Professional Documents
Culture Documents
Sullair AC185D Operators-Manual PDF
Sullair AC185D Operators-Manual PDF
PART NUMBER:
02250174-684 R01
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
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!
200803010000
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.
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
3 1.1 GENERAL
3 1.2 TOWING
6 1.3 PRESSURE RELEASE
7 1.4 FIRE AND EXPLOSION
8 1.5 MOVING PARTS
9 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
9 1.7 TOXIC AND IRRITATING SUBSTANCES
10 1.8 ELECTRICAL SHOCK
10 1.9 LIFTING
10 1.10 ENTRAPMENT
11 1.11 JUMP STARTING
12 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT
13 1.13 CALIFORNIA
PROPOSITION 65
14 1.14 SYMBOLS AND REFERENCES
SECTION 2—DESCRIPTION
17 2.1 INTRODUCTION
17 2.2 DESCRIPTION OF COMPONENTS
19 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
19 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
20 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
21 2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
24 2.7 PIPING AND INSTRUMENTATION—COMPRESSOR SYSTEM
26 2.8 PIPING AND INSTRUMENTATION—ENGINE SYSTEM
28 2.9 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
29 2.10 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
31 2.11 WIRING DIAGRAM—CAT & JD
32 2.12 WIRING DIAGRAM—DEUTZ
33 2.13 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
33 2.14 COMPRESSOR SHUTDOWN & WARNING SYSTEM, FUNCTIONAL DE-
TABLE OF CONTENTS
SCRIPTION
SECTION 3—SPECIFICATIONS
35 3.1 SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR
37 3.2 SPECIFICATIONS – 125, 130 AND 185 DEUTZ
39 3.3 SPECIFICATIONS—125, 130, 49 HP AND 185 JOHN DEERE
40 3.4 LUBRICATION GUIDE – COMPRESSOR
41 3.5 APPLICATION GUIDE
41 3.6 LUBRICATION GUIDE – ENGINE
SECTION 4—GENERAL
43 4.1 GENERAL
43 4.2 PURPOSE OF CONTROLS
44 4.3 INITIAL STARTUP/SHUTDOWN PROCEDURE
44 4.4 RESTART PROCEDURE
SECTION 5—MAINTENANCE
45 5.1 GENERAL
45 5.2 ENGINE COOLANT REQUIREMENT FOR RADIATORS
45 5.3 DAILY MAINTENANCE
45 5.4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
46 5.5 MAINTENANCE EVERY 50 HOURS
46 5.6 MAINTENANCE EVERY 100 HOURS
46 5.7 MAINTENANCE EVERY 250 HOURS
46 5.8 MAINTENANCE EVERY 1500 HOURS
46 5.9 PART REPLACEMENT AND ADJUSTMENT PROCEDURES
52 5.10 TROUBLESHOOTING
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.
(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED
PORTABLE AIR COMPRESSORS AS WELL.
3
SECTION 1
A. Prior to hitching the air compressor to the tow G. If provided, make sure chain length, brake and
vehicle, inspect all attachment parts and equip- electrical interconnections provide sufficient
ment, checking for (i) signs of excessive wear or slack to prevent strain when cornering and
corrosion, (ii) parts that are cracked, bent, maneuvering, yet are supported so they cannot
dented or otherwise deformed or degraded, and drag or rub on road, terrain or towing vehicle sur-
(iii) loose nuts, bolts or other fasteners. Should faces which might cause wear that could render
any such condition be present, DO NOT TOW
them inoperative.
until the problem is corrected.
B. Back the tow vehicle to the compressor and posi-
tion it in preparation for coupling the compressor. WARNING
C. If the compressor is provided with a drawbar
latched in the vertical upright position, carefully This equipment may be tongue heavy. DO
unlatch drawbar and lower it to engage the cou- NOT attempt to raise or lower the drawbar
pling device. If not, raise drawbar to engage cou- by hand if the weight is more than you can
pling device or otherwise couple the compressor safely handle.
to the towing vehicle.
WARNING CAUTION
This equipment may be tongue heavy. DO
NOT attempt to raise or lower the drawbar Retract the front screw jack only after
by hand if the weight is more than you can attaching the compressor to the tow vehi-
safely handle. cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to
Use the screw jack provided or a chain fall the drawbar. Rotate the screw jack to its
if you cannot lift or lower it without avoiding stowed position, parallel to the drawbar,
injury to yourself or others. Keep hands and reinsert the pin. Make sure the jack is
and fingers clear of the coupling device and secured in place prior to towing.
all other pinch points. Keep feet clear of
drawbar to avoid injury in case it should If a caster wheel is provided on the screw
slip from your hands. jack it is part of the screw jack and can not
be removed. Follow the same procedure for
stowing away the wheeled jack as you
D. Make sure the coupling device is fully engaged,
would for the standard screw jack. Pull the
closed and locked.
pin connecting the jack to the drawbar and
E. If chains are provided, pass each chain through raise the screw jack to its full up position.
its point of attachment on the towing vehicle; Rotate the screw jack to its stowed posi-
then hook each chain to itself by passing the tion, parallel to the drawbar, and reinsert
grab hook over (not through) a link. Cross chains the pin. Make sure the jack is secured in
under front of drawbar before passing them place prior to towing.
through points of attachment on towing vehicle to
support front of drawbar in case it should acci- H. On two-wheeled models, fully retract front screw
dentally become uncoupled. jack and any rear stabilizer legs. If a caster wheel
F. Make sure that the coupling device and adjacent is provided on the screw jack it is part of the
structures on the towing vehicle (and also, if uti- screw jack, and can not be removed. Follow the
lized, chain adjustment, brake and/or electrical same procedure for stowing away the wheeled
interconnections) DO NOT interfere with or jack as you would for the standard screw jack.
restrict motion of any part of the compressor, Pull the pin connecting the jack to the drawbar
including its coupling device, with respect to the and raise the screw jack to its full upright posi-
towing vehicle when maneuvering over any tion. Rotate the screw jack to its stowed position,
anticipated terrain. parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to
towing.
4
SECTION 1
I. Make sure tires are in good condition and are the according to posted speed limits, weather, traffic,
size (load range) specified and are inflated to the road or terrain conditions:
specified pressures. DO NOT change the tire
1. Two axle four-wheel or three axle six-wheel
size or type. Also, make sure wheel bolts, lugs or steerable models: 15 MPH (24 km/h).
nuts are tightened to the specified torques.
2. All other models: 55 MPH (88 km/h).
J. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating properly C. Remember that the portable air compressor may
and that their lenses are clean and functional. approach or exceed the weight of the towing
Also, make sure all reflectors and reflecting sur- vehicle. Maintain increased stopping distances
faces, including the slow moving vehicle emblem accordingly. DO NOT make sudden lane
on compressors provided with same, are clean changes, U-turns or other maneuvers. Such
and functional. maneuvers can cause the compressor to tip, roll
over, jackknife or slide and cause loss of control
K. Make sure all service air hoses (not air brake of the towing vehicle. Tipping, rolling over, etc.
hoses) are disconnected or are fully stowed and can occur suddenly without warning. U-turns
secured on hose reels, if provided. especially should be made slowly and carefully.
L. Make sure all access doors and tool box covers D. Avoid grades in excess of 15° (27%).
are closed and latched. If the compressor is
large enough to hold a man, make sure all per- E. Avoid potholes, rocks and other obstructions,
sonnel are out before closing and latching and soft shoulders or unstable terrain.
access doors. F. Maneuver in a manner that will not exceed the
M. Make sure parking brakes in towing vehicle are freedom of motion of the compressor’s drawbar
set, or that its wheels are chocked or blocked, or and/ or coupling device, in or on the towing vehi-
that it is otherwise restrained from moving. Then, cle’s coupling device and/or adjacent structure
release the compressor parking brakes, if pro- whether towing forward or backing up, regard-
vided. less of the terrain being traversed.
N. Make sure the compressor wheels are not G. DO NOT permit personnel to ride in or on the
chocked or blocked, and that all tie-downs, if any, compressor.
are free. H. Make sure the area behind, in front of, and under
O. Test running brake operation, including break- the compressor is clear of all personnel and
away switch operation if provided, before obstructions prior to towing in any direction.
attempting to tow the compressor at its rated I. DO NOT permit personnel to stand or ride on the
speed or less when conditions prevail. drawbar, or to stand or walk between the com-
P. DO NOT carry loose or inappropriate tools, pressor and the towing vehicle.
equipment or supplies on or in the compressor. PARKING OR LOCATING COMPRESSOR
Q. DO NOT load this equipment with accessories or A. Park or locate compressor on a level surface, if
tools such that it is unbalanced from side to side possible. If not, park or locate compressor across
or front to back. Such unbalance will reduce the grade so the compressor does not tend to roll
towability of this equipment and may increase downhill. DO NOT park or locate compressor on
the possibility of tipping, rolling over, jackknifing, grades exceeding 15° (27%).
etc. Loss of control of the towing vehicle may
result. B. Make sure compressor is parked or located on a
firm surface that can support its weight.
TOWING
C. Park or locate compressor so the wind, if any,
A. Observe all Federal, State, and Local laws while tends to carry the exhaust fumes and radiator
towing this equipment (including those specifying heat away from the compressor air inlet open-
minimum speed). ings, and also where the compressor will not be
B. DO NOT exceed the towing speeds listed below exposed to excessive dust from the work site.
under ideal conditions. Reduce your speed D. On steerable models, park compressor with front
wheels in straight-ahead position.
5
SECTION 1
E. Set parking brakes and disconnect breakaway wheeled jack as you would for the standard
switch cable and all other interconnecting electri- screw jack. Raise the screw jack to its full upright
cal and/or brake connections, if provided. position and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its stowed
F. Block or chock both sides of all wheels.
position, parallel to the drawbar and reinsert the
G. If provided, unhook chains and remove them pin. Make sure the jack is secured in place prior
from the points of chain attachment on the towing to towing.
vehicle, then hook chains to bail on drawbar or
J. Disconnect coupling device, keeping hands and
wrap chains around the drawbar and hook them
fingers clear of all pinch points. If the compressor
to themselves to keep chains off the ground
is provided with a drawbar, DO NOT attempt to
which might accelerate rusting.
lift the drawbar or if hinged, to raise it to the
H. Lower front screw jack and/or any front and rear upright position by hand, if the weight is more
stabilizer legs. Make sure the surface they con- than you can safely handle. Use a screwjack or
tact has sufficient load bearing capability to sup- chain fall if you cannot lift or raise the drawbar
port the weight of the compressor. without avoiding injury to yourself or others.
K. When possible, stow hinged drawbar in the verti-
cal upright position. Make certain it is securely
WARNING latched in the vertical upright position. Keep feet
clear of drawbar at all times to avoid crushing
This equipment may be tongue heavy. DO accidents in case it should slip from your hands
NOT attempt to raise or lower the drawbar or otherwise fall to the ground.
by hand if the weight is more than you can
safely handle. L. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barri-
cades and/or flares (if at night) if compressor is
I. If a caster wheel is provided on the screw jack, it C. When the hose is to be used to supply a mani-
is part of the screw jack and cannot be removed. fold, install an additional appropriate flow-limiting
Follow the same procedure for stowing away the valve between the manifold and each air hose
6
SECTION 1
exceeding 1/2" (13 mm) inside diameter that is to loosen cap slowly to its stop to relieve any
be connected to the manifold to reduce pressure excess pressure and make sure coolant is not
in case of hose failure. boiling before removing cap completely. Remove
radiator filler cap only when cool enough to touch
D. Provide an appropriate flow-limiting valve for
with a bare hand.
each additional 75 feet (23 m) of hose in runs of
air hose exceeding 1/2" (13 mm) inside diameter P. The ethyl ether in the replaceable cylinders used
to reduce pressure in case of hose failure. in diesel ether starting aid systems (optional) is
under pressure. DO NOT puncture or incinerate
E. Flow-limiting valves are listed by pipe size and
those cylinders. DO NOT attempt to remove the
rated CFM. Select appropriate valve accordingly.
center valve core or side pressure relief valve
F. DO NOT use tools that are rated below the maxi- from these cylinders regardless of whether they
mum rating of this compressor. Select tools, air are full or empty.
hoses, pipes, valves, filters and other fittings
Q. If a manual blowdown valve is provided on the
accordingly. DO NOT exceed manufacturer’s
receiver, open the valve to ensure all internal
rated safe operating pressures for these items.
pressure has been vented prior to servicing any
G. Secure all hose connections by wire, chain or pressurized component of the compressor air/
other suitable retaining device to prevent tools or fluid system.
hose ends from being accidentally disconnected
and expelled. 1.4 FIRE AND EXPLOSION
H. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
WARNING
I. Vent all internal pressure prior to opening any Do not attempt to operate the compressor
line, fitting, hose, valve, drain plug, connection or in any classification of hazardous environ-
other component, such as filters and line oilers, ment or potentially explosive atmosphere
and before attempting to refill optional air line unless the compressor has been specially
anti-icer systems with antifreeze compound. designed and manufactured for that duty.
J. Keep personnel out of line with and away from
the discharge opening of hoses, tools or other A. Refuel at a service station or from a fuel tank
points of compressed air discharge. designed for its intended purpose. If this is not
possible, ground the compressor to the dis-
K. DO NOT use air at pressures higher than 30 psig penser prior to refueling.
(2.1 bar) for cleaning purposes, and then only
with effective chip guarding and personal protec- B. Clean up spills of fuel, fluid, battery electrolyte or
tive equipment per OSHA Standard 29 CFR coolant immediately if such spills occur.
1910.242 (b) or any applicable Federal, State C. Shut off air compressor and allow it to cool. Then
and Local codes, standards and regulations. keep sparks, flames and other sources of ignition
L. DO NOT engage in horseplay with air hoses as away and DO NOT permit smoking in the vicinity
death or serious injury may result. when adding fuel, or when checking or adding
electrolyte to batteries, or when checking or add-
M. This equipment is supplied with an ASME ing fluid, or when checking diesel engine ether
designed pressure vessel protected by an ASME starting aid systems or replacing cylinders, or
rated relief valve. Lift the handle once a week to when refilling air line anti-icer systems antifreeze
make sure the valve is functional. DO NOT lift compound.
the handle while machine is under pressure.
D. DO NOT permit liquids, including air line anti-icer
N. If the machine is installed in an enclosed area it system antifreeze compound or fluid film, to
is necessary to vent the relief valve to the outside accumulate on bottom covers or on, under or
of the structure or to an area of non-exposure. around acoustical material, or on any external or
O. DO NOT remove radiator filler cap until the cool- internal surfaces of the air compressor. Wipe
ant temperature is below its boiling point. Then down using an aqueous industrial cleaner or
7
SECTION 1
steam clean as required. If necessary, remove N. DO NOT operate compressor under low over-
acoustical material, clean all surfaces and then hanging leaves or permit such leaves to contact
replace acoustical material. Any acoustical mate- hot exhaust system surfaces when operating the
rial with a protective covering that has been torn compressor in forested areas.
or punctured should be replaced immediately to
O. Ethyl ether used in diesel engine ether starting
prevent accumulation of liquids or fluid film within
aid systems is extremely flammable. Change cyl-
the material. DO NOT use flammable solvents
inders, or maintain or troubleshoot these sys-
for cleaning purposes.
tems only in well-ventilated areas away from
E. Disconnect the grounded (negative) battery con- heat, open flame or sparks. DO NOT install,
nection prior to attempting any repairs or clean- store or otherwise expose ether cylinders to tem-
ing inside the enclosure. Tag the battery peratures above 160 °F (71 °C). Remove ether
connections so others will not unexpectedly cylinder from the compressor when operating in
reconnect it. ambient temperatures above 60 °F (16 °C).
F. Keep electrical wiring, including the battery ter- P. DO NOT attempt to use ether as a starting aid in
minals and other terminals, in good condition. gasoline engines or diesel engines with glow
Replace any wiring that has cracked, cut plugs as serious personnel injury or property
abraded or otherwise degraded insulation or ter- damage may result.
minals that are worn, discolored or corroded.
Q. DO NOT spray ether into compressor air filter or
Keep all terminals clean and tight.
into an air filter that serves both the engine and
G. Turn off battery charger before making or break- the compressor as serious damage to the com-
ing connections to the battery. pressor or personal injury may result.
H. Keep grounded conductive objects such as tools R. Antifreeze compound used in air line anti-icer
away from exposed live electrical parts such as systems contains methanol which is flammable.
terminals to avoid arcing which might serve as a Use systems and refill with compound only in
source of ignition. well-ventilated areas away from heat, open
flames or sparks. DO NOT expose any part of
I. Replace damaged fuel tanks or lines immediately
these systems or the antifreeze compound to
rather than attempt to weld or otherwise repair
temperatures above 150 °F (66 °C). Vapors from
them. DO NOT store or attempt to operate the
the antifreeze compound are heavier than air.
compressor with any known leaks in the fuel sys-
DO NOT store compound or discharge treated
tem. Tag the compressor and render it inopera-
air in confined or unventilated areas. DO NOT
tive until repair can be made.
store containers of antifreeze compound in direct
J. Remove any acoustical material or other material sunlight.
that may be damaged by heat or that may sup-
S. Store flammable fluids and materials away from
port combustion prior to attempting weld repairs.
your work area. Know where fire extinguishers
Remove diesel engine ether starting aid cylin-
are and how to use them, and for what type of
ders and air line anti-icer system components
fire they are intended. Check readiness of fire
containing antifreeze compound, prior to
suppression systems and detectors if so
attempting weld repairs in any place other than
equipped.
the fuel system. DO NOT weld on or near the
fuel system.
1.5 MOVING PARTS
K. Keep a suitable, fully charged class BC or ABC
fire extinguisher or extinguishers nearby when A. Keep hands, arms and other parts of the body
servicing and operating the compressor. and also clothing away from belts, pulleys and
other moving parts.
L. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor. B. DO NOT attempt to operate the compressor with
the fan or other guards removed.
M. Open all access doors and allow the enclosure to
ventilate thoroughly prior to attempting to start C. Wear snug-fitting clothing and confine long hair
the engine. when working around this compressor, especially
8
SECTION 1
when exposed to hot or moving parts inside the 1.7 TOXIC AND IRRITATING
enclosure. SUBSTANCES
D. Keep access doors closed except when making
A. DO NOT use air from this compressor for respi-
repairs or adjustments, performing service or
ration (breathing) except in full compliance with
when starting or stopping the compressor.
OSHA Standards 29 CFR 1920 and any other
E. Make sure all personnel are out of and clear of Federal, State or Local codes or regulations.
the compressor prior to attempting to start or
operate it.
F. Shut off engine before adding fuel, fluid, coolant DANGER
lubricants, air line antifreeze compound or bat-
tery electrolyte, or before replacing ether starting
aid cylinders.
G. Disconnect the grounded negative battery con-
nection to prevent accidental engine operation
prior to attempting repairs or adjustments. Tag
the battery connection so others will not unex-
pectedly reconnect it.
INHALATION HAZARD!
H. When adjusting the controls, it may require oper-
ation of the equipment during adjustment. DO Death or serious injury can result from
NOT come in contact with any moving parts inhaling compressed air without using
while adjusting the control regulator and setting proper safety equipment. See OSHA stan-
the engine RPM. Make all other adjustments with dards and/or any applicable Federal, State,
the engine shut off. When necessary, make and Local codes, standards and regulations
adjustment, other than setting control regulator on safety equipment.
and engine RPM, with the engine shut off. If nec-
essary, start the engine and check adjustment. If B. DO NOT use air line anti-icer systems in air lines
adjustment is incorrect, shut engine off, readjust, supplying respirators or other breathing air utili-
then restart the engine to recheck adjustment. zation equipment and DO NOT discharge air
from these systems into unventilated or other
I. Keep hands, feet, floors, controls and walking
confined areas.
surfaces clean and free of fluid, water, antifreeze
or other liquids to minimize possibility of slips and C. Operate the compressor only in open or well-
falls. ventilated areas.
D. If the compressor is operated indoors, discharge
1.6 HOT SURFACES, SHARP engine exhaust fumes outdoors.
EDGES AND SHARP
CORNERS E. Locate the compressor so that exhaust fumes
are not apt to be carried towards personnel, air
A. Avoid bodily contact with hot fluid, hot coolant, intakes servicing personnel areas or towards the
hot surfaces and sharp edges and corners. air intake of any portable or stationary compres-
sor.
B. Keep all parts of the body away from all points of
air discharge and away from hot exhaust gases. F. Fuels, fluids, coolants, lubricants and battery
electrolyte used in the compressor are typical of
C. Wear personal protective equipment including
the industry. Care should be taken to avoid acci-
gloves and head covering when working in, on or
dental ingestions and/or skin contact. In the
around the compressor.
event of ingestion, seek medical treatment
D. Keep a first aid kit handy. Seek medical assis- promptly. DO NOT induce vomiting if fuel is
tance promptly in case of injury. DO NOT ignore ingested. Wash with soap and water in the event
small cuts and burns as they may lead to infec- of skin contact.
tion.
G. Wear an acid-resistant apron and a face shield or
goggles when servicing the battery. If electrolyte
9
SECTION 1
10
SECTION 1
adjustments, inform other personnel before K. Place the starting vehicle in neutral or park, turn
doing so, or else secure the access door in the off all non-essential accessory electrical loads
open position to avoid the possibility of others and start its engine.
closing and possibly latching the door with per-
L. Use only jumper cables that are clean, in good
sonnel inside.
condition and are heavy enough to handle the
starting current.
1.11 JUMP STARTING
M. Avoid accidental contact between jumper cable
A. Observe all safety precautions mentioned else- terminal clips or clamps and any metallic portion
where in this manual. of either the compressor or the starting vehicle to
minimize the possibility of uncontrolled arcing
B. Batteries may contain hydrogen gas which is
which might serve as a source of ignition.
flammable and explosive. Keep flames, sparks
and other sources of ignition away. N. Positive battery terminals are usually identified
by a plus (+) sign on the terminal and the letters
C. Batteries contain acid which is corrosive and poi-
POS adjacent to the terminal. Negative battery
sonous. DO NOT allow battery acid to contact
terminals are usually identified by the letters
eyes, skin, fabrics or painted surfaces as serious
NEG adjacent to the terminal or a negative (-)
personal injury or property damage could result.
sign.
Flush any contacted areas thoroughly with water
immediately. Always wear an acid-resistant O. Connect one end of a jumper cable to the posi-
apron and face shield when attempting to jump tive (POS) (+) battery terminal in the starting
start the compressor. vehicle. When jump starting 24V compressors
and if the starting vehicle is provided with two (2)
D. Remove all vent caps (if so equipped) from the
12V batteries connected in series, connect the
battery or batteries in the compressor. DO NOT
jumper cable to the positive (POS) (+) terminal of
permit dirt or foreign matter to enter the open
the ungrounded battery.
cells.
P. Connect the other end of the same jumper cable
E. Check fluid level. If low, bring fluid to proper level
to the positive (POS) (+) terminal of the starter
before attempting to jump start (not applicable to
motor battery in the compressor, or when jump
maintenance-free batteries).
starting 24V compressor, to the positive (POS)
F. DO NOT attempt to jump start if fluid is frozen or (+) terminal of the ungrounded battery in the
slushy. Bring batteries up to at least 60 °F (16 compressor.
°C) before attempting to jump start or it may
Q. Connect one end of the other jumper cable to the
explode.
grounded negative (NEG) (-) terminal of the bat-
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
11
SECTION 1
normal idle RPM, disconnect the jumper cable reservoir tanks. Lockout or tag lines or
from the engine block in the compressor, then valves.
disconnect the other end of this same cable from
b. Any mechanism under tension or pres-
the grounded negative (NEG) (-) terminal of the
sure, such as springs, should be
battery in the starting vehicle. Then disconnect
released and locked out or tagged.
the other jumper cable from the positive (POS)
(+) terminal of the battery in the compressor, or if c. Block any load or machine part prior to
provided with two (2) 12V batteries connected in working under it.
series, from the ungrounded battery in the com-
d. Electrical circuits should be checked with
pressor, and finally, disconnect the other end of
calibrated electrical testing equipment
this same jumper cable from the positive (POS)
and stored energy and electrical capaci-
(+) terminal of the battery in the starting vehicle
tors should be safely discharged.
or from the positive (POS) (+) terminal of the
ungrounded battery in the starting vehicle, if it is 6. Lockout and/or Tagout each energy source
provided with two (2) 12V batteries connected in using the proper energy isolating devices
series. and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
V. Remove and carefully dispose of the dampened lockout is required by each person
cloths, as they may now be contaminated with performing work. Each person shall be
acid, then replace all vent caps. provided with their own padlock and have
possession of the only key. If more than one
person is working on a machine each person
1.12 IMPLEMENTATION OF shall affix personal lock and tag using a
LOCKOUT/TAGOUT multi-lock device.
The energy control procedure defines actions 7. Tagout devices shall be used only when
power sources are not capable of being
necessary to lockout a power source of any machine locked out by use of padlocks and lockout
to be repaired, serviced or set-up, where unexpected hasp devices. Name of person affixing tag to
motion, or an electrical or other energy source, would power source must be on tag along with date
cause personal injury or equipment damage. The tag was placed on power source.
power source on any machine shall be locked out by 8. Release stored energy and bring the
each employee doing the work except when motion equipment to a “zero mechanical state”.
is necessary during setup, adjustment or trouble-
shooting. 9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
A. The established procedures for the application of B. General Security
energy control shall cover the following elements
and actions and shall be initiated only by Autho- 1. The lock shall be removed by the
rized Persons and done in the following “Authorized” person who put the lock on the
sequence: energy-isolating device. No one other than
the person/persons placing padlock ad
1. Review the equipment or machine to be lockout hasp on power shall remove padlock
locked and tagged out. and lockout hasps and restore power.
However, when the authorized person who
2. Alert operator and supervisor of which applied the lock is unavailable to remove it
machine is to be worked on, and that power his/her Supervisor may remove padlock/
and utilities will be turned off. padlocks and lockout hasps and restore
3. Check to make certain no one is operating power only if it is first:
the machine before turning off the power. a. verified that no person will be exposed to
4. Turn off the equipment using normal danger.
shutdown procedure.
b. verified that the “Authorized” person who
5. Disconnect the energy sources: applied the device is not in the facility.
a. Air and hydraulic lines should be bled, c. noted that all reasonable efforts to con-
drained and cleaned out. There should tact the “Authorized” person have been
be no pressure in these lines or in the made to inform him or her that the lock-
out or tagout device has been removed.
12
SECTION 1
13
SECTION 1
Safety Symbols-1
14
SECTION 1
Safety Symbols-2
15
SECTION 1
Safety Symbols-3
16
125, 130, 49HP AND 185 USER MANUAL
Section 2
DESCRIPTION
2.1 INTRODUCTION 2.2 DESCRIPTION OF
COMPONENTS
The Sullair 125, 130, 49HP, and 185 CFM Standard
Portable Air Compressors offer superior Figure 2-1 shows the main components and
performance, reliability and require a minimal amount subassemblies of the Sullair 125, 130, 49HP, and
of maintenance. Compared to other compressors, 185 Standard Portable Air Compressors. These
Sullair’s are unique in terms of reliability and packages include a heavy duty rotary screw air
durability. Compressor internal components require compressor, a diesel engine, fuel tank, compressor
no routine maintenance inspections. inlet system, compressor cooling and lubrication
system, compressor discharge system, capacity
control system, instrument panel and electrical
system. A low profile canopy offers improved
handling and mobility. A clamshell canopy provides
easy access to all serviceable components.
17
125, 130, 49HP AND 185 USER MANUAL SECTION 2
18
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
The control system can easily be adjusted for 2.4 COMPRESSOR COOLING
pressures from 80 to 125 psig (5.6 to 8.6 bar). The AND LUBRICATION
compressor unit is driven by an industrial diesel SYSTEM, FUNCTIONAL
engine designed to provide enough horsepower to DESCRIPTION
provide an adequate reserve under rated conditions.
Refer to Figure 2-2. The compressor cooling and
Refer to the Engine Operator’s Manual for a more
lubrication system is designed to provide adequate
detailed description of the engine. The engine
lubrication as well as maintain the proper operating
cooling system is comprised of a radiator, high
temperature of the compressor. In addition to the
capacity fan, and thermostat. The high capacity fan
fluid cooler and interconnecting piping, the system
pushes air through the radiator to maintain the
consists also of three other components: a fluid filter,
engine’s specified operating temperature. The same
thermal valve, and a fan which perform the following
fan also cools the fluid in the compressor cooling and
functions:
lubrication system.
• The fluid filter removes and collects any contami-
The engine radiator and the compressor fluid cooler
nants in the fluid.
are next to each other allowing the fan air to push
through both simultaneously. As air passes through • The thermal valve functions as a temperature regu-
the fluid cooler, the heat of compression is removed lator directing fluid either to the cooler or to the
from the fluid. compressor unit.
• The fan pushes air through the cooler dissipating
2.3 SULLAIR COMPRESSOR the heat resulting from compression of the fluid.
UNIT, FUNCTIONAL The functions of the lubrication system are explained
DESCRIPTION in more detail below. Fluid is used in the system as a
coolant and as a lubricant: the sump serves as the
Sullair compressors are single-stage, positive
fluid reservoir. At start-up, fluid flows from the sump
displacement, flood lubricated-type compressors that
to the fluid thermal valve. Fluid circulation is achieved
provide continuous (pulse-free) compression to meet
by forcing the fluid from the high pressure region of
various demand loads. Sullair compressors require
the sump to a lower pressure area in the compressor
no routine maintenance or inspection of their internal
unit. A minimum pressure device (See Compressor
parts or systems. The compressor works by injecting
Discharge System, Functional Description on page
fluid into the compressor unit where it mixes directly
20) is provided to assure adequate fluid flow under
with the air as the rotors turn. The fluid flow has three
all conditions. When entering the thermal valve upon
main functions:
start-up, the fluid temperature is cool and thus it is
1. It acts as a coolant, to control the rise of air not necessary to route it through the cooler. The fluid
temperature which is generated by compres- flows through the fluid filter and on to the compressor
sion (heat of compression). unit bypassing the cooler. As the compressor
continues to operate, the temperature of the fluid
2. Seals the leakage paths between the rotors
rises and the thermostatic control opens, allowing a
and the stator and also between the rotors
portion of the fluid into the cooler.
themselves.
When the temperature reaches 170°F (77°C), the
3. Lubricates the rotors allowing one rotor to
thermostat is fully open allowing all fluid entering the
directly drive the other.
thermal valve to flow to the cooler.
The cooler is a radiator type that works in concert
After the air/fluid mixture is discharged from the with the engine fan. The fan pushes air through the
compressor unit, the fluid is separated from the air. cooler removing the heat from the fluid. From the
At this time, the air flows to the service line and the cooler, the fluid is then routed back through the fluid
fluid is cooled in preparation for re-injection. filter. All fluid flowing to the compressor unit passes
through this filter. The fluid leaving the filter flows to
the compressor unit where it lubricates, seals and
cools the compression chamber; and lubricates the
bearings and gears.
19
125, 130, 49HP AND 185 USER MANUAL SECTION 2
2.5 COMPRESSOR DISCHARGE on the element surface, it then flows to the bottom of
SYSTEM, FUNCTIONAL the separator. A return line (or scavenge tube) leads
DESCRIPTION from the bottom of the separator element to the inlet
region of the compressor unit. Fluid collecting on the
Refer to Figure 2-2. The Sullair compressor unit bottom of the separator element is returned to the
discharges a compressed air/fluid mixture into the compressor by the pressure difference between the
receiver tank. The receiver tank has three functions: area surrounding the separator element and the
compressor inlet. An orifice (protected by a strainer)
1. It acts as a primary fluid separator.
is included in this return line to assure proper and
2. Serves as the compressor fluid reservoir. unobstructed flow. The receiver tank is code rated at
200 psig (13.8 bar) working pressure. A minimum
3. Houses the air/fluid separator.
pressure device located downstream from the
The compressed air/fluid mixture enters the receiver separator, ensures a minimum receiver pressure of
tank and is directed against the side of the sump. 80 psig (5.5 bar) during all conditions. Keeping this
Because of a change of direction and reduction of pressure level stable is necessary for proper air/fluid
velocity, large droplets of fluid separate and fall to the separation and proper fluid circulation. A pressure
bottom of the sump. The small amount of fluid relief valve (located on the wet side of the separator)
remaining in the compressed air collects on the is set to open if the sump pressure exceeds 200 psig
surface of the separator element as the compressed (13.8 bar).
air flows through the separator. As more fluid collects
20
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
21
125, 130, 49HP AND 185 USER MANUAL SECTION 2
12
15 1
3 4
14 7
11
8 9
16
17
18
10
13
SA_0000023
22
BLANK PAGE
23
125, 130, 49HP AND 185 USER MANUAL SECTION 2
24
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
25
125, 130, 49HP AND 185 USER MANUAL SECTION 2
26
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
27
125, 130, 49HP AND 185 USER MANUAL SECTION 2
28
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
29
125, 130, 49HP AND 185 USER MANUAL SECTION 2
Figure 2-5: Instrument Panel Group (Optional Full Gauge Panel Shown)
30
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
31
125, 130, 49HP AND 185 USER MANUAL SECTION 2
32
SECTION 2 125, 130, 49HP AND 185 USER MANUAL
33
BLANK PAGE
34
125, 130, 49HP AND 185 USER MANUAL
Section 3
SPECIFICATIONS
3.1 SPECIFICATIONS – 125, 130 AND 185 CATERPILLAR
Table 3-1: Overall Specifications—Caterpillar
35
125, 130, 49HP AND 185 USER MANUAL SECTION 3
36
SECTION 3 125, 130, 49HP AND 185 USER MANUAL
37
125, 130, 49HP AND 185 USER MANUAL SECTION 3
38
SECTION 3 125, 130, 49HP AND 185 USER MANUAL
39
125, 130, 49HP AND 185 USER MANUAL SECTION 3
AMBIENT TEMPERATURE
FLUID TYPE CHANGE PERIOD/HOURS
RANGE °F (°C)
40
SECTION 3 125, 130, 49HP AND 185 USER MANUAL
NOTE
Proper compressor fluid level visible half-
way in fluid sight glass when checked on
a level surface with the compressor not
running.
41
BLANK PAGE
42
125, 130, 49HP AND 185 USER MANUAL
Section 4
GENERAL
4.1 GENERAL COMPRESSOR DISCHARGE TEMPERATURE
SWITCH
While Sullair has built into this compressor a
complete set of controls and indicators that allow the Opens the electrical circuit to shut down the
operator to control and monitor the compressor’s compressor when the discharge temperature
operation and performance. Operators should learn reaches a specific value (See Specifications on page
to recognize indications which identify a service 35).
requirement or conditions that could lead to (or show) THERMAL VALVE
a (current) malfunction. Before starting the
Functions as a temperature regulator by directing the
compressor, read this section thoroughly to gain compressor fluid either to the cooler or to the
familiarity with the controls and indicators – their compressor unit.
function and location.
MINIMUM PRESSURE DEVICE
4.2 PURPOSE OF CONTROLS Maintains the minimum of 80 psig (5.6 bar) in the
compressor sump.
CONTROL OR INDICATOR PURPOSE PRESSURE RELIEF VALVE
ENGINE SWITCH
Vents sump pressure to the atmosphere if pressure
Press this switch to the ON (ignition) position to inside the sump exceeds 200 psig (13.8 bar).
energize the electrical system of the compressor.
Press the switch to the START position to AIR INLET VALVE
momentarily engage the starter and start the
compressor. Press the switch to the OFF position to Regulates the amount of air allowed to enter the air
shut the compressor down. This switch is located on compressor inlet. Regulation is determined by a
signal from the pressure regulator(s).
the instrument panel.
COLD WEATHER STARTING AID BUTTON PRESSURE REGULATOR
Allows the pressure signal to reach the engine speed
Push this button, prior to compressor start-up, to
control and the air inlet valve to control air delivery
allow the engine to pre-heat for easier starting.
according to demand.
HOURMETER SHUTDOWN SYSTEM/ANNUNCIATOR MODULE
Indicates the accumulated hours of operation. Useful (SSAM)
for planning and logging service schedules.
Monitors the compressor safety system for
AIR PRESSURE GAUGE conditions requiring shutdown. The annunciator on
the instrument control will flash the applicable
Continuously monitors the pressure inside the shutdown code.
receiver tank at various load and unload conditions.
BLOWDOWN VALVE
FLUID SIGHT LEVEL GLASS
Vents sump pressure to the atmosphere at
Indicates the fluid level in the receiver tank. Proper shutdown.
level is marked halfway up the sight glass. Check the
level when the compressor is shutdown and on level IDLE WARM-UP CONTROL
ground.
Keeps the compressor inlet valve closed for reduced
compressor load at start-up. When the compressor is
warmed-up, the handle is turned from the START to
the RUN position for full operation.
43
125, 130, 49HP AND 185 USER MANUAL SECTION 4
3. Check the oil and fluid levels in the engine 6. Press the ENGINE SWITCH to the ON posi-
and compressor: add oil and/or fluid if neces- tion.
sary. 7. In cold weather, press the cold weather start-
4. Fill the fuel tank and drain any water from the ing aid button. Hold button for 10 to 30 sec-
fuel/ water separator. onds and then release.
5. Crack open one service line. 8. Momentarily press the ENGINE SWITCH to
the START position to engage the starter:
6. Place the WARM-UP control in the START release the switch when the engine starts.
position.
9. After 30 seconds (the annunciator light will
7. Press the ENGINE SWITCH to the ON posi- go off after 30 seconds) Turn the IDLE
tion. WARM-UP SWITCH from START to RUN to
8. In cold weather, press the cold weather start- put the compressor in full operation.
ing aid button. Hold button for 10 to 30 sec- 10. To shut down the compressor, see Shutdown
onds and then release. procedure on previous page.
9. Momentarily press the ENGINE SWITCH to
the START position to engage the starter:
release the switch when the engine starts. WARNING
10. After 30 seconds (the annunciator light will
go off after 30 seconds) Turn the IDLE DO NOT us aerosol types of starting aids
WARM-UP SWITCH from START to RUN to such as ether.
put the compressor in full operation.
Such use could result in an explosion and
11. Close all doors to maintain proper noise personal injury.
level.
SHUTDOWN If the engine fails to start within 30 seconds,
release the starter switch or button and wait
1. Close the service valves and run the com- two minutes to allow the starting motor to
pressor for approximately five minutes to cool before attempting to start the engine
allow the compressor to cool down. again.
44
125, 130, 49HP AND 185 USER MANUAL
Section 5
MAINTENANCE
Corrosion to radiator surfaces may occur, thus reducing
radiator life expectancy. It is extremely important to
WARNING evacuate/purge all air within the cooling system
before replacing the radiator cap.
DO NOT remove caps. Plugs and/or other
components when the compressor is run-
ning or pressurized. Shutdown the com-
5.3 DAILY MAINTENANCE
pressor before removing any components. See Initial Startup Shutdown/Procedure for general
operation.
5.1 GENERAL
Consistent and correctly performed maintenance will
ensure the compressor’s performance and extend its
CAUTION
operational life. See Part Replacement And
Adjustment Procedures on page 46 for a detailed The radiator and engine cooling system
description of specific compressor components. must be drained and flushed periodically.
Before performing maintenance actions, read the Refer to the OEM Engine Manual for more
CIMA Safety Manual, if applicable. For engine information. Replace the coolant with a
maintenance requirements and procedures, refer to solution of 50% ethylene glycol and 50%
the Engine Operator’s Manual. water or as required for your geographic
location. DO NOT use a leak sealing type of
antifreeze. Should a 100% water solution be
5.2 ENGINE COOLANT used, a non-chromate rust inhibitor must
REQUIREMENT FOR be added. DO NOT mix coolant types.
RADIATORS
The coolant provided with Sullair portable air
compressors is ethylene glycol based, 50/50 mixture, NOTE
and should never be mixed with a different coolant type,
color or brand. If radiator coolant is to be added, for any Dispose of fluids in accordance with
reason, be sure that the coolant added is the same as applicable federal, state and local regula-
what is in the cooling system, as well as what is tions.
recommended. Refer to the Maintenance Section of the
Engine Operator’s Manual for proper engine coolant
specifications and instructions. Ensure that the proper 5.4 MAINTENANCE AFTER
coolant is used when adding engine coolant to the INITIAL 50 HOURS OF
machine. If you are not sure of the coolant that is OPERATION
installed originally or want to change to a different type,
After the initial 50 hours of operation, the following
the cooling system must be cleaned with a commercial
maintenance actions are required to eliminate
cleaning agent and completely flushed and filled with
contaminants from the system:
distilled water several times to remove all traces of old
coolant. Then, fill the system with the recommended 1. Clean the return line orifice and change the
coolant using only one brand/type. Cross contamination strainer.
which is caused by adding different types of engine
2. Change the compressor fluid filter.
coolants may result in the coolant additives to deplete
(dropout); thus leaving radiator surfaces unprotected.
45
125, 130, 49HP AND 185 USER MANUAL SECTION 5
3. Check the Engine Operator’s Manual for ser- 10. Change the fuel filter. (If the filter tends to
vice requirements. clog more often than what is expected,
change the filter more frequently.)
4. Check the fuel filter for water.
11. Change the engine fuel/water separator.
5. Confirm that the receiver tank cover bolts are
tightened to 60 lb-ft (81N•m). 12. Check the engine rpm idle speed. The idle
speed should be at the specified minimum
5.5 MAINTENANCE EVERY 50 idle speed listed in Section 3.
HOURS
1. Inspect air filter elements and replace if nec-
essary. WARNING
2. Check the fuel filter for water. Operating the compressor below its mini-
mum specified idle speed will damage the
5.6 MAINTENANCE EVERY 100 compressor. Operating the compressor in
HOURS this condition will cause coupling and/or
compressor failure.
1. Clean the radiator and cooler exterior sur-
faces.
2. Check the Engine Operator’s Manual for ser-
5.8 MAINTENANCE EVERY 1500
vice requirements.
HOURS
1. If the compressor fluid is Sullair AWF,
5.7 MAINTENANCE EVERY 250 change the fluid and replace the fluid filter
HOURS element. (See Compressor Fluid Filter Ele-
ment Replacement on page 47.)
1. Check fan belt tension.
2. Service the engine cooling system.
2. Clean the radiator and cooler exterior sur-
faces. (Where dust and other atmospheric 3. Lubricate axle bearings on wheel-mounted
contaminants are present, it might be neces- units.
sary to clean these parts more frequently.)
3. Check the Engine Operator’s Manual for ser-
5.9 PART REPLACEMENT AND
vice requirements.
ADJUSTMENT
PROCEDURES
4. Change the engine oil and filter.
COMPRESSOR FLUID CHANGE PROCEDURE
5. Change the compressor fluid if it is not Sul-
lair AWF. 1. Run the compressor five to ten minutes to
warm the fluid.
46
SECTION 5 125, 130, 49HP AND 185 USER MANUAL
1. Filter Body
2. Filter Cover
3. Primary Element
4. Optional Safety Element
Replacement Primary Element
P/N 02250102-158
Optional Replacement Safety Element
P/N 02250102-160
47
125, 130, 49HP AND 185 USER MANUAL SECTION 5
6. Reposition the cover and lock it into the posi- are diagonally opposite each other. Torque
tion. the bolts to 60 ft-lbs (81 N•m).
7. Reset the filter restriction indicator (if 8. Reconnect all piping. The fluid return line
equipped). tube should extend to the bottom of the sep-
arator element which will ensure proper
ELEMENT INSPECTION return line flow.
1. Insert a bright light source into the element 9. Clean the fluid return line strainer and clear
and look for any light leaks which indicate the orifice before starting the compressor.
the presence of damage (holes, cracks, etc.)
10. After 24 hours of operation, tighten the sump
2. Inspect all gaskets and gasket contact sur- cover bolts to the value given in step 7.
faces of the housing and replace any dam-
aged ones.
3. Store clean elements for later use in a clean 1
container.
4. After installing the element, inspect and 2
tighten all air inlet connections before operat-
ing the compressor.
SEPARATOR ELEMENT REPLACEMENT 3
48
SECTION 5 125, 130, 49HP AND 185 USER MANUAL
PROCEDURE FOR SETTING SPEED AND The following procedure applies to a compressor
PRESSURE CONTROLS ON PORTABLE with full-load pressure rating of 100 psig (6.9 bar).
COMPRESSORS EQUIPPED WITH 1. Start the compressor and allow the engine to
POPPET VALVES warm-up to its normal operating temperature
with the service valve closed.
Refer to Figure 5-4. Before adjusting the
compressor’s control system, the rated full-load 2. With the service valve closed, set the engine
pressure and the high/low rpm settings must be low speed (idle) to its specified setting with
determined. This information is provided in Section 3 the idle stop screw on the engine injector
or can be obtained by contacting a Sullair pump.
representative.
49
125, 130, 49HP AND 185 USER MANUAL SECTION 5
50
SECTION 5 125, 130, 49HP AND 185 USER MANUAL
6
1
2
7
5
SU_0000671
51
125, 130, 49HP AND 185 USER MANUAL SECTION 5
ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START
NO SSAM FLASH CODE Low voltage or battery disconnected Check battery cables and tighten if loose
SSAM FLASH CODE: Compressor temperature switch is open Check wiring connection to the switch and
ONE FLASH tighten if loose
Low receiver tank fluid level Add fluid to receiver tank as required
Cooling air flow is insufficient, dirty fluid Clean core thoroughly and check for proper
cooler core ventilation
52
SECTION 5 125, 130, 49HP AND 185 USER MANUAL
ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START
SSAM FLASH CODE: Engine coolant temperature switch is open Check wiring connection to the switch and
TWO FLASHES tighten if necessary
Cooling air flow is insufficient Clean cooler and check for proper ventilation
SSAM FLASH CODE: Engine oil pressure switch is open Check wiring connection to switch and tighten
THREE FLASHES if necessary
SSAM FLASH Did not start compressor within the 30 "After turning the ignition switch to the ON
CODE:FOUR FLASHES seconds from turning the ignition switch to position, press the switch to the START
the ON position position within 30 seconds"
No fuel Refuel
Water or dirt in the fuel and/or filter Drain water from the fuel/water separators on
the fuel filters. Siphon water from the fuel tank
and clean the tank if necessary
Starter solenoid relay does not engage Check wiring and tighten all connectors
Replace relay
No input frequency from alternator Check alternator “W” terminal (7.5 ± 2.50
VAC greater than 300 HZ)
SSAM FLASH CODE: No fuel Check fuel level and fill tank if empty
FIVE FLASHES
Defective fuel switch Replace switch
53
125, 130, 49HP AND 185 USER MANUAL SECTION 5
ENGINE STOPS, DOES NOT CRANK OR CRANKS BUT DOES NOT START
Compressor does not Run/start switch not in run position For compressors with idle warm-up controls,
achieve full discharge switch toggle to RUN for full operation
pressure
Air demand is excessive Check service lines for leaks or open valves
Dirty air filter Check the filter and change the element if
required
Defective pressure regulator Check the diaphragm and replace with kit if
necessary
Improper unloading with Pressure regulating valve is set too high Readjust
an excessive pressure
build-up causing the Control system leak causing loss of Check control lines
pressure relief valve to pressure signal
Defective pressure regulating valve. Repair
open
valve (kit available)
Restriction in the control system Check all control lines and components. Ice
and/or other contaminants could be the cause
Defective pressure relief valve opens when Replace the pressure relief valve
pressure is too low
Defective pressure regulator Check the diaphragm and replace with kit if
necessary
Insufficient air delivery Run/start switch not in run position For compressors with idle warm-up controls,
switch toggle to RUN for full operation
Excessive compressor Clogged return line Clear orifice and return line strainer
fluid consumption
Lubrication system leak "Check all pipes, connections and
components"
54
125, 130, 49HP AND 185 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 Corporation warrants to the ultimate
or element of design has been removed or
purchaser and each subsequent purchaser that this
rendered inoperative by any person.
air compressor was designed, built and equipped to
conform at the time of sale to the first retail Among those acts included in the prohibition against
purchaser, with all applicable noise control tampering are the acts listed below:
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
U.S. Law prohibits the following acts or the causing d. Fan shroud
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.
55
125, 130, 49HP AND 185 USER MANUAL SECTION 6
Maintenance Performed
By
Location
Date
Maintenance Performed
By
Location
Date
56
SECTION 6 125, 130, 49HP AND 185 USER MANUAL
Maintenance Performed
By
Location
Date
Maintenance Performed
By
Location
Date
Maintenance Performed
By
Location
Date
57
125, 130, 49HP AND 185 USER MANUAL SECTION 6
Maintenance Performed
By
Location
Date
58
BLANK PAGE
59
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835