User Manual: P A C 600H, 750, 750H, 750HH, 825, 900 & 900H V

USER MANUAL
PORTABLE
3257$%/($A,5IR&C2035(6625
OMPRESSOR
600H, 750, 750H, 750HH,
++++
825, 900 & 900H
+++
VOLVO
PART NUMBER:
02250204-107 R01
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
COPYRIGHT 2013 SULLAIR
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
201210010000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
SULLAIR TRAINING DEPARTMENT
1-888-SULLAIR or
219-861-5623
www.sullair.com
training@sullair.com
- Or Write -
Sullair
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 TOWING *
8 1.3 PRESSURE RELEASE
9 1.4 FIRE AND EXPLOSION
10 1.5 MOVING PARTS
11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
11 1.7 TOXIC AND IRRITATING SUBSTANCES
13 1.8 ELECTRICAL SHOCK
13 1.9 LIFTING
13 1.10 ENTRAPMENT
13 1.11 JUMP STARTING
14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT
15 1.13 CALIFORNIA PROPOSITION 65
16 1.14 SYMBOLS AND REFERENCES
SECTION 2—DESCRIPTION
21 2.1 INTRODUCTION
22 2.2 DESCRIPTION OF COMPONENTS
23 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
23 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
24 2.5 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
25 2.6 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
26 2.7 AFTERCOOLED AIR SYSTEM, FUNCTIONAL DESCRIPTION
27 2.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
28 2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR
30 2.10 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE
34 2.11 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
35 2.12 ENGINE CONTROL MODULE, FUNCTIONAL DESCRIPTION
35 2.13 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
36 2.14 CONTROLLER WIRING DIAGRAM
38 2.15 COMPRESSOR WIRING DIAGRAM
TABLE OF CONTENTS
SECTION 3—SPECIFICATIONS
41 3.1 TABLE OF SPECIFICATIONS-600H, 750, 750H, 750HH
43 3.2 TABLE OF SPECIFICATIONS-825, 900, 900H
44 3.3 LUBRICATING GUIDE - COMPRESSOR
44 3.4 APPLICATION GUIDE
45 3.5 LUBRICATION GUIDE, ENGINE
46 3.6 IDENTIFICATION, LESS RUNNING GEAR (DLQ)
48 3.7 IDENTIFICATION, TANDEM AXLE (DTQ)
50 3.8 IDENTIFICATION, 4-WHEEL (DWQ)
SECTION 4—OPERATION
53 4.1 GENERAL
53 4.2 PURPOSE OF CONTROLS
54 4.3 COMPRESSOR START-UP PROCEDURE
54 4.4 COMPRESSOR SHUT-DOWN PROCEDURE
SECTION 5—MAINTENANCE
55 5.1 GENERAL
55 5.2 DAILY OPERATION
55 5.3 ENGINE COOLANT
56 5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
56 5.5 5.5 MAINTENANCE EVERY 100 HOURS
56 5.8 MAINTENANCE EVERY 600 HOURS
57 5.11 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
64 5.12 TROUBLESHOOTING GUIDE
SECTION 6—NOISE CONTROL

67 6.1 NOISE EMISSIONS WARRANTY
67 6.2 TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED
68 6.3 NOISE EMISSIONS MAINTENANCE & MAINTENANCE RECORD LOG
Section 1
SAFETY
DO NOT modify the compressor except with written
NOTE 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
OPERATOR IS REQUIRED TO READ required.
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL 1.2 TOWING *

Sullair designs and manufactures all of its products PREPARING TO TOW
so they can be operated safely. However, the
responsibility for safe operation rests with those who
use and maintain these products. The following WARNING
safety precautions are offered as a guide which, if
conscientiously followed, will minimize the possibility Do NOT tow the compressor should its
of accidents throughout the useful life of this weight exceed the rated limit of the tow
equipment. Read the CIMA Safety Manual prior to vehicle, as the vehicle may not brake safely
compressor operation and towing, if applicable with excess weight. See rated limit in tow
in your area. vehicle Operator's Manual, and review its
instructions and other requirements for
The air compressor should be operated only by those
safe towing.
who have been trained and delegated to do so, and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, procedures
A. Prior to hitching the air compressor to the tow
and safety precautions in this manual can result in vehicle, inspect all attachment parts and equip-
accidents and injuries. ment, checking for (I) signs of excessive wear or
NEVER start the air compressor unless it is safe to corrosion, (II) parts that are cracked, bent,
do so. DO NOT attempt to operate the air dented or otherwise deformed or degraded, and
(III) loose nuts, bolts or other fasteners. Should
compressor with a known unsafe condition. Tag the
any such condition be present, DO NOT TOW
air compressor and render it inoperative by until the problem is corrected.
disconnecting and locking out all power at source or
otherwise disabling its prime mover so others who B. Back the tow vehicle to the compressor and posi-
may not know of the unsafe condition cannot attempt tion it in preparation for coupling the compressor.
to operate it until the condition is corrected. C. If the compressor is provided with a drawbar
Use and operate the air compressor only in full latched in the vertical upright position, carefully
compliance with all pertinent OSHA requirements unlatch drawbar and lower it to engage the cou-
and/or all pertinent Federal, State and Local codes or pling device. If not, raise drawbar with the jack to
requirements.
* 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.
5
SECTION 1
engage coupling device or otherwise couple the

compressor to the towing vehicle.
CAUTION
WARNING
Retract the front screw jack only after
This equipment may be tongue heavy. DO attaching the compressor to the tow vehi-
NOT attempt to raise or lower the drawbar cle. Raise the screw jack to its full up posi-
by hand if the weight is more than you can tion and pull the pin connecting the jack to
safely handle. the drawbar. Rotate the screw jack to its
stowed position, parallel to the drawbar,
Use the screw jack provided or a chain fall and reinsert the pin. Make sure the jack is
if you cannot lift or lower it without avoiding secured in place prior to towing.
injury to yourself or others. Keep hands
and fingers clear of the coupling device and If a caster wheel is provided on the screw
all other pinch points. Keep feet clear of jack it is part of the screw jack and can not
drawbar to avoid injury in case it should be removed. Follow the same procedure for
slip from your hands. stowing away the wheeled jack as you
would for the standard screw jack. Pull the
D. Make sure the coupling device is fully engaged, pin connecting the jack to the drawbar and
closed and locked. raise the screw jack to its full up position.
Rotate the screw jack to its stowed posi-
E. If chains are provided, pass each chain through tion, parallel to the drawbar, and reinsert
its point of attachment on the towing vehicle; the pin. Make sure the jack is secured in
then hook each chain to itself by passing the place prior to towing.
grab hook over (not through) a link. Cross chains
under the front of drawbar before passing them H. On two-wheeled models, fully retract front screw
through points of attachment on towing vehicle to jack and any rear stabilizer legs. If a caster wheel
support the front of drawbar in case it should is provided on the screw jack it is part of the
accidentally become uncoupled. screw jack, and can not be removed. Follow the
F. Make sure that the coupling device and adjacent same procedure for stowing away the wheeled
structures on the towing vehicle (and also, if uti- jack as you would for the standard screw jack.
lized, chain adjustment, brake and/or electrical Pull the pin connecting the jack to the drawbar
interconnections) DO NOT interfere with or and raise the screw jack to its full upright posi-
restrict motion of any part of the compressor, tion. Rotate the screw jack to its stowed position,
including its coupling device, with respect to the parallel to the drawbar, and reinsert the pin.
towing vehicle when maneuvering over any Make sure the jack is secured in place prior to
anticipated terrain. towing.
G. If provided, make sure chain length, brake and I. Make sure tires are in good condition and are the
electrical interconnections provide sufficient size (load range) specified and are inflated to the
slack to prevent strain when cornering and specified pressures. DO NOT change the tire
maneuvering, yet are supported so they cannot size or type. Also, make sure wheel bolts, lugs or
drag or rub on road, terrain or towing vehicle sur- nuts are tightened to the specified torques.
faces which might cause wear that could render J. If provided, make sure all dual stop, tail direc-
them inoperative. tional and clearance lights are operating properly
and that their lenses are clean and functional.
Also, make sure all reflectors and reflecting sur-
WARNING faces, including the slow moving vehicle emblem
on compressors provided with same, are clean
This equipment may be tongue heavy. DO and functional.
NOT attempt to raise or lower the drawbar
by hand if the weight is more than you can K. Make sure all service air hoses (not air brake
safely handle. hoses) are disconnected or are fully stowed and
secured on hose reels, if provided.
6
SECTION 1
L. Make sure all access doors and tool box covers E. Avoid potholes, rocks and other obstructions,
are closed and latched. If the compressor is and soft shoulders or unstable terrain.
large enough to hold a man, make sure all per-
F. Maneuver in a manner that will not exceed the
sonnel are out before closing and latching
freedom of motion of the compressor’s drawbar
access doors.
and/ or coupling device, in or on the towing vehi-
M. Make sure parking brakes in towing vehicle are cle’s coupling device and/or adjacent structure
set, or that its wheels are chocked or blocked, or whether towing forward or backing up, regard-
that it is otherwise restrained from moving. Then, less of the terrain being traversed.
release the compressor parking brakes, if pro-
G. DO NOT permit personnel to ride in or on the
vided.
compressor.
N. Make sure the compressor wheels are not
H. Make sure the area behind, in front of, and under
chocked or blocked, and that all tie-downs, if any,
the compressor is clear of all personnel and
are free.
obstructions prior to towing in any direction.
O. Test running brake operation, including break-
I. DO NOT permit personnel to stand or ride on the
away switch operation if provided, before
drawbar, or to stand or walk between the com-
attempting to tow the compressor at its rated
pressor and the towing vehicle.
speed or less when conditions prevail.
P. DO NOT carry loose or inappropriate tools, PARKING OR LOCATING COMPRESSOR
equipment or supplies on or in the compressor. A. Park or locate compressor on a level surface, if
Q. DO NOT load this equipment with accessories or possible. If not, park or locate compressor across
tools such that it is unbalanced from side to side grade so the compressor does not tend to roll
or front to back. Such unbalance will reduce the downhill. DO NOT park or locate compressor on
towability of this equipment and may increase grades exceeding 15° (27%).
the possibility of tipping, rolling over, jackknifing, B. Make sure compressor is parked or located on a
etc. Loss of control of the towing vehicle may firm surface that can support its weight.
result.
C. Park or locate compressor so the wind, if any,
TOWING tends to carry the exhaust fumes and radiator
heat away from the compressor air inlet open-
A. Observe all Federal, State, and Local laws while
ings, and also where the compressor will not be
towing this equipment (including those specifying
exposed to excessive dust from the work site.
minimum speed).
D. On steerable models, park compressor with front
B. DO NOT exceed the towing speeds listed below
wheels in straight-ahead position.
under ideal conditions. Reduce your speed
according to posted speed limits, weather, traffic, E. Set parking brakes and disconnect breakaway
road or terrain conditions: switch cable and all other interconnecting electri-
cal and/or brake connections, if provided.
1. Two axle four-wheel or three axle six-wheel
steerable models: 15 MPH (24 km/h). F. Block or chock both sides of all wheels.
2. All other models: 55 MPH (88 km/h). G. If provided, unhook chains and remove them
C. Remember that the portable air compressor may from the points of chain attachment on the towing
approach or exceed the weight of the towing vehicle, then hook chains to bail on drawbar or
vehicle. Maintain increased stopping distances wrap chains around the drawbar and hook them
accordingly. DO NOT make sudden lane to themselves to keep chains off the ground
changes, U-turns or other maneuvers. Such which might accelerate rusting.
maneuvers can cause the compressor to tip, roll H. Lower front screw jack and/or any front and rear
over, jackknife or slide and cause loss of control stabilizer legs. Make sure the surface they con-
of the towing vehicle. Tipping, rolling over, etc. tact has sufficient load bearing capability to sup-
can occur suddenly without warning. U-turns port the weight of the compressor.
especially should be made slowly and carefully.
D. Avoid grades in excess of 15° (27%).
7
SECTION 1
chain fall if you cannot lift or raise the drawbar

without avoiding injury to yourself or others.
K. Move the towing vehicle well clear of the parked
WARNING compressor and erect hazard indicators, barri-
cades and/or flares (if at night) if compressor is
This equipment may be tongue heavy. DO parked on or adjacent to public roads. Park so as
NOT attempt to raise or lower the drawbar not to interfere with traffic.
by hand if the weight is more than you can
safely handle.
NOTE
CAUTION While not towed in the usual sense of the
word, many of these instructions are
directly applicable to skidmounted porta-
Retract the front screw jack only after ble air compressors as well.
attaching the compressor to the tow vehi-
cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to 1.3 PRESSURE RELEASE
the drawbar. Rotate the screw jack to its
stowed position, parallel to the drawbar, A. Open the pressure relief valve at least weekly to
and reinsert the pin. Make sure the jack is make sure it is not blocked, closed, obstructed or
secured in place prior to towing. otherwise disabled.
On two-wheeled models, fully retract front B. Install an appropriate flow-limiting valve between
screw jack and any rear stabilizer legs. If a the compressor service air outlet and the shutoff
caster wheel is provided on the screw jack (throttle) valve, when an air hose exceeding 1/2"
it is part of the screw jack and can not be (13 mm) inside diameter is to be connected to
removed. Follow the same procedure for the shutoff (throttle) valve, to reduce pressure in
stowing away the wheeled jack as you case of hose failure, per OSHA Standard 29 CFR
would for the standard screw jack. Pull the 1926.302 (b) (7) or any applicable Federal, State
pin connecting the jack to the drawbar and and Local codes, standards and regulations.
raise the screw jack to its full up position. C. When the hose is to be used to supply a mani-
Rotate the screw jack to its stowed posi- fold, install an additional appropriate flow-limiting
tion, parallel to the drawbar, and reinsert valve between the manifold and each air hose
the pin. Make sure the jack is secured in exceeding 1/2" (13 mm) inside diameter that is to
place prior to towing. be connected to the manifold to reduce pressure
in case of hose failure.
I. If a caster wheel is provided on the screw jack, it
is part of the screw jack and cannot be removed. D. Provide an appropriate flow-limiting valve for
Follow the same procedure for stowing away the each additional 75 feet (23 m) of hose in runs of
wheeled jack as you would for the standard air hose exceeding 1/2" (13 mm) inside diameter
screw jack. Raise the screw jack to its full upright to reduce pressure in case of hose failure.
position and pull the pin connecting the jack to E. Flow-limiting valves are listed by pipe size and
the drawbar. Rotate the screw jack to its stowed rated CFM. Select appropriate valve accordingly.
position, parallel to the drawbar and reinsert the
pin. Make sure the jack is secured in place prior F. DO NOT use tools that are rated below the maxi-
to towing. mum rating of this compressor. Select tools, air
hoses, pipes, valves, filters and other fittings
J. Disconnect coupling device, keeping hands and accordingly. DO NOT exceed manufacturer’s
fingers clear of all pinch points. If the compressor rated safe operating pressures for these items.
is provided with a drawbar, DO NOT attempt to
lift the drawbar or if hinged, to raise it to the G. Secure all hose connections by wire, chain or
upright position by hand, if the weight is more other suitable retaining device to prevent tools or
than you can safely handle. Use a screwjack or hose ends from being accidentally disconnected
and expelled.
8
SECTION 1
H. Open fluid filler cap only when compressor is not 1.4 FIRE AND EXPLOSION
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
WARNING
line, fitting, hose, valve, drain plug, connection or Do not attempt to operate the compressor
other component, such as filters and line oilers, in any classification of hazardous environ-
and before attempting to refill optional air line ment or potentially explosive atmosphere
anti-icer systems with antifreeze compound. unless the compressor has been specially
J. Keep personnel out of line with and away from designed and manufactured for that duty.
the discharge opening of hoses, tools or other
points of compressed air discharge. A. Refuel at a service station or from a fuel tank
K. DO NOT use air at pressures higher than 30 psig designed for its intended purpose. If this is not
(2.1 bar) for cleaning purposes, and then only possible, ground the compressor to the dis-
with effective chip guarding and personal protec- penser prior to refueling.
tive equipment per OSHA Standard 29 CFR B. Clean up spills of lubricant or other combustible
1910.242 (b) or any applicable Federal, State substances immediately, if such spills occur.
and Local codes, standards and regulations.
C. Shut off air compressor and allow it to cool. Then
L. DO NOT engage in horseplay with air hoses as keep sparks, flames and other sources of ignition
death or serious injury may result. away and DO NOT permit smoking in the vicinity
M. This equipment is supplied with an ASME when adding fuel, checking or adding electrolyte
designed pressure vessel protected by an ASME to batteries, checking or adding fluid, checking
rated relief valve. Lift the handle once a week to diesel engine ether starting aid systems, replac-
make sure the valve is functional. DO NOT lift ing cylinders, or when refilling air line anti-icer
the handle while machine is under pressure. systems antifreeze compound.
N. If the machine is installed in an enclosed area it D. DO NOT permit fluids, including air line anti-icer
is necessary to vent the relief valve to the outside system antifreeze compound or fluid film, to
of the structure or to an area of non-exposure. accumulate on, under or around acoustical mate-
rial, or on any external surfaces of the air com-
O. DO NOT remove radiator filler cap until the cool- pressor. Wipe down using an aqueous industrial
ant temperature is below its boiling point. Then cleaner or steam clean as required. If necessary,
loosen cap slowly to its stop to relieve any remove acoustical material, clean all surfaces
excess pressure and make sure coolant is not and then replace acoustical material. Any acous-
boiling before removing cap completely. Remove tical material with a protective covering that has
radiator filler cap only when cool enough to touch been torn or punctured should be replaced
with a bare hand. immediately to prevent accumulation of liquids or
P. The ethyl ether in the replaceable cylinders used fluid film within the material. DO NOT use flam-
in diesel ether starting aid systems (optional) is mable solvents for cleaning purposes.
under pressure. DO NOT puncture or incinerate E. Disconnect and lock out all power at source prior
those cylinders. DO NOT attempt to remove the to attempting any repairs or cleaning of the com-
center valve core or side pressure relief valve pressor or of the inside of the enclosure, if any.
from these cylinders regardless of whether they
are full or empty. F. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace
Q. If a manual blowdown valve is provided on the any wiring that has cracked, cut, abraded or oth-
receiver, open the valve to ensure all internal erwise degraded insulation, or terminals that are
pressure has been vented prior to servicing any worn, discolored or corroded. Keep all terminals
pressurized component of the compressor air/ and pressure connectors clean and tight.
fluid system.
G. Turn off battery charger before making or break-
ing connections to the battery.
9
SECTION 1
H. Keep grounded and/or conductive objects such temperatures above 150 °F (66 °C). Vapors from
as tools away from exposed live electrical parts the antifreeze compound are heavier than air.
such as terminals to avoid arcing which might DO NOT store compound or discharge treated
serve as a source of ignition. air in confined or unventilated areas. DO NOT
store containers of antifreeze compound in direct
I. Replace damaged fuel tanks or lines immediately
sunlight.
rather than attempt to weld or otherwise repair
them. DO NOT store or attempt to operate the S. Store flammable fluids and materials away from
compressor with any known leaks in the fuel sys- your work area. Know where fire extinguishers
tem. Tag the compressor and render it inopera- are and how to use them, and for what type of
tive until repair can be made. fire they are intended. Check readiness of fire
suppression systems and detectors if so
J. Remove any acoustical material or other material
equipped.
that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to T. DO NOT operate the compressor without proper
attempting weld repairs. flow of cooling air or water or with inadequate
flow of lubricant or with degraded lubricant.
K. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when ser- U. DO NOT attempt to operate the compressor in
vicing and operating the compressor. any classification of hazardous environment
unless the compressor has been specially
L. Keep oily rags, trash, leaves, litter or other com-
designed and manufactured for that duty.
bustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure to 1.5 MOVING PARTS
ventilate thoroughly prior to attempting to start
the engine.
N. DO NOT operate compressor under low over-
hanging leaves or permit such leaves to contact
WARNING
hot exhaust system surfaces when operating the Disconnect and lock out all power at source
compressor in forested areas. and verify at the compressor that all circuits
O. Ethyl ether used in diesel engine ether starting are de-energized to minimize the possibility
aid systems is extremely flammable. Change cyl- of accidental start-up, or operation, prior to
inders, or maintain or troubleshoot these sys- attempting repairs or adjustments. This is
tems only in well-ventilated areas away from especially important when compressors are
heat, open flame or sparks. DO NOT install, remotely controlled.
store or otherwise expose ether cylinders to tem-
peratures above 160 °F (71 °C). Remove ether A. Keep hands, arms and other parts of the body
cylinder from the compressor when operating in and also clothing away from couplings, fans and
ambient temperatures above 60 °F (16 °C). other moving parts.
P. DO NOT attempt to use ether as a starting aid in B. DO NOT attempt to operate the compressor with
gasoline engines or diesel engines with glow the fan, coupling or other guards removed.
plugs as serious personnel injury or property
damage may result. C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
Q. DO NOT spray ether into compressor air filter or when exposed to hot or moving parts.
into an air filter that serves both the engine and
the compressor as serious damage to the com- D. Make sure all personnel are out of and/or clear of
pressor or personal injury may result. the compressor prior to attempting to start or
operate it.
R. Antifreeze compound used in air line anti-icer
systems contains methanol which is flammable. E. When adjusting the controls, it may require oper-
Use systems and refill with compound only in ation of the equipment during adjustment. DO
well-ventilated areas away from heat, open NOT come in contact with any moving parts
flames or sparks. DO NOT expose any part of while adjusting the control regulator and setting
these systems or the antifreeze compound to the engine RPM. Make all other adjustments with
10
SECTION 1
the engine shut off. When necessary, make

adjustment, other than setting control regulator
and engine RPM, with the engine shut off. If nec-
essary, start the engine and check adjustment. If
adjustment is incorrect, shut engine off, readjust,
T4 - WARNING
then restart the engine to recheck adjustment.
Increased DPF skin temperature and
F. Keep hands, feet, floors, controls and walking exhaust gas temperature may occur in the
surfaces clean and free of fluid, water or other event of an unexpected engine/aftertreat-
liquids to minimize the possibility of slips and ment failure. An unexpected failure of the
falls. engine/aftertreatment may increase temper-
ature at the DPF as high as 900 °C (1652 °F)
1.6 HOT SURFACES, SHARP gas temperature and 750 °C (1382 °F) skin
EDGES AND SHARP temperature. This may result in fire, burn, or
CORNERS explosion hazards, which may result in per-
sonal injury or death. Do not expose flam-
A. Avoid bodily contact with hot fluid, hot coolant, mable material or explosive atmospheres to
hot surfaces and sharp edges and corners. exhaust gas or exhaust system components
during regeneration. The aftertreatment skin
B. Keep all parts of the body away from all points of
temperature and the gas temperature are
air discharge and away from hot exhaust gases.
difficult to measure and/or simulate and are
C. Wear personal protective equipment including dependent upon many factors including the
gloves and head covering when working in, on or following: the nature of the engine/after-
around the compressor. treatment failure, the design and packaging
of the aftertreatment, the engine speed/load
D. Keep a first aid kit handy. Seek medical assistance
conditions, the condition of the aftertreat-
promptly in case of injury. DO NOT ignore small
ment and ambient conditions. Therefore,
cuts and burns as they may lead to infection.
the potential temperatures are provided as a
1.6.1 TIER 4 EMISSIONS MODULE guideline even under conditions of unex-
pected engine and/or aftertreatment failure.
General Guidelines: Thermal Protection. The main Proper precautions should be taken to
exhaust piping routes exhaust gas from the engine to ensure that the aftertreatment device is not
the Clean Emissions Module (CEM). Normal mounted in close proximity to components
operating temperatures can reach up to 530 °C (986 that may be damaged by heat.
°F). During regeneration of the Diesel Particulate
Filter (DPF), the Auxiliary Regeneration Device
(ARD) will be in operation, this creating temperatures 1.7 TOXIC AND IRRITATING
above normal engine exhaust temperatures. Gas SUBSTANCES
temperatures during the regeneration period can
reach 750 °C (1382 °F). A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other
Federal, State or Local codes or regulations.
DANGER
11
SECTION 1
should be washed with large quantities of clean

DANGER water for fifteen minutes. A physician, preferably
an eye specialist, should be contacted immedi-
ately.
INHALATION HAZARD!
K. DO NOT store ether cylinders or air line anti-icer
Death or serious injury can result from system antifreeze compound in operator’s cabs
inhaling compressed air without using or in other similar confined areas.
proper safety equipment. See OSHA stan-
dards and/or any applicable Federal, State, L. The antifreeze compound used in air line anti-
and Local codes, standards and regulations freeze systems contains methanol and is toxic,
on safety equipment. harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
B. DO NOT use air line anti-icer systems in air lines swallowed, induce vomiting by administering a
supplying respirators or other breathing air utili- tablespoon of salt, in each glass of clean, warm
zation equipment and DO NOT discharge air water until vomit is clear, then administer two
from these systems into unventilated or other teaspoons of baking soda in a glass of clean
confined areas. water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
C. Operate the compressor only in open or ade-
quately ventilated areas. M. When handling DEF (Diesel Emissions Fluid)
wear protective clothing. Tools and clothing that
D. Locate the compressor so that exhaust fumes are come in contact with DEF must be cleaned.
not apt to be carried towards personnel, air intakes
servicing personnel areas or towards the air intake
of any portable or stationary compressor.
E. Fuels, fluids and lubricants used in this compres-
-IMPORTANT
sor are typical of the industry. Care should be It is very important that all electrical connec-
taken to avoid accidental ingestion and/or skin tors are protected from coming in contact
contact. In the event of ingestion, seek medical with DEF. If not, there is a risk that DEF will
treatment promptly. Wash with soap and water in cause oxidation in the wiring that is not pos-
the event of skin contact. Consult Material Safety sible to clean. The resulting oxidation will
Data Sheet for information pertaining to the spe- result in a wiring/connection failure. Water
cific fluid. and compressed air fail to remove DEF. If a
F. Wear goggles or a full face shield when adding connector has been in contact with DEF, it
antifreeze compound to air line anti-icer systems. must be changed immediately to prevent
the chemical from further migrating into the
G. Wear an acid-resistant apron and a face shield or wiring cable harness, which happens at a
goggles when servicing the battery. If electrolyte speed of 0.6 m/h.
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. -WARNING
Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, DO NOT In case of DEF contact with eyes or skin,
induce vomiting and call a physician immediately. the affected area must be thoroughly rinsed
with lukewarm water. If you breathe any
I. Wear goggles or a full face shield when testing
fumes, make sure and breathe fresh air.
ether starting aid systems or when adding anti-
freeze 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 air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
12
SECTION 1
1.8 ELECTRICAL SHOCK I. Keep lift operator in constant attendance when-

ever compressor is suspended.
A. Keep the towing vehicle or equipment carrier,
J. Set compressor down only on a level surface capa-
compressor hoses, tools and all personnel at
ble of supporting at least its net weight plus an
least 10 feet (3 m) from power lines and buried
additional 10% allowance for the weight of water,
cables.
snow, ice, mud, stored tools, and/or equipment.
B. Stay clear of the compressor during electrical
K. If the compressor is provided with parking
storms! It can attract lightning.
brakes, make sure they are set, and in any
C. Keep all parts of the body and any hand-held event, block or chock both sides of all running
tools or other conductive objects away from wheels before disengaging the lifting hook.
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO 1.10 ENTRAPMENT
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed A. Make sure all personnel are out of compressor
live parts of the electrical system. before closing and engaging enclosure doors.
D. Attempt repairs in clean, dry and well lighted and B. If the compressor is large enough to hold a man
ventilated areas only. and if it is necessary to enter it to perform service
adjustments, inform other personnel before
1.9 LIFTING doing so, or else secure the access door in the
open position to avoid the possibility of others
A. If the compressor is provided with a lifting bail, closing and possibly latching the door with per-
then lift by the bail provided. If no bail is provided, sonnel inside.
then lift by sling. Compressors to be air lifted by
helicopter must not be supported by the lifting 1.11 JUMP STARTING
bail, but by slings instead. In any event, lift only in
full compliance with OSHA Standards 29 CFR A. Observe all safety precautions mentioned else-
1910 subpart N or any other Local, State, Military where in this manual.
and Federal regulations that may apply.
B. Batteries may contain hydrogen gas which is
B. Inspect lifting bail and points of attachment for flammable and explosive. Keep flames, sparks
cracked welds and for cracked, bent, corroded or and other sources of ignition away.
otherwise degraded members and for loose bolts
C. Batteries contain acid which is corrosive and poi-
or nuts prior to lifting.
sonous. DO NOT allow battery acid to contact
C. Make sure entire lifting, rigging and supporting eyes, skin, fabrics or painted surfaces as serious
structure has been inspected, is in good condition personal injury or property damage could result.
and has a rated capacity of at least the net weight Flush any contacted areas thoroughly with water
of the compressor plus an additional 10% allow- immediately. Always wear an acid-resistant
ance for weight of water, snow, ice, mud, stored apron and face shield when attempting to jump
tools, and equipment. If your are unsure of the start the compressor.
weight, then weigh compressor before lifting.
D. Remove all vent caps (if so equipped) from the
D. Make sure lifting hook has a functional safety battery or batteries in the compressor. DO NOT
latch or equivalent, and is fully engaged and permit dirt or foreign matter to enter the open
latched on the bail. cells.
E. Use guide ropes or equivalent to prevent twisting E. Check fluid level. If low, bring fluid to proper level
or swinging of the compressor once it has been before attempting to jump start (not applicable to
lifted clear of the ground. maintenance-free batteries).
F. DO NOT attempt to lift in high winds. F. DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60 °F (16
G. Keep all personnel out from under and away
°C) before attempting to jump start or it may
from the compressor whenever it is suspended.
explode.
H. Lift compressor no higher than necessary.
13
SECTION 1
G. Cover open cells of all compressor batteries with tery in the starting vehicle. When jump starting
clean dampened cloths before attempting to 24V compressors and if the starting vehicle is
jump start. provided with two (2) 12V batteries connected in
series, connect the jumper cable to the negative
H. Attempt to jump start only with a vehicle having a
(NEG) (-) terminal of the grounded battery.
negative ground electrical system with the same
voltage, and is also equipped with a battery or R. Check your connections. DO NOT attempt to
batteries of comparable size or larger than sup- start a 24V compressor with one 12V battery in
plied in the compressor. DO NOT attempt to the starting vehicle. DO NOT apply 24V to one
jump start using motor generator sets, welders or 12V battery in the compressor.
other sources of DC power as serious damage
S. Connect the other end of this same jumper cable
may result.
to a clean portion of the compressor engine
I. Bring the starting vehicle alongside the compres- block away from fuel lines, the crank case
sor, but DO NOT permit metal to metal contact breather opening and the battery.
between the compressor and the starting vehicle.
T. Start the compressor in accordance with normal
J. Set the parking brakes of both the compressor (if procedure. Avoid prolonged cranking.
provided) and the starting vehicle or otherwise
U. Allow the compressor to warm up. When the
block both sides of all wheels.
compressor is warm and operating smoothly at
K. Place the starting vehicle in neutral or park, turn normal idle RPM, disconnect the jumper cable
off all non-essential accessory electrical loads from the engine block in the compressor, then
and start its engine. disconnect the other end of this same cable from
the grounded negative (NEG) (-) terminal of the
L. Use only jumper cables that are clean, in good
battery in the starting vehicle. Then disconnect
condition and are heavy enough to handle the
the other jumper cable from the positive (POS)
starting current.
(+) terminal of the battery in the compressor, or if
M. Avoid accidental contact between jumper cable provided with two (2) 12V batteries connected in
terminal clips or clamps and any metallic portion series, from the ungrounded battery in the com-
of either the compressor or the starting vehicle to pressor, and finally, disconnect the other end of
minimize the possibility of uncontrolled arcing this same jumper cable from the positive (POS)
which might serve as a source of ignition. (+) terminal of the battery in the starting vehicle
or from the positive (POS) (+) terminal of the
N. Positive battery terminals are usually identified
ungrounded battery in the starting vehicle, if it is
by a plus (+) sign on the terminal and the letters
provided with two (2) 12V batteries connected in
POS adjacent to the terminal. Negative battery
series.
terminals are usually identified by the letters
NEG adjacent to the terminal or a negative (-) V. Remove and carefully dispose of the dampened
sign. cloths, as they may now be contaminated with
acid, then replace all vent caps.
O. Connect one end of a jumper cable to the posi-
tive (POS) (+) battery terminal in the starting
vehicle. When jump starting 24V compressors 1.12 IMPLEMENTATION OF
and if the starting vehicle is provided with two (2) LOCKOUT/TAGOUT
12V batteries connected in series, connect the
The energy control procedure defines actions
jumper cable to the positive (POS) (+) terminal of
necessary to lockout a power source of any machine
the ungrounded battery.
to be repaired, serviced or set-up, where unexpected
P. Connect the other end of the same jumper cable motion, or an electrical or other energy source, would
to the positive (POS) (+) terminal of the starter cause personal injury or equipment damage. The
motor battery in the compressor when jump start- power source on any machine shall be locked out by
ing 24V compressors, to the positive (POS) (+) each employee doing the work except when motion
terminal of the ungrounded battery in the com- is necessary during setup, adjustment or trouble-
pressor. shooting.
Q. Connect one end of the other jumper cable to the A. The established procedures for the application of
grounded negative (NEG) (-) terminal of the bat- energy control shall cover the following elements
14
SECTION 1
and actions and shall be initiated only by Autho- 1. The lock shall be removed by the
rized Persons and done in the following sequence: “Authorized” person who put the lock on the
energy-isolating device. No one other than
1. Review the equipment or machine to be the person/persons placing padlocks and
locked and tagged out. lockout hasps on power shall remove
2. Alert operator and supervisor of which padlock and lockout hasps and restore
machine is to be worked on, and that power power. However, when the authorized
and utilities will be turned off. person who applied the lock is unavailable to
remove it his/her Supervisor may remove
3. Check to make certain no one is operating padlock/padlocks and lockout hasps and
the machine before turning off the power. restore power only if it is first:
4. Turn off the equipment using normal a. verified that no person will be exposed to
shutdown procedure. danger.
5. Disconnect the energy sources: b. verified that the “Authorized” person who
a. Air and hydraulic lines should be bled, applied the device is not in the facility.
drained and cleaned out. There should c. noted that all reasonable efforts to con-
be no pressure in these lines or in the tact the “Authorized” person have been
reservoir tanks. Lockout or tag lines or made to inform him or her that the lock-
valves. out or tagout device has been removed.
b. Any mechanism under tension or pres- d. ensured that the “Authorized” person is
sure, such as springs, should be notified of lock removal before returning
released and locked out or tagged. to work.
c. Block any load or machine part prior to 2. Tagout System—Tags are warning devices
working under it. affixed at points of power disconnect and are
d. Electrical circuits should be checked with not to be removed by anyone other that the
person placing tag on power lockout. Tags
calibrated electrical testing equipment shall never be by-passed, ignored, or
and stored energy and electrical capaci- otherwise defeated
tors should be safely discharged.
6. Lockout and/or Tagout each energy source 1.13 CALIFORNIA
using the proper energy isolating devices PROPOSITION 65
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person
performing work. Each person shall be WARNING
provided with their own padlock and have
possession of the only key. If more than one CALIFORNIA PROPOSITION 65 WARNING
person is working on a machine each person
shall affix personal lock and tag using a Diesel engine exhaust and some of its con-
multi-lock device. stituents are known to the State of Califor-
7. Tagout devices shall be used only when nia to cause cancer, birth defects and other
power sources are not capable of being reproductive harm.
locked out by use of padlocks and lockout
hasp devices. The name of the person Battery posts, terminals and related acces-
affixing tag to power source must be on tag sories contain lead and other compounds
along with date tag was placed on power known to the State of California to cause
source. cancer and birth defects and other repro-
8. Release stored energy and bring the ductive harm. Wash hands after handling.
equipment to a “zero mechanical state”.
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
15
SECTION 1
1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable
symbols.
DIESEL FUEL HEARING PROTECTION
ROTARY COMPRESSOR
HARD HAT
TEST RUN
DRAIN SAFETY GLASSES
HIGH PRESSURE
HEARING PROTECTION
SHUT-OFF VALVE
W/ SAFETY
DO NOT REMOVE
NO
MANUAL
ENGINE DO NOT BREATHE

COMPRESSED AIR
COMPRESSOR
DO NOT STAND ON
SERV. VALVE
ENGINE OIL
DO NOT OPERATE
ENGINE COOLANT W/ DOORS OPEN
WATER
DO NOT OPEN
OIL
DO NOT STACK
DO NOT ELECTRICAL SHOCK
CLOSED MECHANICAL
AIR FLOW
FUSE
HOT SURFACE
LOW PRESSURE
PRESSURIZED VESSEL
READ MANUAL
PRESSURIZED
COMPONENT
BRAKES SAFETY SYMBOLS 1
16
SECTION 1
DANGEROUS OUTLET ENGINE START
ENGINE ECM
REMOTELY
CONTROLLED
READ/WRITE DATA
CORROSIVE
INTAKE AIR
EXHAUST GAS
WARNING
FAN GUARD
DO NOT
MAINTENANCE
BELOW TEMPERATURE BELT GUARD
DO NOT TOW SERVICE POINT
BAR/PSI
LOW TEMPERATURE
BATTERY
BATTERY DISCONNECT STD AIR
OFF A/C AIR
ON
24 HOURS
RESET
BELTS
NO FORKLIFT FILTER
STRAINER
FORK LIFT HERE
SAFETY SYMBOLS 2
DIRECTION OF ROTATION
17
SECTION 1
RADIATOR HOUR METER
AIR-CIRCULATING COMPRESSOR AIR

FAN PRESSURE
AIR-COOLED START
OIL COOLER
CONTROL
LIQUID-COOLED
OIL COOLER
ENGINE PREHEAT
LOW TEMP AID
LUBRICATION
ENGINE WARNING
TRAILER TOWING
MODE
FUEL LEVEL
AXEL
ENGINE RPM
LUBRICANT GREASE
ENGINE OIL
EXAMINE, CHECK PRESSURE
ENGINE COOLANT
CRUSH/PINCH POINT TEMPERATURE
COMPRESSOR
FUNCTIONAL ARROW TEMPERATURE
DO NOT MIX
ENGINE INTAKE COOLANTS
AIR FILTER
AFTERCOOLER
PRESSURE CONTROL BYPASS VALVE
INLET VALVE SPRING

DRAIN HEATER
INTERNAL FUEL
BATTERY HEATER
COMPRESSOR
EXTERNAL FUEL
OIL HEAT
STACKING LIMIT
SIDE DOOR T-LATCH BY NUMBER
SAFETY SYMBOLS 3
18
SECTION 1
DO NOT OPERATE WATER DRAIN

WHILE STACKED
PRESSURIZED SPRING SEVER (FAN)
DO NOT MIX FLUIDS

DEF FLUID ONLY
AUTO START/STOP
RUN
SAFETY SYMBOLS 4
FLUID DRAIN
19
SECTION 1
20
600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL
Section 2
DESCRIPTION
2.1 INTRODUCTION As you continue reading this manual and come to
learn how the compressor operates and is cared for,
Sullair Portable Air Compressor models offer you will see how surprisingly easy it is to keep a
superior performance and reliability while requiring Sullair compressor in top operating condition.
only minimal maintenance.
Read Section 5 - MAINTENANCE to keep your
The compressor is equipped with a Sullair rotary compressor in top operating condition. Should any
screw compressor unit. Compared to other problem or question arise which cannot be answered
compressors, Sullair is unique in mechanical in this text, contact your nearest Sullair
reliability and compressor durability. No inspection is representative or the Sullair Service Department.
required of the working parts within the compressor
unit.
Figure 2-1: Components and Assemblies front view.
1.MOISTURE SEPARATOR 8.ENGINE RADIATOR 15.DEF FILL

2.THERMAL VALVE 9.DISCHARGE AIR FILTER 16.FUEL FILL
3.REGULATOR VALVES 10.RECEIVER TANK 17.FUEL SELECTOR SWITCH
4.ENGINE COOLANT FILL 11. E-STOP 18.FUEL PRIMER
5. FLUID COOLER 12.ENGINE MUFFLER
6. AFTERCOOLER 13.MANUAL ENCLOSURE
7. ENGINE CHARGE AIR 14.BATTERY DISCONNECT
COOLER SWITCH
21
600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL SECTION 2
Figure 2-2: Component and Assemblies rear view.
1.MOISTURE SEPARATOR 8.ENGINE RADIATOR 15.DEF FILL

2.THERMAL VALVE 9.DISCHARGE AIR FILTER 16.FUEL FILL
3.REGULATOR VALVES 10.RECEIVER TANK 17.FUEL SELECTOR SWITCH
4.ENGINE COOLANT FILL 11. E-STOP 18.FUEL PRIMER
5. FLUID COOLER 12.ENGINE MUFFLER
6. AFTERCOOLER 13.MANUAL ENCLOSURE
7. ENGINE CHARGE AIR 14.BATTERY DISCONNECT
COOLER SWITCH
2.2 DESCRIPTION OF COMPONENTS

Refer to Figure 2-1 and Figure 2-2. The components the engine.
and assemblies of the Sullair Portable Air Compressor
The engine cooling system is comprised of a radiator,
models are clearly shown. The package includes a
high capacity fan and thermostats. The high capacity
compressor, diesel engine, compressor inlet system,
fan draws air through the radiator, keeping the engine
compressor cooling and lubrication system,
at the proper operating temperature.
compressor discharge system, capacity control
system, instrument panel and electrical system. The The same fan also cools the fluid in the compressor
machine is also supplied with sound deadening cooling and lubrication system. While passing through
insulation to lower noise emissions to meet EPA or the radiator, the fan air also passes through the
CE, and/or any Federal, State, or local noise compressor fluid cooler (which is mounted adjacent to
requirement. The Sullair compressor unit is driven by the radiator). As air passes through the cooler, the
an industrial engine designed to provide enough heat of compression is removed from the fluid.
horsepower at rated conditions. Refer to Engine
The same fan also cools the engines intake air supply
Operator’s Manual for a more detailed description of
by passing air through an air to air aftercooler (charge
22
SECTION 2 600H, 750, 750H, 750HH, 825, 900 & 900H USER MANUAL
air cooler). As air passes through the aftercooler heat water separator then to your service line while the
is removed which was introduced by the engine’s fluid is being cooled in preparation for reinjection.
turbo charger. The engine is coupled to the
compressor unit with a non-lubricated, vulcanized 2.4 COMPRESSOR COOLING
rubber disk and a drive flange-type coupling. AND LUBRICATION
SYSTEM, FUNCTIONAL
NOTE DESCRIPTION
Refer to Figure 2-3. The compressor cooling and
DEF tank should be filled every time the lubrication system is designed to provide adequate
fuel is. When the DEF tank is empty the lubrication as well as maintain the proper operating
engine will shut off. temperature of the compressor. In addition to the
cooler and fan, the system consists of a main filter
and thermal valve.
2.3 SULLAIR COMPRESSOR
UNIT, FUNCTIONAL Fluid is used in the system as a coolant and a
DESCRIPTION lubricant. The fluid is housed in the receiver tank.
Sullair compressors feature the Sullair compressor Upon start up, the fluid temperature is cool, and
unit, a single-stage, positive displacement, flood routing to the cooler is not required. The fluid first
lubricated-type compressor. This unit provides enters the thermal valve and then flows to the
compressor unit, bypassing the cooler. As the
continuous compression to meet your needs.
compressor continues to operate, the temperature of
the fluid rises and the thermal valve element begins
NOTE to shift. This forces a portion of the fluid to the fluid
cooler. The cooler is a radiator-type that works in
With a Sullair compressor, there is no conjunction with the engine fan. The fan draws air
maintenance or inspection of the internal through the cooler removing the heat of compression
parts of the compressor unit permitted in from the fluid. From the cooler, the fluid is routed
accordance with the terms of the warranty. back to the thermal valve.
Before the temperature of the fluid reaches the valve
Sullair compressors are factory-filled with Sullair set point, cooled fluid is mixed with warmer fluid.
AWF lubricant. For more information on fluid fill, refer When the temperature of the fluid reaches 170°F
to “Application Guide” on page 45. (77°C), the thermal element shifts completely
causing all fluid to flow to the cooler. The thermal
Fluid is injected into the compressor and mixes valve incorporates a pressure relief valve, which
directly with the air as the rotors turn, compressing allows fluid to bypass the cooler, if the cooler
the air. The fluid flow has three basic functions: becomes plugged or frozen. This helps assure that
1. As coolant, it controls the rise of air tempera- fluid will continue to be provided to the compressor
ture normally associated with the heat of for lubrication. After the fluid passes through the
compression. thermal valve it is then directed through the main
fluid filter. There, the fluid is filtered in preparation for
2. Seals the clearance paths between the injection into the compression chamber and bearings
rotors and the stator and also between the of the compressor unit. The filter has a replaceable
rotors themselves. element and a built-in bypass valve which allows the
3. Acts as a lubricating film between the rotors fluid to flow even when the filter element becomes
allowing one rotor to directly drive the other, plugged and requires changing or when the viscosity
which is an idler. of the fluid is too high for adequate flow. After the
fluid is properly filtered, it then flows on to the
After the air/fluid mixture is discharged from the compressor unit where it lubricates, seals and cools
compressor unit, the fluid is separated from the air. the compression chamber as well as lubricates the
At this time, the air flows through an aftercooler and bearings and gears.
23
Fluid
SU_0000144
Figure 2-3: Compressor Oil, Cooling and Lubrication - All Models

3. RECEIVER TANK 5. THERMAL VALVE
4. FLUID COOLER 6. FLUID FILTER
2.5 CAPACITY CONTROL “START” position and start the engine using the
SYSTEM, FUNCTIONAL START/STOP switch. In the “START” position, the
DESCRIPTION inlet valve is held closed by the springs in the inlet
valve. The valve is cracked open by vacuum in the
The purpose of the control system is to regulate the compressor and is allowed to build up to 65 psig (4.5
amount of air intake in accordance with the amount bar). The reason for keeping the valve closed during
of compressed air demand. The control system start is to allow the engine and compressor fluid to
consists of an inlet valve, the high and low pressure warm up without being loaded by the compressor. Air
regulators, the pressure reducing regulator, the pressure is contained in the receiver tank by the
blowdown valve, the Speed Controller, a START/ minimum pressure valve which has a set point of 65
RUN selector valve, and the HIGH/LOW selector psig (4.5 bar). At this point the valve opens allowing
valve. the air to pass to the service valve. After engine has
warmed up the START/RUN valve should be moved
START - 0 TO 65 PSIG (0 TO 4.5 BAR) to the “RUN” position.
Push OFF/ON switch to “ON” position to initialize the
Controller. Ensure the START/RUN valve is in the
24
LOW PRESSURE - 80 TO 100 PSIG (5.5 TO 6.9 2.6 COMPRESSOR DISCHARGE

BAR) SYSTEM, FUNCTIONAL
DESCRIPTION
With the HIGH/LOW valve in the “LOW” position, and
the START/RUN valve in the “RUN” position, the The Sullair compressor unit discharges compressed
service valve can now be opened. Pressure from the air/fluid mixture into the receiver tank.
60 psig (4.1 bar) reducing regulator opens up the
inlet valve and the Controller increases the engine The receiver tank has three functions:
speed to full load (1800 rpm). As the demand for air 1. It acts as a primary fluid separator.
decreases, the Controller commands the engine to
reduce speed to idle (1400 rpm) and the inlet valve 2. Serves as the compressor fluid storage sump.
closes, where it stabilizes until the air demand is 3. Houses the final fluid separator.
required again. If the machine is not marked with an
“H” or “HH”, it is a single pressure machine and will The compressed air/fluid mixture enters the receiver
not have a HIGH/LOW valve. The machine will run tank and is directed against the tank side wall. By
as if it is in the “LOW” position. change of direction and reduction of velocity, large
droplets of fluid separate and fall to the bottom of the
HIGH PRESSURE - 80 TO 150 PSIG (5.5 TO 10.3 receiver tank. The fractional percentage of fluid
BAR) FOR “H” MODELS OR 80 TO 175 PSIG (5.5 remaining in the compressed air collects on the
TO 12.1 BAR) FOR “HH” MODELS surface of the final separator element as the
compressed air flows through the separator. As more
When the HIGH/LOW valve is switched to the “HIGH” and more fluid collects on the element’s surface, the
position, the low pressure regulator is blocked off fluid descends to the bottom of the separator. A
allowing the high pressure regulator to take over return line (or scavenge tube) leads from the bottom
control of the machine. The 60 psig (4.1 bar) of the separator element to the inlet region of the
reducing regulator fully opens the inlet valve and the compressor unit. Fluid collecting on the bottom of the
Controller commands maximum speed (1800 rpm) separator element is returned to the compressor by
from the engine. As the pressure reaches the set the pressure difference between the area
point of the system the high pressure regulator surrounding the separator element and the
cracks open and closes the inlet valve and the compressor inlet. An orifice (protected by a strainer)
Controller returns the engine back to idle, until a is included in this return line to help assure proper
demand for air is seen. flow.
SHUTDOWN The receiver tank is code rated. A minimum
pressure/ check valve, located downstream from the
To shutdown the unit, slowly close the service valve.
separator, helps assure a minimum receiver
The blowdown valve is normally closed. When the
pressure during all conditions. This pressure is
compressor is shutdown, system pressure backs up
necessary for proper air/fluid separation and proper
to the inlet valve causing the check spring in the inlet
fluid circulation.
valve to close the air inlet valve. This sends a
pressure signal to the blowdown valve causing it to A minimum pressure/check valve at the outlet of the
open and vent the pressure in the system. After the receiver is installed to prevent compressed air in the
pressure is vented, the blowdown valve spring service line from bleeding back into the receiver on
returns the blowdown valve to the closed position. shutdown when the compressor is being run in
Push the START/STOP switch to the STOP position. parallel with other compressors tied to a large air
This will shut the engine off. Once the engine off, system.
Push OFF/ON switch to the OFF position to shutoff
Fluid is added to the receiver tank via a capped fluid
the controller. Note: The controller can not be shutoff
filler. A fluid level gauge glass enables the operator
unless the engine is stopped.
to visually monitor the receiver tank fluid level.
25
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
WARNING cooler air and discharged. This condensation does
carry some oil and it should be disposed of properly
DO NOT remove caps, plugs and/or other in accordance with local regulations. A condensation
components when compressor is running drain port is located in the frame on the front of the
or pressurized. machine for convenience of condensate removal.
Stop compressor and relieve all internal This drain port should never be plugged or closed off
pressure before doing so. in any way. From the moisture separator the
compressed air goes through the discharge filters (if
2.7 AFTERCOOLED AIR equipped) and on to the service valve.
SYSTEM, FUNCTIONAL
DESCRIPTION NOTE
Refer to Figure 2-4. The purpose of the aftercooled
air system is to operate the air compressor in Aftercooled system should not be operated
conditions when compressed air temperatures are in ambient conditions below 32°F (0°C). If it
is necessary to operate in these conditions,
required to be 10 to 25°F (5 to 13 °C) over ambient
Sullair can supply optional equipment to
temperature. Two discharge valves are provided on accommodate this requirement.
all aftercooled compressor models. One valve is To operate in the non-aftercooled mode,
labeled standard air and one valve is labeled close the aftercooler service valve com-
aftercooled air. Closing the standard air (non- pletely and open non-aftercooled valve.
aftercooled) valve completely forces the air flow from
the receiver tank to the aftercooler. The ambient air,
Figure 2-4: Aftercooled Air System

1. RECEIVER TANK 5. MOISTURE SEPARATOR
2. MINIMUM PRESSURE 6. DISCHARGE FILTERS
CHECK VALVE 7. PNEUMATIC VALVE
3. AIR VALVE 8. STANDARD AIR OUT
4. AFTERCOOLER 9. AFTERCOOLED AIR OUT
26
2.8 AIR INLET SYSTEM, Referring to the engine air filter restriction gauge or
FUNCTIONAL DESCRIPTION the compressor air filter restriction gauge will indicate
when restriction of the air passing through the filter
Refer to Figure 2-5. The compressor inlet system becomes too high.
consists of one air filter, a compressor air inlet valve
At this time, change the air filter element. Refer to Air
and interconnecting piping to the engine and
Filter Maintenance on page 59. These indicators
compressor. Also, air filter restriction indicator
should be checked daily, after start-up under normal
gauges are located next to the air filter housings.
conditions.
The air filter is a 2-stage unit with a safety element
The compressor air inlet valve controls the amount of
dry element-type filter. This filter is capable of
air intake of the compressor in response to the air
cleaning extremely dirty air. However, in such cases,
demand.
frequent checks of the air filter will be required.
Figure 2-5: Air Inlet System
1. Engine Air FIlter 4. Compressor

2. Compressor Air Filter 5. Engine Inter-Cooler
3. Air Inlet Valve 6. Air Inlet System
27
2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR
28
SECTION 2
02250201-490-R01S-1
2.9 PIPING AND INSTRUMENTATION DIAGRAM—COMPRESSOR
SECTION 2
KEY QTY DESCRIPTION KEY QTY DESCRIPTION
1 1 FILTER, AIR 31 2 VALVE, PRESSURE DIFF. BYPASS
2 1 GAUGE, AIR FILTER RESTRICTION 32 1 SEPARATOR, ELEMENT
3 1 INLET VALVE 33 1 MANIFOLD, OIL CONTROL
4 1 COMPRESSOR 34 1 MANIFOLD, AIR CONTROL
5 1 VALVE, RELIEF 35 1 VALVE, SHUTTLE
6 1 SWITCH, TEMPERATURE 36 1 VALVE, RECIRCULATING
7 1 SENSOR, TEMPERATURE CHART
8 2 SENSOR, PRESSURE KEY DESCRIPTION
9 1 VALVE, BACK PRESSURE REGULATOR P1 DRY SIDE PRESSURE
10 1 RECEIVER, AIR/OIL P2 CONTROL PRESSURE
11 12 GLASS, SIGHT OIL LEVEL T1 COMPRESSOR DISCHARGE TEMPERATURE SENSOR
12 1 VALVE, MINIMUM PRESSURE T3 RECEIVER TANK TEMPERATURE SWITCH (RTT)
13 2 VALVE, BALL
14 1 COOLER, AIR (OPTIONAL)
15 1 SEPARATOR, MOISTURE
16 1 TRAP, DRAIN
17 4 ORIFICE
18 2 VALVE, BLOWDOWN N.C.
19 2 STRAINER
20 1 SIGHTGLASS, ORIFICE BLOCK
21 1 VALVE, THERMAL BYPASS
22 1 COOLER, OIL
23 1 FILTER, OIL
24 1 CONTROLLER
25 1 VALVE, BALL HIGH/LOW PRESSURE
26 1 VALVE, BALL START/RUN
27 1 GAUGE, PRESSURE
28 1 VALVE, REGULATOR HIGH PRESSURE
29 2 VALVE, CHECK
30 1 VALVE, REGULATOR LOW PRESSURE
29
2.10 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE
30
SECTION 2
02250201-490-R01-2
2.10 PIPING AND INSTRUMENTATION DIAGRAM—ENGINE
SECTION 2
KEY QTY DESCRIPTION KEY QTY DESCRIPTION
1 1 TURBOCHARGER, ENGINE 29 1 HEATER, WATER JACKET (OPTIONAL)
2 1 COOLER, CHARGE AIR 30 1 OIL LEVEL (DIPSTICK)
3 1 MUFFLER, SCR ENGINE 31 1 FILTER, AIR
4 1 SENDER, FUEL LEVEL 32 1 TANK, FUEL
5 1 RAIN CAP, EXHAUST SYSTEM 33 1 PAN, ENGINE OIL
6 1 FILTER, FUEL W/ WATER SEPARATOR 34 1 GAUGE, FILTER RESTRICTION
7 1 PUMP, FUEL (INTERNAL TO ENGINE) 35 1 SENSOR, INLET AIR TEMPERATURE
8 1 PUMP, FUEL HAND OPERATED PRIMING 36 1 VALVE, RELIEF (INTEGRAL TO ENGINE)
9 1 FILTER, FUEL 37 1 VALVE, AIR STOP (OPTIONAL)
10 1 VENT, FUEL TANK 38 1 VALVE, BALL 3-WAY (DUAL PORT)
11 1 CAP, FUEL TANK FILL 39 1 COUPLING, QUICK CONNECT 1/2” SUPPLY
12 1 HEATER, AIR INLET 40 1 COUPLING, QUICK CONNECT 3/8” RETURN
13 1 CAT, PRE 41 1 CAP, DEF FILL
14 1 PUMP, OIL (INTEGRAL TO ENGINE) 42 1 SENDER, DEF TANK LEVEL
15 1 BY-PASS VALVE (INTERNAL TO ENGINE) 43 1 VALVE, 2-WAY COOLANT
16 1 COOLER, OIL (INTERNAL TO ENGINE) 44 2 ORIFICE
17 1 FILTER, OIL 45 1 TANK, EXPANSION
18 1 PUMP, WATER (INTEGRAL TO ENGINE) 46 1 SENSOR, NOX
19 1 RADIATOR, ENGINE 47 1 SENSOR, EXHAUST TEMPERATURE
20 1 ENGINE THERMO (INTEGRAL TO ENGINE) 48 1 BLOCK, TURBO AND ENGINE LUBE SYS
21 1 SENSOR, INLET AIR PRESS (TURBO BOOST) 49 1 CYLINDER AND HEADS
22 1 SWITCH, COOLANT LEVEL 50 1 ECM
23 1 SENSOR, FUEL PRESSURE 51 1 CONTROLLER, FUEL
24 2 PUMP, HIGH PRESSURE FUEL 52 1 INJECTORS, FUEL
25 1 SENSOR, COOLANT TEMPERATURE 53 1 MANIFOLD, INTAKE
26 1 SENSOR, ENGINE OIL PRESSURE 54 1 INJECTOR, DEF
27 1 TANK, DEF 55 1 CONTROL, DEF MODULE
28 1 VENT, DEF TANK
31
32
KEY QTY DESCRIPTION
NOTES:
A1: AIR INTAKE AND EXHAUST SYSTEM
A2: FUEL SYSTEM
A3: COOLING SYSTEM
A4: LUBRICATION SYSTEM
A5: DEF SYSTEM
CHART
KEY DESCRIPTION
L1 COOLANT LEVEL
L2 FUEL LEVEL
L3 OIL LEVEL (DIPSTICK)
L4 DEF FLUID LEVEL
P1 INLET MANIFOLD AIR PRESSURE
P2 FUEL PRESSURE
P3 OIL PRESSURE
T1 EXHAUST TEMPERATURE
T2 INLET AIR TEMPERATURE
T3 COOLANT TEMPERATURE
S1 NOX SENSOR
SECTION 2
33
2.11 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
Figure 2-6: Instrument Panel Group
1. COMPRESSOR TEMPERATURE 5. HIGH/LOW VALVE

GAUGE 6. START/RUN VALVE
2. PRESSURE GAUGE 7. DIAGNOSTIC SERVICE PORT
3. FUEL GAUGE 8. ON/OFF CONTROLLER
4. ENGINE START/STOP 9. INFORMATION DISPLAY
34
2.12 ENGINE CONTROL MODULE, 2.13 ELECTRICAL SYSTEM,

FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION
Diagnostic Fault Codes are provided to indicate an Refer to Controller wiring diagram on page 36. The
electrical or electronic problem has been detected by electrical system is comprised of not only the
the ECM (Engine Control Module). In some cases, necessary equipment required to operate the
the engine performance can be affected when the compressor, but also a system to shut it down in the
condition causing the code exists. More frequently, event of a malfunction. The components of the
however, the operator cannot detect any difference electrical system are an engine starter (with an
in the engine performance. integral solenoid), battery, a breaker protected
alternator with a built-in voltage regulator, a breaker
The Controller indicates a performance problem has
protected engine air inlet heater (for cold weather
occurred.
starting), a compressor discharge temperature
If the Controller does not indicate a problem with the sensor and receiver tank temperature switch will shut
engine performance but a diagnostic code is logged down the compressor should the compressor
by the ECM, the ECM detected an abnormal temperature exceed 250°F [121°C], and a fuel level
condition that did not affect performance. sensor.
If this is the case, unless there are several The electrical system also incorporates a lockable
occurrences of the code in a very short period of battery disconnect to be utilized for extended periods
time, or, the ECM is indicating an Active Code at the of non use and during machine maintenance. In case
present time, there is most likely nothing wrong with of emergency, an emergency stop switch is located
the system. just above the Controller on the canopy of the
machine. The Compressor wiring diagram on page
38 shows the wiring diagram for the Compressor.
NOTE
Only Active diagnostic codes can be read
in this manner. Logged diagnostic codes
WARNING
must be retrieved with an Electronic Ser-
vice Tool. Ether starting aids should NOT be used with
this engine. The engine is equipped with an
air inlet heater for cold-starting conditions.
35
2.14 CONTROLLER WIRING DIAGRAM
2.00 SP7
10.00
15.00
12.00
4.00
SP8
5.00
4.00
SP9
02250204-058 R00
36
2.14 CONTROLLER WIRING DIAGRAM
10.50 10.00
SP4
0.50
SP5
SP2
2.00
3.00
0.50
0.50
SP1
SP3
2.00
9.00
15.00
02250204-058 R00
37
2.15 COMPRESSOR WIRING DIAGRAM
02250202-871 R03
38
2.15 COMPRESSOR WIRING DIAGRAM
39
NOTES
40
600H, 750, 750H, 750HH, 825, 900, 900H, USER MANUAL
Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS-600H, 750, 750H, 750HH
Table 3-1: Overall Specifications-600H, 750, 750H, 750HH
Length (I) Width Height (II) Weight (wet)
Model Series
in mm in mm in mm lb kg
DTQ (Tandem Axle) 191 4851 87 2210 89.75 2280 10045 4554
DWQ (4-Wheel) 204 5182 87 2210 97 2464 10195 4662
DLQ (LRG) 131 3372 87 2210 80 2032 9670 4474
(l) Length over drawbar where applicable
(II) Over lifting bail
Table 3-2: Compressor Specifications
Compressor 600H/750H 750 750HH
Type Rotary Screw Rotary Screw Rotary Screw
Delivery @ Operating
600/750 750 750
Pressure
Maximum Operating
150 psig (10.3 bar) 125 psig (8.5 bar) 175 psig (12 bar)
Pressure
Rated Pressure 150 psig (10.3 bar) 125psig (8.5 bar) 175 psig (12 bar)
Pressurized Compressor Pressurized Compressor Pressurized Compressor
Cooling
Fluid Fluid Fluid
Lubricating Compressor
See Lubrication Guide See Lubrication Guide See Lubrication Guide
Fluid
Receiver Tank Capacity 21 US gallons (80 liters) 21 US gallons (80 liters) 21 US gallons (80 liters)
Operating Tilt (maximum) 15° 15° 15°
Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt
Electrical System
Instrument System – 24 Volt Instrument System – 24 Volt instrument System – 24 Volt
Battery (2) 1150 CCA @ 0°F (-18°C) 1150 CCA @ 0°F (-18°C) 1150 CCA @ 0°F (-18°C)
Alternator 100 Amp 100 Amp 100 Amp
Sound Level (US EPA)1 76dBA 76dBA 76dBA
1 Sound level measured per U.S. 40 CFR Ch. 1 Part 204
41
600H, 750, 750H, 750HH, 825, 900, 900H, USER MANUAL SECTION 3
Table 3-3: Engine Specifications

Engine 600H/750H 750 750HH
Make Volvo Volvo Volvo
Type TAD764VE Tier 4i/Stage 3B TAD764VE Tier 4i/Stage 3B TAD764VE Tier 4i/Stage 3B
Rated Speed 1800 RPM 1800 RPM 1800 RPM
Horsepower, SAE 307 HP (225 kW) 307 HP (225 kW) 307 HP (225 kW)
Cylinders 6 6 6
Cycles 4 4 4
Bore x Stroke 4.25 x 5.12 in (108 x 130 mm) 4.25 x 5.12 in (108 x 130 mm) 4.25 x 5.12 in (108 x 130 mm)
Displacement 436 cu. in (7.15 liters) 436 cu. in (7.15 liters) 436 cu. in (7.15 liters)
See Engine Operator’s See Engine Operator’s See Engine Operator’s
Type of Motor Oil
Manual Manual Manual
Fuel Tank Capacity 115 U.S. gallons (435 liters) 115 U.S. gallons (435 liters) 115 U.S. gallons (435 liters)
DEF Tank Capacity 5.3 U.S. gallons (20 liters) 5.3 U.S. gallons (20 liters) 5.3 U.S. gallons (20 liters)
Engine Cooling System
6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters)
Capacity
Idle Speed 1400 RPM 1400 RPM 1400 RPM
Table 3-4: Trailer Specifications
Trailer: DTQ DWQ
Track Width 77 in (1956 mm) 79.5 in (2019 mm)

Tire Size (Load Range) ST 235/80 R16 (E) ST 235/80 R16 (E)
Tire Pressure 75 psig (5.2 bar) 75 psig (5.2 bar)
Wheel Size 16 x 6 16 x 6
Wheel Bolt/Lugnut Torque 80 to 90 ft. lbs (108.5 to 12.0 Nm) 80 to 90 ft. lbs (108.5 to 12.0 Nm)
42
SECTION 3 600H, 750, 750H, 750HH, 825, 900, 900H, USER MANUAL
3.2 TABLE OF SPECIFICATIONS-825, 900, 900H

Table 3-5: Overall Specifications-825, 900, 900H
Length (I) Width Height (II) Weight (wet)
Model Series
in mm in mm in mm lb kg
DTQ (Tandem Axle) 191 4851 87 2210 89.75 2280 10045 4554
DWQ (4-Wheel) 204 5182 87 2210 97 2464 10195 4662
DLQ (LRG) 131 3372 87 2210 80 2032 9670 4474
(l) Length over drawbar where applicable
(II) Over lifting bail
Table 3-6: Compressor Specifications
Compressor 825 900 900H
Type Rotary Screw Rotary Screw Rotary Screw
Delivery @ Operating
825 900 900
Pressure
Maximum Operating
125 psig (8.5 bar) 100 psig (7 bar) 150 psig (10.3 bar)
Pressure
Rated Pressure 125psig (8.5 bar) 100 psig (7 bar) 150 psig (10.3 bar)
Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid Pressurized Compressor Fluid
Lubricating Compressor See Lubrication Guide See Lubrication Guide See Lubrication Guide
Receiver Tank Capacity 21 US gallons (80 liters) 21 US gallons (80 liters) 21 US gallons (80 liters)
Operating Tilt (maximum) 15° 15° 15°
Engine – 24 Volt Engine – 24 Volt Engine – 24 Volt
Electrical System
Instrument System – 24 Volt Instrument System – 24 Volt Instrument System – 24 Volt
Battery (2) 1150 CCA @ 0°F (-18°C) 1150 CCA @ 0°F (-18°C) 1150 CCA @ 0°F (-18°C)
Alternator 100 Amp 100 Amp 100 Amp
Sound Level (US EPA)1 76dBA 76dBA 76dBA
1 Sound level measured per U.S. 40 CFR Ch. 1 Part 204
43
Table 3-7: Engine Specifications

Engine 825 900 900H
Make Volvo Volvo Volvo
Type TAD 764VE Tier 4i/Stage 3B AD 764VE Tier 4i/Stage 3B AD 764VE Tier 4i/Stage 3B
Rated Speed 1800 RPM 1800 RPM 1800 RPM
Horsepower, SAE 307 HP (225 kW) 307 HP (225 kW) 307 HP (225 kW)
Cylinders 6 6 6
Cycles 4 4 4
Bore x Stroke 4.25 x 5.12 in (108 x 130 mm) 4.25 x 5.12 in (108 x 130 mm) 4.25 x 5.12 in (108 x 130 mm)
Displacement 436 cu. in (7.15 liters) 436 cu. in (7.15 liters) 436 cu. in (7.15 liters)
See Engine Operator’s See Engine Operator’s See Engine Operator’s
Type of Motor Oil
Manual Manual Manual
Fuel Tank Capacity 115 U.S. gallons (435 liters) 115 U.S. gallons (435 liters) 115 U.S. gallons (435 liters)
DEF Tank Capacity 5.3 U.S. gallons (20 liters) 5.3 U.S. gallons (20 liters) 5.3 U.S. gallons (20 liters)
Engine Cooling System
6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters) 6 U.S. gallons (22.7 liters)
Capacity
Idle Speed 1400 RPM 1400 RPM 1400 RPM
Table 3-8: Trailer Specifications
Trailer: DTQ DWQ
Track Width 77 in (1956 mm) 79.5 in (2019 mm)

Tire Size (Load Range) ST 235/80 R16 (E) ST 235/80 R16 (E)
Tire Pressure 75 psig (5.2 bar) 75 psig (5.2 bar)
Wheel Size 16 x 6 16 x 6
Wheel Bolt/Lugnut Torque 80 to 90 ft. lbs (108.5 to 12.0 Nm) 80 to 90 ft. lbs (108.5 to 12.0 Nm)
3.3 LUBRICATING GUIDE - COMPRESSOR

Fluid Type Change Period, Hours Ambient Temperature Range °F (°C)
Sullair AWF (I) 1500 -20 to 120 (-29 to 49)
D-A Torque Fluid 300 10 to 110 (-12 to 43)
SAE 10W DSE, SF, SG, CD 300 0 to 100 (-18 to 38)
MIL-L-2104E 10W 300 0 to 100 (-18 to 38)
(I) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5gallons/18.9 liters), 250030-758 (55 gallons,208
liter drum)
3.4 APPLICATION GUIDE

Refer to Figure 3-1. Sullair Air Compressors are drained from the receiver tank periodically.
supplied with Sullair AWF which is heavy duty multi-
In high ambient temperature and high humidity
viscosity, all weather fluid. Sullair AWF also allows
conditions, condensed moisture may emulsify with
an extended change interval. The fluids in Section
the oil forming a “milky” color. ATF or SAE 10W is
3.3 Lubrication Guide – Compressor can be used.
especially prone to this condition. The fluid should be
Any of these oils are suitable under conditions where
severe oil oxidations can occur. Water must be
44
SECTION 3 600H, 750, 750H, 750HH, 825, 900, 900H, USER MANUAL
changed if this condition develops.
CAUTION 2
DO NOT mix types of fluids. Combinations

of different fluids may lead to operational
problems such as foaming, filter plugging,
orifice or line plugging.
When ambient conditions exceed those noted or if

conditions warrant use of other extended life 1
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 offers a fluid analysis program for Sullair
AWF. Contact your local Sullair representative for SU_0000142
details.
D-A Lubricant® Company Inc. offers an analysis Figure 3-1: Fluid Fill Location
program for users of D-A products and Sullair AWF.
Contact your D-A Lubricant® representative for 1. Sight Glass (I)
details.
2. Fluid Fill Port
*** If fluid is seen in the sight glass when the
machine is not running, no fluid is needed.
3.5 LUBRICATION GUIDE, ENGINE

For engine oil specifications, refer to the Engine Operator’s Manual.
45
IDENTIFICATION, LESS RUNNING GEAR (DLQ)
02250204-061-r00
3.6
46
3.6 IDENTIFICATION, LESS RUNNING GEAR (DLQ)
SECTION 3
NOTES NOTES
DIMENSIONS ARE IN INCHES A15: AUX. FUEL PORTS
A1: [ ] DIMENSIONS ARE IN MILLIMETERS. A16: LIFTING BAIL
ALL DOORS REQUIRE 5 FOOT [1524] A17: COOLING AIR EXHAUST (3)
A2: CLEARANCE.
A18: AIR CONTROL DOOR
REAR DOOR ACCESS BATTERIES AND
A3: COOLERS. A19: INSTRUMENT PANEL DOOR
REFERENCE: A STANDARD 40’ CONTAINER SIZE IS A20: E-STOP
A4: 88” WIDE X 89” TALL X 234” LONG. A21: DOOR (4)
REFERENCE: THREE COMPRESSORS CAN FIT IN A 40’ A22: OVERALL HEIGHT
A5: HIGH CUBE CONTAINER.
A23: SEPARATOR TANK FILTER
A6: COOLING AIR INTAKE (3)
A24: ENGINE EXHAUST AIR OUT

A7: WATER CONDENSATE DRAIN (DO NOT PLUG)
A25: ENGINE COOLANT PORT ACCESS COVER
A8: ENGINE COOLANT DRAIN
A26: ENGINE AIR INTAKE
A9: ENGINE OIL DRAIN
A27: UNIT AIR INTAKE
A10: COMPRESSOR OIL DRAIN
2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-
A11: DRAIN PLUG (4) A28: COOLED MODELS ONLY)
A12: TIEDOWN (4) A29: 2” NPT STANDARD AIR DISCHARGE
A13: 100% SPILL CONTAINMENT FRAME A30: DEF FILL
A14: FUEL FILL
47
IDENTIFICATION, TANDEM AXLE (DTQ)
02250204-062-R00
3.7
48
3.7 IDENTIFICATION, TANDEM AXLE (DTQ)
SECTION 3
NOTES NOTES
DIMENSIONS ARE IN INCHES A19: HYDRAULIC SURGE BRAKE (OPTIONAL)
A1: [] DIMENSIONS ARE IN MILLIMETERS. A20: AIR CONTROL DOOR
ALL DOORS REQUIRE 5 FOOT [1524] A21: INSTRUMENT PANEL DOOR
A2: CLEARANCE.
A22: E-STOP
A3: COOLERS. A23: DOOR (4)
REFERENCE: A STANDARD 40’ CONTAINER SIZE IS A24: OVERALL HEIGHT
A4: 88” WIDE X 89” TALL X 234” LONG. A25: SEPARATOR TANK FILTER
REFERENCE: TWO COMPRESSORS CAN FIT IN A 40’ A26: ENGINE EXHAUST AIR OUT

BREAK AWAY BOX (ELECTRIC BRAKES ONLY)
A9: ENGINE OIL DRAIN A30: (STANDARD)
A10: COMPRESSOR OIL DRAIN A31: STABILIZING JACK
A11: DRAIN PLUG (4) A32: TOWING RING
A12: HAND BRAKE A33: SAFETY CHAIN
A13: TIEDOWN (4) 2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-
A14: 100% SPILL CONTAINMENT FRAME A34: COOLED MODELS ONLY)
A15: FUEL FILL A35: 2” NPT STANDARD AIR DISCHARGE
A16: AUX. FUEL PORTS A36: TRACK WIDTH
A17: LIFTING BAIL A37: DEF FILL
A18: COOLING AIR EXHAUST (3)
49
IDENTIFICATION, 4-WHEEL (DWQ)
02250204-063-R00
3.8
50
3.8 IDENTIFICATION, 4-WHEEL (DWQ)
SECTION 3
NOTES NOTES
DIMENSIONS ARE IN INCHES A16: LIFTING BAIL
A1: [ ] DIMENSIONS ARE IN MILLIMETERS. A17: COOLING AIR EXHAUST (3)
ALL DOORS REQUIRE 5 FOOT [1524] A18: AIR CONTROL DOOR
A2: CLEARANCE.
A19: INSTRUMENT PANEL DOOR
A3: COOLERS. A20: E-STOP
REFERENCE: A STANDARD 40’ CONTAINER SIZE IS A21: DOOR (4)
A4: 88” WIDE X 89” TALL X 234” LONG. A22: OVERALL HEIGHT
REFERENCE: THREE COMPRESSORS CAN FIT IN A 40’ A23: SEPARATOR TANK FILTER
A24: ENGINE EXHAUST AIR OUT

A9: ENGINE OIL DRAIN
A28: TOWING RING
A10: COMPRESSOR OIL DRAIN
2” NPT AFTER-COOLED AIR DISCHARGED (AFTER-
A11: DRAIN PLUG (4) A29: COOLED MODELS ONLY)
A12: TIE DOWN (4) A30: 2” NPT STANDARD AIR DISCHARGE
A13: 100% SPILL CONTAINMENT FRAME A31: TRACK WIDTH
A14: FUEL FILL A32: DEF FILL
A15: AUX. FUEL PORTS
51
NOTES
52
600H, 750, 750H, 750HH, 825, 900H USER MANUAL
Section 4
OPERATION
4.1 GENERAL
for service or indicate the beginning of a malfunction.
While Sullair has built into this compressor a
Before starting your Sullair compressor, read this
comprehensive array of controls and indicators to
section thoroughly and familiarize yourself with the
assure you that it is operating properly, you will want
controls and indicators—their purpose, location and
to recognize and interpret the readings which will call
use.
4.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE
OFF/ON Switch The switch is used to engage the engine’s starter and to turn off the
engine. It is also used to energize the compressor’s electrical system.
Voltmeter Monitors the condition of the batteries and the charging circuit. The
normal reading is 24 to 28 volts.
Air Pressure Gauge Continually monitors the pressure inside the receiver tank at various
load and unload conditions.
Engine Water Temperature Gauge Monitors the temperature of the engine water. The normal operating
temperature should read approximately 160ºF to 210ºF (71ºC to 99ºC).
Controller Depicts system related diagnostics. Can be used for system
performance monitoring.
Compressor Discharge Temperature Gauge Monitors the temperature of the air/fluid mixture leaving the compressor
unit. The normal reading should be approximately 210ºF to 250ºF
(99ºC to 121ºC).
Fluid Level Sight Glass Monitors the fluid level in the receiver tank. Proper level is always
visible in the sight glass. Check the level when the compressor is
shutdown.
Receiver Tank Temperature Switch Opens the electrical circuit to shut down the compressor when then
receiver tank temperature reaches 250ºF (121ºC).
Reducing Regulator Valve Provides regulated air pressure to the inlet valve.
START/STOP Valve Provides an air signal to the inlet valve and engine to close or open the
inlet valve.
Minimum Pressure/Check Valve Maintains a minimum of 65 psig (4.5 bar) in the compressor receiver
tank. This valve restricts receiver air discharge from receiver/receiver
tank when pressure falls to 65 psig (4.5 bar). Also prevents back flow
into the receiver tank during upload conditions and after shutdown.
HIGH/LOW Selector Valve Select high pressure 150 psig (10.3 bar) or low pressure100 psig (6.9
bar) at instrument panel to correspond to operator’s needs.
Pressure Relief Valve Opens receiver tank pressure to atmosphere should pressure inside
the receiver tank exceed the pressure relief valve setting.
53
600H, 750, 750H, 750HH, 825, 900H USER MANUAL SECTION 4
CONTROL OR INDICATOR PURPOSE

Air Inlet Valve Regulates the amount of air allowed to enter the air inlet. This
regulation is determined by the amount of air being used at the service
line.
Blowdown Valve Vents receiver tank pressure to the atmosphere at shutdown.
Thermal Valve 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.
4.3 COMPRESSOR START-UP not starting. Try to correct the issue and
PROCEDURE restart the compressor.
1. Turn the START/RUN valve to the “START” 4.4 COMPRESSOR SHUT-DOWN

position. PROCEDURE
2. Push the controller switch to the “ON” position.
1. Close the service valve.
3. Once the information display is powered and
2. Move the HIGH/LOW valve to the “LOW”
showing the engine’s status, the compressor
pressure setting.
can be started.
3. After 60 seconds, Press the engine START/
4. Start the compressor by pressing and hold-
STOP switch to the “STOP” position. The
ing the engine START/STOP switch in the
engine will now shut off.
“START” position. Hold the switch down until
the engine is started. 4. Once the engine stops, the controller can
now be powered down by pressing the
5. Once the engine is warmed, the START/
“OFF” position on the ON/OFF controller
RUN valve can be moved to the “RUN” posi-
switch.
tion and the service valve can be opened.
5. Pull frame containment plugs and dispose of
6. If the compressor does not start, the informa-
all captured fluids per local, state and Fed-
tion display may show a possible reason for
eral requirements after a complete system
shut-down.
54
600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL
Section 5
MAINTENANCE
5.1 GENERAL After a routine start has been made, it is necessary to
perform an inspection to ensure all operations are
A good maintenance program is the key to long performing correctly. Perform the following
compressor life. Below is a program that when inspections to prevent unnecessary problems.
adhered to, should keep the compressor in top
1. Observe the instrument panel gauges and
operating condition. For engine maintenance
be sure they monitor the correct readings for
requirements, refer to the Engine Operator’s Manual
their particular phase of operation.
for a detailed description of service instructions.
2. After the compressor has warmed up, it is
Refer to Description Of Components on page 22 for
recommended that a general check on the
a detailed description of specific compressor system
overall compressor and instrument panel be
components. Prior to performing maintenance, read
made to assure that the compressor is run-
the CIMA Safety Manual, if applicable. ning properly.
3. Check the air filter restriction gauges. Should
they indicate restriction, replace the ele-
CAUTION ments immediately. Refer to Air Filter Mainte-
nance on page 59.
DO NOT remove caps, plugs and/or other
components when compressor is running or
pressurized. Stop compressor and relieve all
5.3 ENGINE COOLANT
internal pressure before doing so. This machine is factory filled with Mobil Delvac
Extended Life Coolant. It is an ethylene glycol based,
OAT inhibited coolant. This coolant is able to protect
5.2 DAILY OPERATION the cooling system from freezing, extend the boiling
point, provide corrosion protection for all metals
Prior to starting the compressor, it is necessary to within the cooling system; especially for systems with
perform a daily inspection. Perform the following aluminum radiators, provide liner cavitation
maintenance operations to prevent unnecessary protection for heavy duty diesel engines, and be safe
problems. to use with all seals/gasket materials.
1. Check the fluid level in the compressor This coolant should never be mixed with a different
receiver tank. Should the level be low, simply coolant type, color, or brand. If radiator coolant is to
add the necessary amount. If the addition of be added, for any reason, be sure that the coolant
fluid becomes too frequent, a simple problem added is the same as what is in the cooling system,
has developed which is causing this exces- as well as what is recommended.
sive loss. Refer to Troubleshooting Guide on The Engine Coolant type should follow these
page 64 under Excessive Compressor Fluid recommended specifications:
Consumption for a probable cause and rem- • Organic acid technology (OAT)
edy.
• Premixed coolant pH range of 8.0 to 9.5.
2. Drain water from the fuel/water separator. • Contains no silicates, phosphates, borates,
3. Check the fuel level in the fuel tank. nitrates and amines
4. Check the engine oil level. • Solution states that it is formulated for use
in heavy duty diesel applications
5. Check the engine coolant level.
55
600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL SECTION 5
• Protects all standard metals within the cool- 1. Clean the return line orifice and strainer.
ing system (i.e. brass, copper, steel, solder,
2. Change compressor fluid filter
cast iron, and aluminum.)
• Meets specification requirements of current 3. Check Engine Operator’s Manual for
industry standards which include: ASTM D required service.
3306.
• Meets or exceeds performance require- 5.5 5.5 MAINTENANCE EVERY
ments of current industry standards which 100 HOURS
include: ASTM D 6210.
After 100 hours of operation, it will be necessary to
If you are not sure of the coolant that is installed perform the following: Check Engine Operator’s
originally or want to change to a different type, the Manual for required service.
cooling system must be cleaned with a commercial
cleaning agent and then completely flushed and filled
with water (preferably distilled) several times to
5.6 5.6 MAINTENANCE EVERY
remove all traces of cleaner and old coolant. Finally, 250 HOURS
fill the system with the recommended coolant using
only one brand/type. Cross contamination, which is Perform the following after every 250 hours of
caused by adding different types of engine coolants, operation:
may result in the depletion or dropout of coolant 1. Check fan belt tension and adjust if needed.
additives; thus leaving cooling system surfaces
unprotected against corrosion. 2. Clean the radiator and cooler exterior.
Depending on how contaminated the atmo-
Corrosion to radiator surfaces may reduce cooling
efficiency and radiator life expectancy. It is extremely sphere may be, more frequent cooler and
important to evacuate/purge all air within the cooling radiator cleaning may be necessary.
system before replacing the radiator cap. 3. Check Engine Operator’s Manual for
Engine coolant must not only maintain proper freeze required service
protection levels but also maintain proper corrosion
inhibitor levels. Please contact the coolant 5.7 5.7 MAINTENANCE EVERY
manufacture for specifics on testing methods and 300 HOURS
suggested coolant maintenance intervals.
When not using Sullair AWF, change the compressor
Coolant Service Life fluid and replace the fluid filter element. Refer to
Main Fluid Filter Servicing on page 58.
Coolant Type Service Life
5.8 MAINTENANCE EVERY 600
Mobil Delvac EXTENDED *Six Years/12,000 Hours HOURS
LIFE Coolant/Antifreeze
When not using Sullair AWF, replace the fluid filter
*(Using manufactures extender additive to system at element only. Refer to Main Fluid Filter Servicing on
3 years or 6000 hours) page 58.
5.4 MAINTENANCE AFTER 5.9 MAINTENANCE EVERY 1000

INITIAL 50 HOURS OF HOURS
OPERATION
Perform the following after every 1000 hours of
After the initial 50 hours of operation, a few simple operation:
maintenance routines can rid the system of any
1. Clean the return line orifice and strainer.
possible foreign materials, if any. Perform the
following maintenance operations to prevent 2. Repack the wheel bearings on wheel-
unnecessary problems. mounted units.
56
SECTION 5 600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL
5.10 MAINTENANCE EVERY 1500 all internal pressure before proceeding. Drain the
HOURS fluid by opening the appropriate drain valve located
in the frame at the front of the machine. Close the
When using Sullair AWF, change the compressor valve when draining is complete. Change the
fluid and replace the fluid filter element. compressor fluid and replace the fluid filter element.
For element replacement see procedure for servicing
Refer to Parts Replacement And Adjustment
the fluid filter in this section. Fill the receiver tank with
Procedures in Section 5 on page 57.
fluid according to Lubrication Guide in Section 3 on
page 44.
5.11 PARTS REPLACEMENT AND
ADJUSTMENT RUNNING GEAR LUBRICATION
PROCEDURES Refer to Figure 5-1. An inspection of the running gear
should be made on a routine basis. On four-wheel
COMPRESSOR FLUID CHANGE PROCEDURE
steerable running gear models, front-axle pivot joints
Warm-up the compressor for 5 to 10 minutes to and rod ends are fitted with grease zerks which
warm the fluid. Shut the compressor off and relieve should be lubricated every six months.
Figure 5-1: Running Gear Lubrication
57
3
1
2
5
7
6
SU_0000076
Figure 5-2: Typical E-Z Lube Axle

1. RUBBER PLUG 4. GREASE FLOW
2. OUTER BEARING 5. GREASE FITTING
3. INNER BEARING 6. METAL END CAP
7. SPRING-LOADED DOUBLE LIP SEAL
WHEEL BEARING LUBRICATION 3. Pump grease into the zerk. The old, dis-
placed grease will flow back out of the cap
Refer to Figure 5-2. Proper lubrication is essential to around the grease gun nozzle.
the proper functioning and reliability of your portable
compressor axle. Wheel bearings should be 4. When new, clean grease is observed,
lubricated at least once every 12 months, or more remove the grease gun, wipe off any excess,
frequently to help insure proper performance. Use and replace the rubber plug in the cap.
wheel bearing grease that conforms to military
MAIN FLUID FILTER SERVICING
specification MIL-G-10924 or a high temperature
wheel bearing grease such as lithium complex NLGI Refer to Figure 5-3. The main fluid filters are located
Consistency #2. schematically in the coolant line between the
receiver tank and the compressor unit. The main filter
If your axle is equipped with the E-Z Lube feature,
elements are replaceable. For installation of the filter
the bearings can be periodically lubricated without
elements, follow the procedure explained below:
removing the hubs from the axle. This feature
consists of axle spindles that have been specially 1. The compressor MUST be shut off and sys-
drilled and fitted with a grease zerk in their ends. tem pressure MUST be relieved.
When grease is pumped into the zerk, it is channeled
2. Position a suitable container beneath the
to the inner bearing and then flows back to the outer
elements to catch fluid drainage.
bearing and eventually back out of the grease cap
hole (refer to Figure 5-2). The procedure is as 3. Remove elements using a suitable tool.
follows:
4. Rotate each element counterclockwise to
1. Remove the rubber plug from the end of the remove.
grease cap.
5. Remove element and discard. These ele-
2. With a standard grease gun filled with a qual- ments are not cleanable.
ity wheel bearing grease, place the gun onto
6. Make certain that the mounting surfaces and
the grease zerk located in the end of the
filter heads are clean.
spindle. Make sure the grease gun nozzle is
fully engaged on the fitting.
58
7. Apply a light film of clean fluid to each ele- AIR FILTER MAINTENANCE
ment gasket surface.
Refer to Figure 5-4. Air filter maintenance should be
8. Center the new elements on filter housing performed when indicated on the air filter restriction
heads and tighten until the filter gaskets make gauge. The air filters are both equipped with a
contact with the filter housing. After gaskets primary element and secondary element each.
make contact, tighten 1/2 to 2/3 of a turn.
The secondary element must be replaced after every
9. Run compressor and check for leaks. third primary element change. DO NOT reconnect
the secondary element once it is removed.
4 2
Figure 5-3: Main FLuid FIlter Assembly and Thermostat
1. CAPSCREW 5. THERMOSTAT
2. WASHER ELEMENT*
3. UPPER HOUSING 6. O-RING
4. O-RING 7. LOWER HOUSING
*Repair kit for thermostat element, part number 02250087-682

**Replacement filter element (2 required) part number 250025-526
59
ELEMENT REMOVAL ELEMENT INSPECTION

1. Clean the exterior of the air filter housing. 1. Place a bright light inside the element to
inspect for damage or leak holes. Concen-
2. Remove the cover/element assembly by
trated light will shine through the element
loosening the wingnut securing the cover/
and disclose any holes.
element assembly.
2. Inspect all gaskets and gasket contact sur-
3. Remove the cover/element assembly from
faces of the housing. Should faulty gaskets
the housing by unscrewing the wingnut.
be evident, correct the condition immedi-
4. Clean the interior of the housing by using a ately.
damp cloth. DO NOT blow out dirt with com-
3. If the clean element is to be stored for later
pressed air as this may introduce dust down-
use, it must be stored in a clean container.
stream of the filter.
4. After the element has been installed, inspect
5. When it becomes necessary to remove the
and tighten all air inlet connections prior to
secondary element, pull the element out of
resuming operation.
the housing.
6. Install the new secondary element over the PRIMARY ELEMENT REPLACEMENT
rod. 1. Place the element in position over the sec-
7. With the secondary element in place, replace ondary element.
the primary element. 2. Install the cover with clean-out port pointing
down. Clamp in place using all latches
located on canister.
3 6
5
Figure 5-4: Filter Components SU_0000077
1. HOUSING 4. PRIMARY ELEMENT*

2. SECONDARY ELEMENT** 5. SEALING WASHER
3. DUST COLLECTOR 6. WING NUT
* Primary Filter Element, Part No. 048462

** Secondary Filter Element, Part No. 048463
60
CONTROL SYSTEM ADJUSTMENT on the instrument panel. If not, repeat step,

but adjust the unload service pressure up or
Refer to Figure 5-5. Prior to adjusting the control down as needed until 100 psig (6.9 bar) is
system, it is necessary to determine the desired maintained when engine speed is 1800 rpm.
operating pressure range as well as the maximum
pressure at which the machine is to operate. This 3. For 150 psig (10.3 bar) “H” machines, turn
pressure must not exceed the maximum operating the “HIGH/LOW” valve to “HIGH” position.
pressure which is stamped on the machine serial Close the service valve and set the “HIGH”
number plate. pressure control regulator to maintain 165 to
175 psig (11.4 to 12.1 bar) discharge pres-
1. Start the machine and let it warm-up and sure. Open the service valve to maintain 150
enter “RUN” mode. psig (10.3 bar) and check for 1800 RPM full-
2. Open service valve slightly until engine tries load speed. If lower speed is observed, raise
to speed up. Slowly close the service valve. the setting of the low pressure control regu-
With service valve closed, check and adjust lator until rated speed is achieved.
the pressure at the reducing regulator to a 4. For 175 psig (12.1 bar) “HH” machines, turn
minimum of 60 psig (4.1 bar) and not to the “HIGH/ LOW” valve to “HIGH” position.
exceed 75 psig (5.2 bar). With service valve Close the service valve and set the “HIGH”
still closed, and the “HIGH/LOW” valve in the pressure control regulator to maintain 190 to
“LOW” position, adjust the low-pressure 200 psig (13.1 to 13.8 bar) discharge pres-
back-pressure regulator so the service pressure. Open the service valve to maintain 175
sure is between 115 to 125 psig (7.9 to 8.6 psig (12.1 bar) and check for 1800 RPM full-
bar) with the engine at 1400 rpm. Open the load speed. If lower speed is observed, raise
service valve to load the compressor to the setting of the low pressure control regu-
maintain 100 psig (6.9 bar) discharge pres- lator until rated speed is achieved.
sure. Operating speed should be 1800 RPM
61
Figure 5-5: Control System Components
1. PNEUMATIC INLET 5. LOW PRESSURE

VALVE REGULATOR
2. CONTROLLER 6. HIGH PRESSURE
REGULATOR
3. HIGH/LOW VALVE
7. REDUCING PRESSURE
4. START/RUN VALVE REGULATOR
62
SEPARATOR ELEMENT REPLACEMENT capscrews to 112 to 127 ft.lbs (151 to 172

N·m).
Refer to Figure 5-6. When fluid carry-over is evident
after the fluid return-line strainer and orifice, as well 9. Reconnect all piping. The fluid return line
as the blowdown valve diaphragm, have been should extend to the bottom of the separator
inspected and found to be in satisfactory condition, or element or no more than 1/16 in (1.6 mm) up
if the separator restriction gauge reads in excess of from the bottom. This will assure the proper
10 psig (0.7 bar), separator element replacement is fluid return flow.
necessary. Follow the procedure explained below: 10. Clean the fluid return line strainer and clear
the orifice prior to restarting the compressor.
NOTE
RELIEVE PRESSURE PRIOR TO 1
WORKING ON.
2
1. Remove all piping connected to the receiver

tank cover to allow removal (return line, ser-
vice line, etc.).
2. Remove the fluid return line from the fitting in 3
the cover.
3. Remove the twelve (12) 5/8 x 2.25 in cap-
screws and lock washers and lift the cover
from the receiver tank with the minimum
pressure/check valve in place.
4. Remove the separator element.
4
5. Scrape the old gasket material from the
cover and the flange on the receiver tank. Be
sure to keep all scrapings from falling inside
the tank.
6. Install the gaskets.
5
7. Make sure grounding staples are attached to
separator gasket.
Figure 5-6: Separator Element Assembly
CAUTION 1. CAPSCREW
2. LOCKWASHER
DO NOT REMOVE STAPLES.
3. COVER
4. SEPARATOR ELEMENT *
8. Replace the receiver tank cover. Install the
twelve (12) 5/8 x 2.25 in capscrews and lock 5. RECEIVER TANK
washers in finger-tight, then gradually tighten * Repair kit, part number 250034-086
in a criss-cross pattern in 4 to 5 steps.
Always tighten the capscrews alternately at
opposite sides of the cover. Never tighten
capscrews adjacent to each other. Torque
63
5.12 TROUBLESHOOTING GUIDE • Check for loose wiring.

• Check for damaged piping.
The following Troubleshooting Chart is based on
• Check for parts damaged by heat or an electrical
both the data obtained from actual tests conducted at
short circuit, usually apparent by discoloration or a
our factory and real applied situations. It contains
burnt odor.
symptoms and usual causes for the described
problems. However, DO NOT assume that these are Should your problem persist after making the
the only problems that may occur. All available data recommended check, consult your nearest Sullair
concerning the trouble should be systematically representative or the Sullair.
analyzed before undertaking any repairs or
component replacement procedures.
SYMPTOM PROBABLE CAUSE REMEDY

Compressor will not start No fuel Check fuel level and add fuel if necessary.
Plugged fuel filter Replace the fuel filter element.
Battery Check electrolyte level and add distilled water and
recharge if necessary.
Loose battery cables; tighten cables.
Dirty battery cables; clean thoroughly.
Plugged air filter Replace the air filter element.
Engine problems may have developed Refer to Engine Operator’s Manual
Instrument panel problems may have Refer to Controller Manual.
developed
DEF bad or empty (engine derated) Fill/Replace DEF (Refer to Engine Operator’s
Manual
Compressor shuts down No fuel Check fuel gauge and add fuel if necessary.
with air demand present Compressor discharge temperature Cooling air flow is insufficient; clean cooler and
switch is open 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 checkout normal, it could be possible
that the temperature switch itself is defective.
Instrument panel problems may have Refer to Controller Manual.
developed
DEF bad or empty (engine derated) Fill/Replace DEF (Refer to Engine Operator’s
Manual
Compressor will not build Air demand is too great Check service lines for leaks of open valves.
up full discharge pressure Dirty air filter Check the filter gauges on instrument panel and
change element if required.
Pressure regulator out of adjustment Adjust regulator according to control adjustment
instructions in the Maintenance section.
Defective pressure regulator Check diaphragm and replace if necessary (kit
available).
Defective air inlet cylinder Replace cylinder
64

Improper unloading with Fluid charge lost from spring chamber Add fluid to inlet valve spring chamber by
an excessive pressure on inlet valve pressure regulating valve removing plugs in the top of the spring chamber
build-up causing pressure is set too high and filing with compressor fluid.
relief valve to open Some fluid may leak from the control regulator at
first but will stop leaking when fluid level in the
spring chamber equalizes.
Running blowdown valve pressure Readjust.
regulating valve set too high
Leak in control system causing loss of Check control lines.
pressure signal Worn seals in inlet valve. Replace seals (kit
available).
Defective pressure regulating valves; repair valves
(kits available).
Inlet valve jammed Free or replace valve.
Restriction in the control system Check all control lines and components.
Ice and other contaminants could cause
restrictions.
Defective pressure relief valve Replace pressure relief valve.
Insufficient air delivery Plugged air filter Replace.
Plugged air/fluid separator Replace separator element and also change
compressor fluid and fluid filter at this time.
Defective pressure regulator Adjust or repair.
Engine speed too low Readjust engine speed.
Control air cylinder defective Replace cylinder.
Excessive compressor Clogged return line Clear orifice.
fluid consumption Leak in the lubrication system Check all pipes, connections and components
Separator element damaged or not Change separator element.
functioning properly
Defective minimum pressure/check Repair or replace.
valve
Fluid receiver tank overfilled Drain to proper level.
Compressor overheating Loose or broken fan belt Tighten or change belt
Dirty fluid cooler core Clean core thoroughly.
Dirty aftercooler Clean core thoroughly.
Dirty radiator core Clean core thoroughly.
Faulty thermostat element Change thermostat element.
Plugged fluid cooler tube (internal) Clean tube thoroughly.
Low receiver tank fluid level Refill.
Plugged compressor fluid filter Change element.
65

Engine overheating Loose or broken fan belt Tighten or change belt.
Dirty radiator core Clean thoroughly.
Dirty oil cooler Clean thoroughly.
Low water level Refill.
Dirty aftercooler Clean thoroughly.
Low fluid level Refill.
Faulty water pump Change pump.
Plugged radiator Clean and flush thoroughly.
Defective engine thermostat Replace engine thermostat.
Shutdown panel lights Faulty switch indicated by light Replace the switch.
Engine warning Refer to Engine Manual Refer to Engine Manual
66
600H, 750, 750H, 750HH, 825, 900, 900H USER MANUAL
Section 6
NOISE CONTROL
6.1 NOISE EMISSIONS control prior to its sale or delivery to the ulti-
WARRANTY mate purchaser or while it is in use.
2. The use of the compressor after such device
Sullair warrants to the ultimate purchaser and each
or element of design has been removed or
subsequent purchaser that this air compressor was
rendered inoperative by any person.
designed, built and equipped to conform at the time
of sale to the first retail purchaser, with all applicable Among those acts included in the prohibition against
U.S. E.P.A. and/or any Federal, State or Local noise tampering are the acts listed below:
control regulations.
1. Removal or rendering inoperative any of the
This warranty is not limited to any particular part, following:
component, or system of the air compressor. Defects
a. Engine exhaust system or parts thereof
in the design, assembly, or in any part, component,
or system of the compressor which, at the time of b. Compressor air intake system or part thereof
sale to the first retail purchaser, caused noise
c. Enclosure of part thereof
emissions to exceed Federal standards are covered
by this warranty for the life of the air compressor. 2. Removal of any of the following:
a. Vibration isolators
6.2 TAMPERING WITH THE
NOISE CONTROL SYSTEM IS b. Control silencer
PROHIBITED c. Floor panel
Federal Law prohibits the following acts or the d. Fan shroud
causing thereof:
e. Acoustical materials including fiberglass
1. The removal or rendering inoperative by any foam or foam tape
persons, other than for purposes of mainte-
3. Operation with canopy doors open for any
nance, repair, or replacement, of any device
purpose other than starting, stopping, adjust-
or element of design incorporated into any
ment, repair, replacement of parts or mainte-
new compressor for the purpose of noise
nance.
67
6.3 NOISE EMISSIONS MAINTENANCE & MAINTENANCE RECORD LOG

The following instructions and maintenance record log book, for the proper maintenance, use and repair of this
compressor, is intended to prevent noise emission degradation.
NOISE EMISSION MAINTENANCE & 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
By
Location
Date
2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION

In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet
system should be inspected at least annually, 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.
By
Location
Date
By
Location
Date
68
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.
By
Location
Date
By
Location
Date
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.
By
Location
Date
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.
By
Location
Date
By
Location
Date
69
6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.

In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to make sure
all systems are operating properly and that engine runs at rated speed and pressure. DO NOT operate malfunctioning or
improperly adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required.
By
Location
Date
By
Location
Date
70
NOTES
Always air. Always there.
WWW.SULLAIR.COM
SULLAIR
3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451
Printed in the U.S.A.

Specifications subject to change
without prior notice.
E12EP

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USER MANUAL

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

SECTION 6—NOISE CONTROL

1.1 GENERAL 1.2 TOWING *

engage coupling device or otherwise couple the

chain fall if you cannot lift or raise the drawbar

the engine shut off. When necessary, make

should be washed with large quantities of clean

1.8 ELECTRICAL SHOCK I. Keep lift operator in constant attendance when-

1.14 SYMBOLS AND REFERENCES

DIESEL FUEL HEARING PROTECTION

DRAIN SAFETY GLASSES

ENGINE DO NOT BREATHE

DO NOT ELECTRICAL SHOCK

DANGEROUS OUTLET ENGINE START

BELOW TEMPERATURE BELT GUARD

DO NOT TOW SERVICE POINT

BATTERY DISCONNECT STD AIR

OFF A/C AIR

RADIATOR HOUR METER

AIR-CIRCULATING COMPRESSOR AIR

INLET VALVE SPRING

DO NOT OPERATE WATER DRAIN

PRESSURIZED SPRING SEVER (FAN)

DO NOT MIX FLUIDS

Figure 2-1: Components and Assemblies front view.

1.MOISTURE SEPARATOR 8.ENGINE RADIATOR 15.DEF FILL

Figure 2-2: Component and Assemblies rear view.

1.MOISTURE SEPARATOR 8.ENGINE RADIATOR 15.DEF FILL

2.2 DESCRIPTION OF COMPONENTS

Figure 2-3: Compressor Oil, Cooling and Lubrication - All Models

LOW PRESSURE - 80 TO 100 PSIG (5.5 TO 6.9 2.6 COMPRESSOR DISCHARGE

which is drawn through the aftercooler by the engine

Figure 2-4: Aftercooled Air System

Figure 2-5: Air Inlet System

1. Engine Air FIlter 4. Compressor

2.11 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION

Figure 2-6: Instrument Panel Group

1. COMPRESSOR TEMPERATURE 5. HIGH/LOW VALVE

2.12 ENGINE CONTROL MODULE, 2.13 ELECTRICAL SYSTEM,

2.14 CONTROLLER WIRING DIAGRAM

2.14 CONTROLLER WIRING DIAGRAM

2.15 COMPRESSOR WIRING DIAGRAM

2.15 COMPRESSOR WIRING DIAGRAM

Table 3-3: Engine Specifications

Trailer: DTQ DWQ

Track Width 77 in (1956 mm) 79.5 in (2019 mm)

3.2 TABLE OF SPECIFICATIONS-825, 900, 900H

Table 3-7: Engine Specifications

Table 3-8: Trailer Specifications

Trailer: DTQ DWQ

Track Width 77 in (1956 mm) 79.5 in (2019 mm)

3.3 LUBRICATING GUIDE - COMPRESSOR

3.4 APPLICATION GUIDE

changed if this condition develops.

DO NOT mix types of fluids. Combinations

When ambient conditions exceed those noted or if

3.5 LUBRICATION GUIDE, ENGINE