex gr5 3/4-10 x 1 1/2 capscrew, hex gr5 5/16-18 x 3/4

quantity 1 1 2 ft. 1 1 2 1 1 1 2 1 1 1 1 1 1 4 2 1 1 6 1 1 1 1 1

Continued on page 61 (I) For additional information pertaining to the radiator sub-assembly no. 02250127-634, consult Section 7.7, Engine Radiator Assembly - All Models. (II) For additional information pertaining to receiver & parts sub-assembly no. 02250127-668, consult Section 7.15A, Receiver and Parts - 900XH & 1150XH Standard and Aftercooled. (III) For maintenance on filter assembly no. 250031-849, order replacement element kit no. 250031-850. (IV) for maintenance on compressor model, consult factory with serial number. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

59

Section 7 ILLUSTRATIONS AND PARTS

7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM

02250127-635R02

60

Section 7 ILLUSTRATIONS AND PARTS

7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM (CONTINUED) key number 26 27 28 29 30 31 32 33 34 part number 829705-075 829705-100 837205-071 837212-112 837505-078 837508-125 837512-188 837805-078 870708-153

description screw, hex ser washer 5/16-18 x 3/4 screw, hex ser washer 5/16-18 x 1 washer, pl-b reg unfin 5/16 washer, pl-b reg unfin 3/4 washer, spr lock 5/16 washer, spr lock 1/2 washer, spr lock 3/4 washer, spr lock reg pltd 5/16 washer, extra thk pltd 1/2

quantity 5 1 5 1 1 2 1 1 2

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

61

Section 7 ILLUSTRATIONS AND PARTS

7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM - AFTERCOOLED

02250150-195R01

62

Section 7 ILLUSTRATIONS AND PARTS

7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM - AFTERCOOLED key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 02250052-613 02250053-495 02250054-257 02250078-197 02250111-592 02250117-607 02250117-890 02250123-111 02250131-783 02250148-550 02250148-551 02250148-552 02250148-553 02250148-554 02250148-556 02250148-575 02250148-710 02250148-711 02250127-628 02250150-201 250016-435 250041-069 825205-273 825208-448 825212-665 825305-283 825505-166

description guard, fan 48 rh 900h/350-1600 guard, fan 48 lh 900h/350-1600 hose, medium pressure .25 x 28 lg channel, ext rub u 3/32 filter, oil assy parker (I) support, bracket oil filter 900xh support, bracket oil filter 900xh support, cooler oil/air 1600h-1900 sub-assembly, radiator assy 900xh ac (II) pipe, asy 2 900-1350xh 77lg pipe, asy 2 road side 73.75lg hose, asy 2 braided ss 48lg hose, asy 2 braided ss 32 lg hose, asy 2 braided ss 65 lg hose, asy 2 braided ss 51lg support, pipe 900xh clamp, cushion omega for 2 pipe support, for 02250148-710 sub assembly, cooler air/oil assy 900xh sub-assembly, clr/air/oil vert flo lvrs 900xh (III) flange, kit sae splt 2 valve, oil stop 2 sae code 61 (IV) nut, hex pltd 5/16-18 nut, hex pltd 1/2-13 nut, hex pltd 3/4-10 nut, hex f pltd 5/16-18 nut, hex locking 5/16-18

quantity 1 1 1 4 ft. 1 1 1 2 1 1 1 3 1 1 1 1 3 1 1 1 12 1 4 6 4 21 6

Continued on page 65 (I) For maintenance on fluid filter no. 02250111-592, order replacement element no. 250031-850. (II) For additional information pertaining to the radiator sub-assembly no. 02250127-634, consult Section 7.7, Engine Radiator Assembly - All Models. (III) Refer to inset in drawing for sub-assembly with louvers. (IV) For maintenance on fluid stop valve no. 250041-069, order repair kit no. 02250051-747. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

63

Section 7 ILLUSTRATIONS AND PARTS

7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM - AFTERCOOLED

02250150-195R01

64

Section 7 ILLUSTRATIONS AND PARTS

7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM - AFTERCOOLED (CONTINUED) key number 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 part number 826502-228 829105-075 829108-125 829108-150 829112-150 829705-075 829705-100 829705-175 837805-078 837808-125 837812-188 838205-071 838212-112 838305-071 860204-025 867101-010 867305-100 868305-200 870708-153

description o-ring, viton 2 1/4 x 1/8 capscrew, hex gr5 5/16-18 x 3/4 capscrew, hex gr5 1/2-13 x 1 1/4 capscrew, hex gr5 1/2-13 x 1 1/2 capscrew, hex gr5 3/4-10 x 1 1/2 screw, hex ser washer 5/16-18 x 3/4 screw, hex ser washer 5/16-18 x 1 screw, hex ser washer 5/16-18 x 1 3/4 washer, spr lock reg pltd 5/16 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 5/16 washer, pl-b reg pltd 3/4 washer, pl-b wide pltd 5/16 elbow, 37fl 90m 1/4 x 1/4 bushing, red pltd 3/8 x 1/4 capscrew, ferry head hd pltd 5/16-18 x 1 u-bolt,5/16 x 2 pipe pltd washer, extra thk pltd 1/2

quantity 1 4 4 2 4 12 8 2 4 6 4 16 4 4 2 1 4 1 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

65

Section 7 ILLUSTRATIONS AND PARTS

7.7 ENGINE RADIATOR ASSEMBLY - ALL MODELS

02250127-633R02

66

Section 7 ILLUSTRATIONS AND PARTS

7.7 ENGINE RADIATOR ASSEMBLY - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 part number 013978 02250048-926 02250092-488 02250127-631 02250127-632 02250128-893 02250131-791 02250131-792 040343 041063 043258 245738 825305-283 829105-100 829705-075 829705-150 837805-078 838205-071

description seal, door extruded sponge hose, rad lower cat 3406 venturi, 50.50 special baffle, rad ss 900xh tier ii baffle, rad cs 900xh tier ii radiator, 900xh-1900 baffle, canopy cs 900xh ac baffle, canopy ss 900xh ac clamp, hose 3 draincock,1/2 connector, hose 5/16hose x 1/4npt weatherstrip, 1/2 x 1 nut, hex f pltd 5/16-18 capscrew, hex gr5 5/16-18 x 1 screw, hex ser washer 5/16-18 x 3/4 screw, hex ser washer 5/16-18 x 1 1/2 washer, spr lock reg pltd 5/16 washer, pl-b reg pltd 5/16

quantity 2 ft. 1 1 1 1 1 1 1 2 1 1 2 ft 3 1 2 1 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

67

Section 7 ILLUSTRATIONS AND PARTS

7.8 AFTERCOOLER MOUNTING - ALL MODELS

02250150-135R03

68

Section 8 ILLUSTRATIONS AND PARTS LIST

7.8 AFTERCOOLER MOUNTING - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 part number 02250108-474 02250124-822 02250126-734 02250150-059 02250150-088 02250150-130 02250154-061 02250154-062 825305-283 825508-262 829105-100 827908-150 829706-100 827908-125 838208-112 838305-071

description damper, louver acf 1200/1500 cooler, air cat 3406e tier ii cooler, oil ca 3406 tier ii 900xh cooler, air vert flow 500 psig support, brk vert flow clr 900xh-1150xh support, vertical flow clr 900xh-1150xh support, aftercooler 900xh-1300xh support, aftercooler 900xh-1300xh nut, hex f pltd 5/16-18 nut, hex locking 1/2-13 capscrew, hex gr5 5/16-18 x 1 capscrew, hex gr8 1/2-13 x 1 1/2 screw, hex ser washer 3/8-16 x 1 capscrew, hex gr8 1/2-13 x 1 1/4 washer, pl-b reg pltd 1/2 washer, pl-b wide pltd 5/16

quantity 1 1 1 1 2 4 1 1 26 12 18 6 8 6 24 32

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

69

Section 7 ILLUSTRATIONS AND PARTS

7.9 CONTROL SYSTEM HOSE ROUTING - ALL MODELS

02250133-812R05

70

Section 7 ILLUSTRATIONS AND PARTS

7.9 CONTROL SYSTEM HOSE ROUTING - ALL MODELS key number 1 2 3 4 5 6 7 8 part number 02250073-546 02250083-838 02250110-099 02250119-172 02250127-142 249604-022 860205-025 867102-010

description hose, mp 5/16 x 98" lg 37deg st hose, mp 5/16 x 54" lg 37deg st hose, mp 5/16 x 17 hose, mp 5/16 x 40" lg 37deg st hose, drain 3/4 84" 3/4 fsn hose, med press .25 x 44" lg elbow, 37fl 90m 5/16 x 1/4 bushing, red pltd 1/2 x 1/4

quantity 4 1 1 5 1 1 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

71

Section 7 ILLUSTRATIONS AND PARTS

7.10 SPEED CONTROL CYLINDER AND PARTS - ALL MODELS

02250132-482R00

72

Section 7 ILLUSTRATIONS AND PARTS

7.10 SPEED CONTROL CYLINDER AND PARTS - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 part number 02250085-277 02250112-029 02250112-037 02250112-561 040136 042004 250010-103 250011-491 825505-166 829105-150 829105-200 829704-075 831702-118 832204-038 837802-047 866605-195 868205-195

description support, speed cyl mtg 3406e cylinder, air dbl acting (I) lever, speed control 1600h-1900 washer, sprlock hi clr 5/16 rod end, spherical rh 5/16 rod end, spherical lh 5/16 spacer, control butterfly rod, sullicon ctl 5/15 x 2 nut, hex locking 5/16-18 capscrew, hex gr5 5/16-18 x 1 1/2 capscrew, hex gr5 5/16-18 x 2 screw, hex ser washer 1/4-20 x 3/4 screw, mach-rd hd #10-32 x 1 1/8 screw, set cup 1/4-20 x 3/8 washer, spr lock reg pltd #10 nut, hex jam lh pltd 5/16-24 nut, hex jam rh pltd 5/16-24

quantity 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2

(I) For maintenance on control cylinder no. 02250112-029, order repair kit no. 022250112-030. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

73

Section 7 ILLUSTRATIONS AND PARTS

7.11 AIR CONTROL MANIFOLD ASSEMBLY - ALL MODELS

02250132-419R04

74

Section 7 ILLUSTRATIONS AND PARTS

7.11 AIR CONTROL MANIFOLD ASSEMBLY - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 26 27 28 part number 02250116-255 02250116-869 02250118-270 02250118-584 02250129-848 02250132-418 048059 048354 048448 811504-025 825506-198 829106-300 837806-094 838306-112 860105-025 860205-025 860208-050 861805-025 866900-010 867102-005 867102-010 867103-020 868306-200 868504-025 868504-025 873104-004 877600-010 877700-010 877900-010

description housing, air ctrl manifold valve, check 1/2 cartridge type hose, mp-5 11lg 37deg svl str orifice, .047 .25 fnpt x .25 mnpt switch, pressure nc 15 psi 600 mp support, control manifold tier ii valve, regulator 400 psi (I) valve, pressure regulator (II) gauge, ctl air press 0-200 psi adapter, female pipe 1/2 x 1/4 nut, hex locking 3/8-16 capscrew, hex gr5 3/8-16 x 3 washer, spr lock reg pltd 3/8 washer, pl-b wide pltd 3/8 connector, 37 fl/mpt pltd 5/16 x 1/4 elbow, 37fl 90m 5/16 x 1/4 elbow, 37fl 90m 1/2 x 1/2 tee, 37fl male rn 5/16 x 1/4 plug, pipe 1/4 3000# stl plt bushing, red pltd 1/2 x 1/8 bushing, red pltd 1/2 x 1/4 bushing, red pltd 3/4 x 1/2 u-bolt, 3/8 x 2 pipe pltd nipple, pipe-hx pltd 1/4 x 1/4 nipple, pipe-hx pltd 1/4 x 1/4 tee, f branch npt 1/4 x 1/4 elbow, pipe 45 deg 1/4 3000# cross, pipe 1/4 3000# plt elbow, pipe 90 deg 1/4 3000# plt

quantity 1 1 1 1 1 1 2 1 1 1 2 1 1 3 1 7 1 1 2 1 1 1 1 5 8 1 1 1 3

(I) For maintenance on regulator valve no. 048059, order repair kit no. 048409. (II) For maintenance on pressure regulator valve no. 048354, order repair kit no. 048410. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

75

Section 7 ILLUSTRATIONS AND PARTS

7.12A INLET VALVE AND PARTS (6.5) - 900XH

02250140-983R01

76

Section 7 ILLUSTRATIONS AND PARTS

7.12A INLET VALVE AND PARTS (6.5) - 900XH key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 part number 02250062-124 02250109-209 02250110-100 02250118-588 02250141-182 040422 040696 807800-020 824208-448 828412-125 837508-125 839408-030 860105-025 860205-025 868430-010 868504-025 868902-010

description adapter, inlet 8.5 to 6.5 plug, sae 45 deg 5/16 1/2-20 hose, medium pressure 5/16 x 4.5lg 37$s jic orifice, .109 .25 fnpt x .25 mnpt valve assembly, inlet 6 350psi (I) (II) gasket, 11 x 8 5/8 x 1/32 gasket, 1/32 x 6 1/4idx8 1/4od plug, pipe 1/2 3000# stl nut, hex unfin 1/2-13 capscrew, ferry head hd 3/4-10 x 1 1/4 washer, spr lock 1/2 stud, threaded 1/2-13 x 3 connector, 37 fl/mpt pltd 5/16 x 1/4 elbow, 37fl 90m 5/16 x 1/4 tee, pipe pltd 1/4 nipple, pipe-hx pltd 1/4 x 1/4 bushing, red hex pltd 1/2 x 1/4

quantity 1 1 1 1 1 1 1 2 1 1 1 1 1 4 1 1 1

(I) For maintenance on 6.5 inlet valve assembly no. 02250054-763, order repair kit no. 02250073-277, and replacement gasket no. 040696 (refer to key number 7 of this Section). (II) For additional information pertaining to the 6.5 inlet valve assembly, refer to Section 7.13A, Inlet Valve Parts- 6.5 - 900XH. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

77

Section 7 ILLUSTRATIONS AND PARTS

7.12B INLET VALVE AND PARTS (8) - 1150XH AND 1350XH

02250134-298R01

78

Section 7 ILLUSTRATIONS AND PARTS

7.12B INLET VALVE AND PARTS (8) - 1150XH AND 1350XH key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 part number 02250045-626 02250109-209 02250110-100 02250118-588 040422 250034-077 807800-020 828612-250 837812-188 839412-035 860105-025 860205-025 868430-010 868504-025 868902-010

description sub assembly, 8 inlet valve (I) (II) plug, sae 45 deg 5/16 1/2-20 hose, medium pressure 5/16 x 4.5lg 37 jic orifice, .109 .25 fnpt x .25 mnpt gasket, 11 x 8 5/8 x 1/32 nut, thin hex 3/4-10 plug, pipe 1/2 3000# stl capscrew, hex gr5 3/4-10 x 2 1/2 washer, spr lock reg pltd 3/4 stud, threaded 3/4-10 x 3 1/2 connector, 37 fl/mpt pltd 5/16 x 1/4 elbow, 37fl 90m 5/16 x 1/4 tee, pipe pltd 1/4 nipple, pipe-hx pltd 1/4 x 1/4 bushing, red hex pltd 1/2 x 1/4

quantity 1 1 1 1 1 2 2 1 3 2 1 4 1 1 1

(I) For maintenance on 8 inlet valve assembly no. 02250045-626, order repair kit no. 02250112-531, and replacement gasket no. 040422 (refer to key number 5 of this Section). (II) For additional information pertaining to the 8 inlet valve assembly, refer to Section 7.13B, Inlet Valve Parts - 8 1150XH-1350XH . PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

79

Section 7 ILLUSTRATIONS AND PARTS

7.13A INLET VALVE PARTS - 6.5 - 900XH

02250054-762R06

80

Section 7 ILLUSTRATIONS AND PARTS

7.13A INLET VALVE PARTS - 6.5 - 900XH key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 part number 02250054-750 02250054-754 02250054-757 02250054-759 02250054-761 02250054-868 02250139-189 250014-060 250042-384 826502-214 826502-340 828406-175 828604-075 837504-062 866900-010

description housing, body 6.5 inlet valve plate, assy 6.5 inlet valve cover, inter 6.50valve piston, 6.50 inlet valve spring, compresion, 1.50 lbs cover, assembly 6.50 inlet valve shaft, 6.50 inlet valve orifice, ctl .094 1/8 fnpt x 1/8 mnpt spring, com 144#inter o-ring, viton 1 x 1/8 o-ring, viton 3 3/8 x 3/16 capscrew, ferry head hd 3/8-16 x 1 3/4 capscrew, hex gr5 1/4-20 x 3/4 washer, spr lock 1/4 plug, pipe 1/4 3000# stl plt

quantity 1 1 1 1 1 1 1 1 1 1 1 18 1 1 1

NOTE
For maintenance on 6.5 inlet valve assembly no. 02250054-763, order repair kit no. 02250073277, and replacement gasket no. 040696 (refer to key number 7 of Section 7.12A). PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

81

Section 7 ILLUSTRATIONS AND PARTS

7.13B INLET VALVE PARTS - 8 - 1150XH AND 1350XH

02250045-625R05

82

Section 7 ILLUSTRATIONS AND PARTS

7.13B INLET VALVE PARTS - 8 - 1150XH AND 1350XH key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 part number 250042-276 02250048-491 250042-297 250042-301 250042-299 250042-384 02250139-188 250042-383 250042-656 828604-075 837504-062 826502-426 826502-214 828406-175 807800-010 250014-060

description housing, body 8 inlet valve cover, assembly 8 inlet valve plate, flow control 8 inlet valve cover, inter 8 inlet valve piston, 8 inlet valve spring, comp 144 lbs inter shaft, 8 inlet valve spring, comp 109 lbs outer spring, comp 2.61 lbs capscr, hx gr. 5 1/4-20 x 3/4 washer, springlock reg. 1/4 o-ring, viton 4 5/8 x 1/4 o-ring, viton 1 x 1/8 screw, ferry hd,3/8-16 x 13/4 lg plug, pip e 1/4 -1 8 npt; stl 3000# orifice, .093 x .125m x .125f

quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 18 1 1

NOTE
For maintenance on 8 inlet valve assembly no. 02250045-626, order repair kit no. 02250112-531, and replacement gasket no. 040422 (refer to key number 5 of Section 7.12B). PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

83

Section 7 ILLUSTRATIONS AND PARTS

7.14A DISCHARGE SYSTEM - 900XH AND 1150XH

02250127-667R10

84

Section 7 ILLUSTRATIONS AND PARTS

7.14A DISCHARGE SYSTEM - 900XH AND 1150XH key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 A1 part number 02250054-259 02250056-338 02250073-323 02250081-044 02250092-744 02250099-416 045641 046053 047628 047630 820330-040 825106-337 825506-198 825510-329 827912-225 829110-350 837806-094 837810-156 837812-188 838206-071 838210-112 838306-112 860204-025 860205-012 866440-050 868306-200 02250127-668

description hose, medium pressure .25 x 104 lg angle, discharge pipe support 3 tee, 37fl swivel f-m-m sub assembly, vlv assy 2.5 npt x 2.5 4bsf disch (I) hose, disch 2.5 st stl 900xh flange, kit sae splt 2.5 - viton switch, temp-265f 54 los nc gasket, 2-1/2 flange mount, vibration (50 durometer) mount, vibration isolator 185q flange, thrd 2 1/2 300# rf nut, hex pltd 3/8-16 nut, hex locking 3/8-16 nut, hex locking 5/8-11 capscrew, hex gr8 3/4-10 x 2 1/4 capscrew, hex gr5 5/8-11 x 3 1/2 washer, spr lock reg pltd 3/8 washer, spr lock reg pltd 5/8 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 3/8 washer, pl-b reg pltd 5/8 washer, pl-b wide pltd 3/8 elbow, 37fl 90m 1/4 x 1/4 elbow, 37fl 90m 5/16 x 1/8 nipple, pipe-xs plt 2 1/2 x 5 u-bolt, 3/8 x 2 pipe pltd sa, receiver & parts (II)

quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 2 1

Refer to Section 7.17 Sub-assembly - High Pressure Filter / Check Valve / Orifice for additional information.

(I) For maintenance on assembly valve sub-assembly no. 02250081-044, order repair kit no. 606208-001, and replacement gasket no. 046053 (see key number 8 of this Section). For additional information, consult Section 7.18, Discharge / Check Valve Assembly. (II) For additional information pertaining to receiver and parts sub-assembly no. 02250127-668, refer to Section 7.15A Receiver and Parts - 900XH & 1150XH Standard and Aftercooled. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

85

Section 7 ILLUSTRATIONS AND PARTS

7.14B DISCHARGE SYSTEM - 900XH-1150XH AFTERCOOLED

02250139-931R06

86

Section 7 ILLUSTRATIONS AND PARTS

7.14B DISCHARGE SYSTEM - 900XH-1150XH AFTERCOOLED key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 A1 part number 02250054-261 02250081-044 02250083-838 02250086-337 02250092-744 02250099-415 02250099-416 02250131-654 02250131-977 02250132-421 02250132-481 02250133-469 02250133-724 02250134-299 02250139-929 02250139-932 02250142-706

description hose, medium pressure .25 x 86 w/37 swvls sub assembly, vlv assy 2.5 npt x 2.5 4bsf disch (I) hose, medium pressure 5/16 x 54 lg 37deg st valve, ball 2 fnpt w/o drain hose, disch 2.5 st stl 900xh flange, kit sae splt 2 - viton flange, kit sae splt 2.5 - viton sub assembly, water trap assy 900xh ac (II) adapter, 2 tube assy w/4-bolt flg sub assembly, air control manifold 900xh tier ii (III) sub assembly, speed control tier ii (IV) pipe, assembly trap/svr vlv 900xh ac support, pipe cs 900xh sub assembly, inlet valve 8 1150/350 (V) support, discharge pipe 1150xha w/o canopy sub assembly, receiver cat 1150xha w/o canopy (VI) pipe, assembly rec tank/aftclr 900xhh ac

quantity 1 1 1 3 1 5 1 1 2 1 1 1 1 1 1 1 1

Refer to Section 7.17 Sub-assembly - High Pressure Filter / Check Valve / Orifice for additional information. Continued on page 89

(I) For maintenance on valve sub-assembly no. 02250081-044, order repair kit no. 606208-001, and replacement gasket no. 046053 (refer to key number 21 of this Section). (II) For additional information pertaining to water trap sub-assembly no. 02250131-654, consult Section 7.16, Water Separator Trap - Aftercooled Only. (III) For additional information pertaining to air control manifold sub-assembly no. 02250132-421, consult Section 7.11, Air Control Manifold Assembly - All Models. (IV) For additional information pertaining to speed control sub-assembly no. 02250132-481, consult Section 7.10, Speed Control Cylinder and Parts - All Models. (V) For additional information pertaining to inlet valve sub-assembly no. 02250134-299, consult Section 7.12B, Inlet Valve and Parts (8) - 1150XH-1350XH for external parts, and Section 7.13B, Inlet Valve and Parts - 8 - 1150XH-1350XH for assembly. (VI) For additional information pertaining to receiver sub-assembly no. 02250139-932, consult Section 7.15B, Receiver and Parts - 1350XH Standard and Aftercooled, and Section 7.17, Sub-assembly High Pressure Filter / Check Valve / Orifice. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

87

Section 7 ILLUSTRATIONS AND PARTS

7.14B DISCHARGE SYSTEM - 900XH-1150XH AFTERCOOLED

02250139-931R06

88

Section 7 ILLUSTRATIONS AND PARTS

7.14B DISCHARGE SYSTEM - 900XH-1150XH AFTERCOOLED (CONTINUED) key number 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 part number 02250142-708 02250148-552 045641 046053 047628 047630 249604-027 820330-040 825106-337 825208-448 825210-559 827912-225 829108-150 829110-275 829110-350 837806-094 837808-125 837810-156 837812-188 838206-071 838208-112 838210-112 860105-025 860204-025 866440-050 867103-010 868306-200 868430-010 868504-025 02250142-801

description pipe, asy rec tnk/a-clr 1150/500 ac w/val hose, asy 2 braided ss 48lg switch, temp-265f 54 los nc gasket, 2-1/2 flange mount, vibration (50 durometer) mount, vibration isolator 185q hose, med press .25 x 58 lg flange, thrd 2 1/2 300# rf nut, hex pltd 3/8-16 nut, hex pltd 1/2-13 nut, hex pltd 5/8-11 capscrew,hex gr8 3/4-10 x 2 1/4 capscrew, hex gr5 1/2-13 x 1 1/2 capscrew, hex gr5 5/8-11 x 2 3/4 capscrew, hex gr5 5/8-11 x 3 1/2 washer, spr lock reg pltd 3/8 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 3/8 washer, pl-b reg pltd 1/2 washer, pl-b reg pltd 5/8 connector, 37 fl/mpt pltd 5/16 x 1/4 elbow, 37fl 90m 1/4 x 1/4 nipple, pipe-xs plt 2 1/2 x 5 bushing, red pltd 3/4 x 1/4 u-bolt, 3/8 x 2 pipe pltd tee, pipe pltd 1/4 nipple, pipe-hx pltd 1/4 x 1/4 pipe, asy 2 900xh open frame

quantity 1 2 1 1 1 1 1 1 5 1 2 1 1 1 1 5 1 2 1 5 1 1 1 3 1 2 5 1 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

89

Section 7 ILLUSTRATIONS AND PARTS

7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED

02250148-288R01

90

Section 7 ILLUSTRATIONS AND PARTS

7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 A1 A2 part number 02250054-261 02250081-044 02250083-838 02250086-337 02250092-744 02250099-415 02250099-416 02250131-977 02250133-469 02250133-724 02250139-929 02250142-706 02250142-708 02250147-984 02250148-285 02250148-552 045641 046053 047628 047630 249604-027 820330-040

description hose, medium pressure .25 x 86 w/37 swvls sub-assembly, vlv assy 2.5 npt x 2.5 4bsf disch (I) hose, medium pressure 5/16 x 54 lg 37deg st valve, ball 2 fnpt w/o drain hose, disch 2.5 st stl 900xh flange, kit sae splt 2 - viton flange, kit sae splt 2.5 - viton adapter, 2 tube assy w/4-bolt flg pipe, assembly trap/svr vlv 900xh ac support, pipe cs 900xh support, discharge pipe 1150xha w/o canopy pipe, assembly rec tank/aftclr 900xhh ac pipe, asy rec tnk/a-clr 1150/500 ac w/val sub-assembly, water sep 1350xha (II) sub-assembly, rec tnk 1350/350 (III) hose, asy 2 braided ss 48lg switch, temp-265f 54 los nc gasket, 2-1/2 flange mount, vibration (50 durometer) mount, vibration isolator 185q hose, med press .25 x 58 lg flange, thrd 2 1/2 300# rf

quantity 1 1 1 3 1 7 2 2 1 1 1 1 1 1 1 2 1 1 3 3 1 1

Refer to Section 7.10 Speed Control Cylinder and Parts - All Models for additional information. Refer to Section 7.11 Air Control Manifold Assembly - All Models for additional information. Continued on page 93

(I) For additional information pertaining to 2.5 valve sub-assembly no. 02250081-044, consult Section 7.18, Discharge / Check Valve Assembly. (II) For additional information pertaining to water separator sub-assembly no. 02250147-984, consult Section 7.16, Water Separator Trap - Aftercooled Only. (III) For additional information pertaining to receiver tank sub-assembly no. 02250148-285, consult Section 7.15B, Receiver and Parts - 1350XH Standard and Aftercooled, and Section 7.17 Sub-assembly - High Pressure Filter / Check Valve / Orifice. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

91

Section 7 ILLUSTRATIONS AND PARTS

7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED

02250148-288R01

92

Section 7 ILLUSTRATIONS AND PARTS

7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED (CONTINUED) key number 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 part description nut, hex pltd 3/8-16 nut, hex pltd 1/2-13 nut, hex pltd 5/8-11 capscrew, hex gr8 3/4-10 x 2 1/4 capscrew, hex gr5 1/2-13 x 1 1/2 capscrew, hex gr5 5/8-11 x 2 3/4 capscrew, hex gr5 5/8-11 x 3 1/2 washer, spr lock reg pltd 3/8 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 3/8 washer, pl-b reg pltd 1/2 washer, pl-b reg pltd 5/8 washer, pl-b wide pltd 3/8 connector, 37 fl/mpt pltd 5/16 x 1/4 elbow, 37fl 90m 1/4 x 1/4 nipple, pipe-xs plt 2 1/2 x 5 bushing, red pltd 1/2 x 1/4 bushing, red pltd 3/4 x 1/4 u-bolt, 3/8 x 2 pipe pltd tee, pipe pltd 1/4 nipple, pipe-hx pltd 1/4 x 1/4

number 825106-337 825208-448 825210-559 827912-225 829108-150 829110-275 829110-350 837806-094 837808-125 837810-156 837812-188 838206-071 838208-112 838210-112 838306-112 860105-025 860204-025 866440-050 867102-010 867103-010 868306-200 868430-010 868504-025

quantity 10 4 12 8 4 8 3 10 4 14 8 8 4 3 2 2 2 1 1 2 5 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

93

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED

02250127-666R14

94

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 part number 02250044-227 02250058-442 02250069-820 02250077-466 02250121-613 866432-060 02250142-938 045244 040029 042148 045641 046255 048046 234342 249604-019 249608-021 250006-536 250026-145 250029-235 02250164-871 408300-005 409805-007 810505-025 825212-665 825305-283

description cap, nut .50 x 37d flare separator, moisture 425 psi @ 265deg (I) valve, blwdwn n.c. 5.4:1 ratio (II) receiver, air/oil vert. 400 psig plate, receiver 425xh & 900xh nipple, pipe-xs plt 2 x 6 valve, thermal 210 deg 2 sae 4bsf (III) valve, inline check(1/4npt)dc plug, o-ring boss sae 1 1/4 indicator, delta-p 10lb 110-185dpq switch, temp-265f 54 los nc nut, d-loc 3/4-10 glass, sight oil level 2 adapter, oil fill high press hose, med press .25 x 30 lg hose, med press 0.50 x 038 gasket, sep cover hi pressure valve, relief 1 x 1-1/2 400 psig tube, stainless steel 5/16 x 6.25 lg valve, sa, vlv min press/chk asm 2.5 (IV) clamp, hose 5/8 i.d. element, sep 750-1150/350 (vtn) (V) elbow, tube 90 deg m 5/16 x 1/4 nut, hex pltd 3/4-10 nut, hex f pltd 5/16-18

quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2

Continued on page 97 (I) For maintenance on moisture separator no. 02250058-442, order replacement filter no. 02250058-441. (II) For maintenance on blowdown valve no. 02250069-820, order repair kit no. 02250077-469. (III) For maintenance on thermal by-pass valve no. 02250142-938, order repair kit no. 02250142-940. (IV) For additional information on minimum pressure / check valve assembly no. 02250164-871, consult factory with machine serial number. (V) For maintenance on separator element no. 409805-007, order replacement kit no. 250028-244. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

95

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED

02250127-666R14

96

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED (CONTINUED) key number 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 part number 826502-228 829705-075 837808-125 843512-190 860104-025 860105-025 860108-050 860108-075 860204-012 02250154-059 860504-025 862108-050 866408-030 866416-020 866424-000 866424-120 866432-030 02250131-977 866900-010 866900-020 867100-005 867102-010 867110-080 867308-250 867700-020 867700-080 868502-012 868504-025 868508-050 02250142-801 877900-010

description o-ring, viton 2 1/4 x 1/8 screw, hex ser washer 5/16-18 x 3/4 washer, spr lock reg pltd 1/2 rod, threaded plated 3/4-10 x 19 connector, 37 fl/mpt pltd 1/4 x 1/4 connector, 37 fl/mpt pltd 5/16 x 1/4 connector, 37 fl/mpt pltd 1/2 x 1/2 connector, 37 fl/mpt pltd 1/2 x 3/4 elbow, 37fl 90m 1/4 x 1/8 orifice, .125 .50m x .50m elbow, pipe-90m 1/4 x 1/4 union, 37fl bhd 1/2 nipple, pipe-xs plt 1/2 x 3 nipple, pipe-xs plt 1 x 2 nipple, pipe-xs plt 1 1/2 x cl nipple, pipe-xs plt 1 1/2 x 12 nipple, pipe-xs plt 2 x 3 adapter, 2 tube assy w/4-bolt flg (VI) plug, pipe 1/4 3000# stl plt plug, pipe 1/2 3000# stl plt bushing, red pltd 1/4 x 1/8 bushing, red pltd 1/2 x 1/4 bushing, red pltd 2 1/2 x 2 capscrew, ferry head hd pltd 1/2-13 x 2 1/2 tee, pipe pltd 1/2 tee, pipe pltd 2 nipple, pipe-hx pltd 1/8 x 1/8 nipple,pipe-hx pltd 1/4 x 1/4 nipple, pipe-hx pltd 1/2 x 1/2 pipe, asy 2 900xh open frame elbow, pipe 90 deg 1/4 3000# plt

quantity 1 2 4 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 1 2 1 1 3 1 1

Continued on page 99 (VI) Used for air-cooled machine. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

97

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED

02250127-666R14

98

Section 7 ILLUSTRATIONS AND PARTS

7.15A RECEIVER AND PARTS - 900XH & 1150XH STANDARD AND AFTERCOOLED (CONTINUED) key number 57 58 59 60 61 part number 877900-020 877900-040 877900-060 02250099-415 866900-080

description elbow, pipe 90 deg 1/2 3000# plt elbow, pipe 90 deg 1 3000# plt elbow, pipe 90 deg 1 1/2 3000# plt flange, kit sae splt 2 - viton plug, pipe 2 3000# stl plt (VII)

quantity 2 1 1 1 1

(VII) Used for standard machine. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

99

Section 7 ILLUSTRATIONS AND PARTS

7.15B RECEIVER AND PARTS- 1350XH STANDARD AND AFTERCOOLED

02250148-287R02

100

Section 7 ILLUSTRATIONS AND PARTS

7.15B RECEIVER AND PARTS- 1350XH STANDARD AND AFTERCOOLED key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 part number 837808-125 867308-250 02250044-227 02250081-218 02250097-611 02250099-415 02250116-862 02250121-613 02250131-977 02250135-495 02250135-530 866432-060 02250142-801 02250142-938 02250145-168 02250147-981 02250148-251 02250148-253 42148 45641 46255 249604-019 250029-235

description washer, spr lock reg pltd 1/2 capscr, ferry hd pltd 1/2-13 x 2 1/2 cap, nut .50 x 370 flare elbow, 900 5/16 tube x 1/4npt plug, sight glass 1-7/8 sae flg, kit sae splt 2 -vi ton gskt, sep cover h i press (I) plate, rece iver 425xh & 900xh adpt, 2 tube assy w/4-bolt flg (II) hose, mp 0.50 x 1-1/16 sae x 38 lg sa, bdv 900/500 tier ii nipple, pipe-xs plt 2 x 6 pipe, asy 2 900xh open frame vlv, thrm 210 deg 2 sae 4bsf (III) sa, hi press flr/check/orifice (IV) vlv, rlf 1 x1 1/2 440 psig rec, air/oil vrtcl 600psig 1350 sep, air/oil 1350/175/350 spcl (V) indicator, delta-p 10lb 110-185dpo switch, temp-265f 54 los nc nut, d-loc 3/4-10 hose, med press. 25 x 30 lg tube, stainless steel 5/16 x 6.25 lg

quantity 4 4 1 1 1 1 1 1 2 1 1 0 1 1 1 1 1 1 1 1 1 1 1

Continued on page 103 (I) This gasket is included in kit no. 02250148-260 for separator element (refer to key no. 18 of this Section). (II) Use for air-cooled machine. (III) For maintenance on thermal valve no. 02250142-938, order repair kit no. 02250142-940. NOTE: When performing maintenance on thermal valve, order replacement viton o-ring no. 826502-228, which seals between the thermal valve and the receiver tank (refer to key no. 29 of this Section). (IV) For complete breakdown of high pressure filter / check valve / orifice sub-assembly, refer to Section 7.17 Sub-assembly - High Pressure Filter / Check Valve / Orifice. (V) For maintenance on air/fluid separator no. 02250148-253, order maintenance kit no. 02250148-260. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

101

Section 7 ILLUSTRATIONS AND PARTS

7.15B RECEIVER AND PARTS- 1350XH STANDARD AND AFTERCOOLED

02250148-287R02

102

Section 7 ILLUSTRATIONS AND PARTS

7.15B RECEIVER AND PARTS- 1350XH STANDARD AND AFTERCOOLED (CONTINUED) key number 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 part number 02250164-871 250042-627 408300-005 825212-665 825305-283 826502-228 829705-075 843512-270 860104-025 860204-012 860504-025 862108-050 866416-020 866424-000 866424-120 866900-010 866900-020 866900-080 867110-080 867700-080 868502-012 868504-025 877900-040 877900-060 878001-005

description sa, vlv min press/chk asm(2.5) (VI) plug, str tho 1 5/8-12 sae vit clamp, hose 5/8 1.0. nut, hex pltd 3/4-10 nut, hex f pltd 5/16-18 o-ring, vi ton 2 1/4 x 1/8 screw, hex ser washer 5/16-18 x 3/4 rod, thrd pltd 3/4-10 x 27 conn, 37 fl/mpt pltd 1/4 x 1/4 elbow, 37fl 90m 1/4 x 1/8 elbow, pipe-90m 1/4 x 1/4 union, 37fl bhd 1/2 nipple, pipe-xs plt 1 x 2 nipple, pipe-xs plt 1 1/2 x cl nipple, pipe-xs plt 1 1/2 x 12 plug, pipe 1/4 3000 # stl plt plug, pipe 1 /2 3000 # stl plt plug, pipe 2 3000# stl plt (VII) bushing, red pltd 2 1/2 x 2 tee, pipe pltd 2 nipple, pipe-hx pltd 1/8 x 1/8 nipple, pipe-hx pltd 1/4 x 1/4 elbow, pipe 90 deg 1 3000 # plt elbow, pipe 90 deg 1 1/2 3000# plt elbow, red 1/4 x 1/8 3000# plt

quantity 1 1 2 2 2 1 2 0 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(VI) For maintenance on minimum pressure / check valve no. 02250164-871, order repair kit no. 02250166-761. (VII) Use for standard machine. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

103

Section 7 ILLUSTRATIONS AND PARTS

7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY

02250131-653R11

104

Section 7 ILLUSTRATIONS AND PARTS

7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 part number 02250069-820 02250073-544 02250077-839 02250131-542 02250131-543 02250131-656 02250131-977 02250161-248 043197 044408 240621-006 250026-145 820330-032 825208-448 825210-559 829110-275 837808-125 837810-156 838208-112 842115-062 860205-025 861805-025 866408-030 866416-000 866432-000 866432-030 867102-010 867102-015 867108-040 867700-020 867700-080

description valve, blwdwn n.c. 5.4:1 ratio (I) hose, medium pressure 5/16 x 85 lg 37deg st hose, medium pressure 5/16 x 54lg 37deg jic 90 separator, t type gas/liq 2 npt trap, drain float type 1 npt panel, separator assy 900xh ac adapter, 2 tube assy w/4-bolt flg orifice, .060 .50m x .50m clamp, hose 1/2 fitting, hose end m 5/8 x 1/2 gasket, asa flange 150# 2 valve, relief 1 x 1-1/2 400 psig flange, thrd 2 300# rf nut, hex pltd 1/2-13 nut, hex pltd 5/8-11 capscrew, hex gr5 5/8-11 x 2 3/4 washer, spr lock reg pltd 1/2 washer, spr lock reg pltd 5/8 washer, pl-b reg pltd 1/2 hose, heater 5/8 elbow, 37fl 90m 5/16 x 1/4 tee, 37fl male rn 5/16 x 1/4 nipple, pipe-xs plt 1/2 x 3 nipple, pipe-xs plt 1 x cl nipple, pipe-xs plt 2 x cl nipple, pipe-xs plt 2 x 3 bushing, red pltd 1/2 x 1/4 bushing, red pltd 1/2 x 3/8 bushing, red pltd 2 x 1 tee, pipe pltd 1/2 tee, pipe pltd 2

quantity 1 1 1 1 1 1 1 1 2 2 2 1 1 4 8 8 4 8 4 2 ft. 1 1 1 1 2 1 1 1 1 1 1

Continued on page 107 (I) For maintenance on blowdown valve no. 02250069-820, order repair kit no. 02250077-469. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

105

Section 7 ILLUSTRATIONS AND PARTS

7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY

02250131-653R11

106

Section 7 ILLUSTRATIONS AND PARTS

7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY (CONTINUED) key number 32 33 34 35 36 37 part number 868308-600 868506-038 868904-020 877600-080 877900-020 877900-080

description u-bolt, 1/2 x 6 pipe pltd nipple, pipe-hx pltd 3/8 x 3/8 bushing, red hex pltd 1 x 1/2 elbow, pipe 45 deg 2 3000# elbow, pipe 90 deg 1/2 3000# plt elbow, pipe 90 deg 2 3000# plt

quantity 2 1 1 1 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

107

Section 7 ILLUSTRATIONS AND PARTS

7.17 SUB-ASSEMBLY - HIGH PRESSURE FILTER / CHECK VALVE / ORIFICE

02250145-009R01

7.18 DISCHARGE / CHECK VALVE ASSEMBLY

02250049-879R04

108

Section 7 ILLUSTRATIONS AND PARTS

7.17 SUB-ASSEMBLY - HIGH PRESSURE FILTER / CHECK VALVE / ORIFICE key number 1 2 3 4 5 6 7 8 9 part number 02250117-782 02250125-776 02250126-129 045244 860204-025 868504-025 870104-004 249604-022 02250162-941

description filter, assembly screen filter (I) orifice, plug brass 1/8npt x 3/32 sightglass, orf block sae valve, inline check (1/4npt) dc elbow, 37fl 90m 1/4 x 1/4 nipple, pipe-hx pltd 1/4 x 1/4 connector, straight x jic 7/16 x 7/16 hose,med press .25 x 44 lg elbow, 45 1/4 street

quantity 1 1 1 1 1 1 1 1 1

(I) For maintenance on filter assembly no. 02250117-782, order replacement assembly no. 02250117782. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 7.18 DISCHARGE / CHECK VALVE ASSEMBLY key number 1 2 3 4 5 6 7 8 9 part number 250003-977 02250077-816 consult chart below 40263 822408-125 807800-020 248418 839608-060 224593

description discharge check assy (I) cover, valve discharge body, check valve spring, discharge capscrew, 1/2-13unc x 1 1/4 plug, pipe 1/2 plate, identification screw, drive #8 x 3/8 gasket, mp cover

quantity 1 1 1 1 6 2 1 2 1

(I) For maintenance on discharge check valve assembly, order repair kit no. 606208-001. ITEM #3 234475 02250045-892 02250073-670 02250125-896 02250125-898 INLET 3" NPT 2.5 NPT 2.5 NPT M85 M85 DISCHARGE 3" NPT 2.5 NPT 2.5 4 BSF 2.5 4 BSF 3" 4 BSF ASSEMBLY P/N 016732B 02250049-880 02250081-044 02250126-832 02250127-507

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

109

Section 7 ILLUSTRATIONS AND PARTS

7.19 MINIMUM PRESSURE / CHECK VALVE

02250164-870R01

110

Section 7 ILLUSTRATIONS AND PARTS

7.19 MINIMUM PRESSURE / CHECK VALVE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 part number 02250045-892 02250045-893 02250045-894 224589 224593 224594 02250164-872 242104 02250164-873 242552 248418 249031 250031-844 250031-845 250031-846 807800-020 826502-152 828408-150 839608-060

description body assy, min/press valve piston, min/pressure valve spacer, min/press valve spring cover. mpv lv dhh20 gi ma gasket, mp cover retainer, 2.94 x 0.31 spl spring, min pressure valve capscrew, hex gr8 1/2-13 x 7 spring, com 2.09x7.07 150lb spacer. 00.75x00.56x3.68 plate, identification washer, pl b r 1/2 hardened spring, compr 1.293od w/.063 sleeve, check vlv guide min press piston, 250039-629 min press plug, pipe 1/2 3000# stl o-ring, viton 3 1/4 x 3/32 capscrew, ferry head hd 1/2-13 x 1 1/2 screw, drive rd hd #8 x 3/8

quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 2

NOTE
For maintenance on discharge check valve assembly, order repair kit no. 02250166-761. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

111

Section 7 ILLUSTRATIONS AND PARTS

7.20 FUEL SYSTEM AND PARTS - ALL MODELS

02250136-066R00

112

Section 7 ILLUSTRATIONS AND PARTS

7.20 FUEL SYSTEM AND PARTS - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 part number 02250047-049 02250047-335 02250049-998 02250051-257 02250111-934 02250125-437 02250126-242 250017-204 250020 -358 810510 -050 812106-025 841115-006 860206-050 866900-020 868906-015 868906-030 870606-038

description sender, fuel level 45 length sw, liq level vert fuel 12v tube, assy fuel pick-up 16000 conn, tube 3/8t x 3/8p special valve, check fuel 1/2 npt hose, fuel 1/2 x 98 lg rgd/swl hose, fuel rtrn swv/swv 3/8* 12 aid, starting elec 24v 1600cat grommet, rubber 1-3/4 hol e elbow, tube 90 deg m 5/8 x 1/2 conn, tube female 1/4p x 3/8t tubing, steel 3/8 elbow, 37fl 90m 3/8 x 1/2 plug, pipe 1/2 3000# stl plt bushing, red hex pltd 1 1/2 x 3/8 bushing, red hex pltd 1 1/2 x 3/4 conn, 900 str x jlc 9/16 x 9/16

quantity 1 1 1 1 1 1 1 1 1 1 1 5 ft. 1 1 1 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

113

Section 7 ILLUSTRATIONS AND PARTS

7.21 ELECTRICAL PARTS - ALL MODELS

02250127-727R01

114

Section 7 ILLUSTRATIONS AND PARTS

7.21 ELECTRICAL PARTS - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 part number 020130 02250048-005 02250051-629 02250053-256 02250053-257 02250058-614 02250058-615 02250127-728 02250127-732 02250137-257 040091 040162 040318 040703 041561 250034-212 408300-005 408300-009 824206-337 824815-006 825304-236 825305-283 829705-100 837205-071 837206-071 837506-094 843200-023 843200-025

description rod, 3/8-16 x 12 hold down, battery 16000 sol, spno 24vdc cont -duty cover, battery rubber 900/350-1600 plate, battery cover 1300h-1600 cable, batt 2/0 x 114 lg red cable, batt 2/0 x 114 lg black pnl, instr 900 xh tier ii (I) harness, eng/compr 900xh tier ii cable, ground #4 awg blk c 15 isolator, vibration l od x 3/4 tall grommet, rubber 1 hole cable, battery 1/0 12 battery, 8d/12 volt -wet boot, battery terminal cable, battery 34 3/8-1/2 eye black clamp, hose 5/8 i.d. clamp, hose 1 13/16 i.d. nut, hex unfin 3/8-16 nut, wing pltd 3/8-16 nut, hex f pltd 1/4-20 nut, hex f pltd 5/16-18 screw, hex ser washer 5/16-18 x 1 washer, pl-b reg unfin 5/16 washer, pl-b reg unfin 3/8 washer, spr lock 3/8 wrap, tie nylon ty 23m wrap, tie nylon tf4-8

quantity 3 1 1 1 1 1 1 1 1 1 2 2 1 2 4 1 3 2 8 1 8 2 4 2 3 2 8 20

(I) For complete breakdown of instrument panel parts, refer to Section 7.22 Instrument Panel and Parts All Models. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

115

Section 7 ILLUSTRATIONS AND PARTS

7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS

02250127-728R03

116

Section 7 ILLUSTRATIONS AND PARTS

7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 part number 02250047-254 02250050-514 02250050-519 02250050-521 02250051-144 02250054-511 02250075-312 02250084-933 02250086-008 02250086-011 02250086-113 02250087-540 02250087-547 02250087-558 02250094-725 02250127-731 02250127-733 040091 044205 250021-379 250022-436 250025-692 250032-761 250034-601 825202-130 825615-004 825905-080 837504-062 838805-120 860105-025

description divider, voltage 24v system gauge, temp mech 72 140-300 of gauge, fuel level 12vdc 2 gauge, vm 24dc 2 dia gauge, restr fltr 30 wc 2 lamp, 24v annunciator panel lens, flat top amber circuit breaker, 15 amp panel, instr 1600 h cat340 6e (I) switch, toggle spot on-none-mo cover, instr panel wiring 1600h plug, 40 pos male sealed plug, sealing plug and recept circuit, board first out annun lamp, miniature 24v-psb decal, instrument panel 900xh tier ii harness, instr panel 900xh tier ii isolator, vibration 100 x 3/4tall valve, 3-way ball (press sel) conn, str 1/4t pls 1/8 npt f weatherstrip, 3/16 x 3/8 screw, mach ph ill #10-24 x 1/2 gauge, pressure 2.5 cbm 600 psi switch, ignition anti-restart nut, hex pltd #10-24 nut, acorn pltd 1/4-20 nut, hex metric m5 x .8 washer, spr lock 1/4 washer, spr lock-metric pltd m5 conn, 37 fl/mpt pltd 5/16 x 1/4

quantity 1 1 1 1 2 4 4 2 1 1 1 1 34 1 4 1 1 4 2 2 3 ft. 4 1 1 4 4 4 4 4 2

Continued on page 119 (I) For detailed view of panel screen, consult Section 7.24, Decal Group (refer to key number 30 /part number 02250086-010). PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

117

Section 7 ILLUSTRATIONS AND PARTS

7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS

02250127-728R03

118

Section 7 ILLUSTRATIONS AND PARTS

7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS (CONTINUED) key number 31 32 33 part number 860205-025 860305-025 866900 -010

description elbow, 37fl 90m 5/16 x 1/4 elbow, 37fl 90f 5/16 x 1/4 plug, pipe 1 /4 3000 # stl plt

quantity 3 1 1

NOTE
Engine mounting panel: decal and bazel are supplied with engine. For additional assisstance, consult factory with serial number of machine.

NOTE
Refer to wiring diagram in Figure 2-7 (in Section 2, Description) for harness installation. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

119

Section 7 ILLUSTRATIONS AND PARTS

7.23 FRAME AND PARTS

02250136-503R02

120

Section 7 ILLUSTRATIONS AND PARTS

7.23 FRAME AND PARTS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 02250044-003 02250044-408 02250044-409 02250044-410 02250050-086 02250135-591 02250135-592 02250135-708 02250136-210 02250137-182 02250137-187 250022-436 824212-665 825106-337 825305-283 825510-329 828212-175 829106-125 829110-175 829705-075 834205-125 837806-094 837812-188 838205-071 838206-071 868706-125

description frame, assembly 1600q panel, belly pan frm mid 1600q panel, belly pan frm frt 1600q panel, hinged rear frm 1600q panel, frame frt 4w option 1600q support, air filter ss support, air filter cs bail, lifting 900xh through 1900 mount, utility feet 4 support, muffler 900xh open frame cover, batt 900xh open frame weatherstrip, 3/16 x 3/8 nut, hex unfin 3/4-10 nut, hex pltd 3/8-16 nut, hex f pltd 5/16-18 nut, hex locking 5/8-11 capscrew, hex gr8 3/4-10 x 1 3/4 capscrew, hex gr5 3/8-16 x 1 1/4 capscrew, hex gr5 5/8-11 x 1 3/4 screw, hex ser washer 5/16-18 x 3/4 screw, tc-hex 5/16-18 x 1 1/4 washer, spr lock reg pltd 3/8 washer, spr lock reg pltd 3/4 washer, pl-b reg pltd 5/16 washer, pl-b reg pltd 3/8 washer, bevel 3/8 plt

quantity 1 1 1 1 1 1 1 1 4 1 1 1 ft. 1 3 5 1 1 3 1 5 3 3 1 5 2 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

121

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP

122

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP key number 1 2 3 4 5 6 7 8 part number 250028-258 049685 02250051-826 049964 407408 049965 02250118-638 040248

description decal, warning 100/1600 (I) sign, warning compressor fluid fill cap decal, warning pressurized clg sys sign, warning sever belt drive sign, warning hot surfaces sign, warning sever fan port decal, warning proposition 65 (U.S. compressors only) decal, diesel fuel

quantity 1 1 1 1 2 2 1 1

Continued on page 125 (I) OSHA guidelines are superseded by any Federal, State or Local regulations whenever applicable. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

123

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP

124

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP (CONTINUED) key number 9 10 11 12 13 14 15 16 17 18 19 20 21 description decal, rated speed 1800/1400 RPM decal, aftercooler filter warning decal, control regulator high pressure decal, control regulator low pressure decal, standard air (all XHA models) decal, aftercooled air (all XHA models) decal, high / low decal, aftercooler warning (all XHA models) decal, Sullair AWF decal, water drain decal, receiver fluid fill level 1.75 decal, ISO 9001 decal, run mode part number 250023-695 02250119-012 02250075-085 02250075-086 02250085-467 02250085-468 02250052-572 02250085-469 250032-902 040345 250023-655 02250057-624 02250075-087 quantity 1 1 1 1 1 1 1 1 1 1 1 1 1

Continued on page 127

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

125

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP

126

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP (CONTINUED) key number 22 23 26 part number 02250086-562 02250094-692 02250121-400 02250121-401 02250138-298 02250138-299 02250147-921 02250147-922 02250109-529 02250145-162 Continued on page 129

description decal, maintenance 1600H - 1900 Cat 3406e decal, start - stop EMS functions decal, rating 900XH - black decal, rating 900XH - white (not shown) decal, rating 1150XH - black (not shown) decal, rating 1150XH - white (not shown) decal, rating 1350XH - black (not shown) decal, rating 1350XH - white (not shown) decal, CAT Diesel Power decal, wiring diagram cat c15 tii 900xh

quantity 1 1 1 1 1 1 1 1 1 1

25 27

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

127

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP

128

Section 7 ILLUSTRATIONS AND PARTS

7.24 DECAL GROUP (CONTINUED) key number 30 31 part number 02250127-731 02250057-607

description decal, panel 900xh tii decal, Sullair logo 8.12 x 67 black

quantity 1 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

129

Section 7 ILLUSTRATIONS AND PARTS

7.25 DECAL LOCATIONS

02250136-067R03

130

Section 7 ILLUSTRATIONS AND PARTS

7.25 DECAL LOCATIONS key number 1 2 3 4 5 6 7 8 9 10 11 12 part number 02250057-624 02250154-354 02250094-692 02250108-078 02250109-529 02250118-638 02250121-332 (I) 02250127-584 040248 040345 049685

description decal, iso 9001 blk 3.44x5.75 decal, maintenance 425xh-1150xhh cat c-16 decal, start/stop ems functions npl, sullair serial no. 1850-8f decal, cat diesel power decal, lead warning proposition 65 decal, sullair 7.63 x 45.75 white decal, 900xh sullair decal, wire-diagram cat c15 decal, diesel fuel decal, water drain decal, warning oil fill

quantity 1 1 1 1 1 1 3 1 1 2 1 1

Continued on page 133 (I) To determine correct part number for specific model and color decal, consult Section 7.24 Decal Group (key number 26), for a breakdown of part numbers by model and color. DECAL, GROUP 600-1600Q (250021-833) : These decals are on one sheet QTY PART NO. DESCRIPTION LOCATION radiator drain engine drain (2 x) 4 040345 decal, water drain rear shown 2 040248 decal, caution diesel fuel only shown ( 2 x) 2 407408 decal, warning hot surfaces lifting bail (2 x) 2 049965 decal, sever fan each side of venturi each side of venturi 3 049964 decal, warning sever belt near end of alternator 1 049685 decal, warning pressurized vessel receiver tank fill 1 250028-258 decal, warning group 100-1600 air discharge 1 250032-902 decal, compressor fluid AWF receiver tank fill 1 02250051-826 decal, warning pres. cooling sysem near radiator fill PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

131

Section 7 ILLUSTRATIONS AND PARTS

7.25 DECAL LOCATIONS

02250136-067R03

132

Section 7 ILLUSTRATIONS AND PARTS

7.25 DECAL LOCATIONS (CONTINUED) key number 13 14 15 16 17 18 part number 250023-655 250023-695 250028-258 250032-902 407408 843102-038

description decal, receiver oil fill level decal, rated 1800 idle 1400 rpm decal, warning group decal, sullair awf decal, hot surfaces rivet, pop 1/8 x 3/8 DECALS NOT SHOWN ON DRAWING DESCRIPTION QTY decal, high pressure select instrument panel 1 decal, low press control reg back pressure reg 1 decal, high pressure valve back pressure reg 1 decal, 60 psig run mode reducing regulator 1

quantity 1 1 1 1 3 4

PART NO. 02250052-572 02250075-085 02250075-086 02250075-087

LOCATION instrument panel back pressure regulator back pressure regulator reducing regulator

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR

133

NOTES

134

WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD.

Sullair Road, No. 1 Chiwan, Shekou Shenzhen, Guangdong PRV. PRC POST CODE 518068 : 755-6851686 Fax: 755-6853473 www.sullair-asia.com

CHAMPION COMPRESSORS, LTD.

Princes Highway Hallam, Victoria 3803 Australia : 61-3-9796-4000 Fax: 61-3-9703-8053 www.championcompressors.com.au/

SULLAIR EUROPE, S.A.

Zone Des Granges BP 82 42602 Montbrison Cedex, France : 33-477968470 Fax: 33-477968499 www.sullaireurope.com

SULLAIR CORPORATION
3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. www.sullair.com : 1-800-SULLAIR (U.S.A. Only) or 1-219-879-5451 Fax: (219) 874-1273

CUSTOMER CARE for PARTS and SERVICE

: 1-888-SULLAIR (7855247) or 219-874-1835

Printed in the U.S.A.

DEV

Specifications Subject To Change Without Prior Notice E06