2.1 INTRODUCTION This Sullaie rotary screw air compressors > anvugrna srna—@) SS ‘SCREW- ‘SEAT ae SPRING —| ‘NUT, saad pect | “DIAPHRAGM. ‘SPRING —' ‘SEAT: =~ I~ REGULATOR: BODY Repair Kit P/N 20019-4583Section 6 MAINTENANCE Figure 8-10 Flexible Coupling E ® © e r SPECIAL NOTE: yan P Seirrestraines i Gasket instalation, B Gasket) Gaskets) E Ratainer(t) Retainer (6) : y , ‘COUPLING (see table) STEPS sTeP2 TABLE 1 INSERTION DEPTH Pipe “> “o" Size Min. Max. Oa 1.16" 1.62" (38.tmm) (295mm) (41.2mm) ‘TABLE 2 ASSEMBLY TORQUE Size Standard 14" 90.19 110 in.-tbs. (38. 1mm) (10.14 to 12.4Nm) ( Tighten as shown in chart or a minimum of %e lugs, whichever comes first. TABLE 3. GASKET RING SELECTION Size Part Number Part Number we (Buna Ny (2axr) (38. fmm) 040517 250007-559 (1.5mm) clearance between couplingSection 6 MAINTENANCE 7. The next step is to reassembie the regulator using the new parts proviced in the repair kit 8, Reassemble the ciaphragm, pressure plata, Gasket, seat disc. and seat disc gasket and Tighten tha nut. All of tnese parts win ine caption of the pressure plate are provided in the repair kit. Replace the Seat ring with the new seat cing provided, Replace the existing brass gasket and cia phragm gasket stop, Next, place these parss in their proper place on the Cogy and replace the spring asit wes prior to disassembly. Place the spring button, over the spring es shown with ali parts in order, replace the spring chamber and tighten, . Tighten the adjusting screw until tension is re: alized. >. AL this time, refer to Control System Adjust- ‘ment procedure and readjust. FLEXIBLE COUPLING MAINTENANCE eter to Figure 6-10. Flexible coupling mainte- ance normally requires the replacement of th (two) 2 gasket rings on the coupling. Select propriate gasket rings from Table 3 and follow the. Procedure below for proper installation. PIPE END. PREPARATION ‘ends should be free of all deep gouges, cents, etc, A special finisn 's not required. JOINT INSTALLATION 1. Install the retainer (1), gasket (2). and sleeve (3) on one side of the pipe as shown in Step 1 2. Install the remaining retainer (4) and gasket (5) on the other pipe end. 3. Position the retainer (4) and gasket to proper ie insertion depth (“D~) as shown in Table 1. . Slide the sieeve (3) to the (8) and ‘move gasket (2) and retainer {1) into position a3 shown in Step 2. The pipe MUST be in- Serted to the proper deptn ("0") into botn gas- kets, COUPLER INSTALLATION 1 Install both V couplings as shown in Step 3, en- gomoassing the retainer, gasket and sieeve. DO NOT tighten either coupling unti the entire joint nas been assembled. Tighten the nuts to the torque valve shown in Table 2. RECOMMENDED ASSEMBLY TOR- QUE MUST BE MAINTAINED. Re-tightening of the coupler will be necessary if leakage oc- curs. SPECIAL NOTES 1. Assembly of the gaskets can be made easier by aipping the gaskets in watar or the ol 10 be sealed. DO NOT USE THE RUBBER LUBAI- CANTS, 2, Flexible joints are not intended to support enc loads caused by internal pressure or other forces causing pipe separation. MINIMUM PRESSURE/CHECK VALVE MAINTE- NANCE Reter to Figure 6-11. Minimum pressure/check valve (PIN 281581) maintenance is quite minimal The only pant which normally requires replace: ment is the o-ring on the piston. Ta replace his fing, order seal repair kitno. 250020-344 and fe! low the procedure explained below # Bertorming maintenance on the eiture that al pressur inthe compressor sump. Br ‘been van 1. Unscrew the minimum pressure/check valve (PIN 241881) from the receiver cover. 2. Remove the hexagonal retaining cap from the main body. 3. Remove the flat washer and heavy spring from 1@ main body. . Tap the piston assembly (with a screwdriver) from the bottom of the main body anc remove. The o-ring will now be seen easily. §. Remove the seal ring and ciscard. 8. Clean piston assembly and vaive thoroughly. 7, Replace seal ring and coat the piston and seal with Parker Super *O" Ring Seal or an equiv Jent quality grease. 8, Reset piston assembly into the main bogy and reposition spring and flat washer. 9. Replace retaining cap. 10. Reattach valve fo receiver cover and recon- ect all piping. SOLENOID VALVE MAINTENANCE Foter to Figure 6-12. Solenoid valve (P/N 250017-993) maintenance is quite minimal but 2 Beriodie cleaning is desirable. The time betwees leanings wil vary depending on operating condi tions. In general, ifthe voltage to the cals is cc £8ct, sluggish valve operation or excassive | age ‘wil indicate that cleaning is required. If parts, feplacement is required, order repair kit number 250018-370 or number’ 250018-971 and tallow the procedure explained below:Figure 8-11 Minimum Pressure / Check Valve (PIN 241581). tees J Repair kit P/N 250026-758 itis not nacessary to remove the valve from the pipe line for repairs DISASSEMBLY AND REASSEMBLY 1. Remove the 1g cap and slip the entire solenoid off the solenoid base subassembly. 2, Unscrew the solencid base assembly. Remove tha core assembly, core spring and Body gas- ke |. Next, remove the end cap, body gasket. disc song, and disc holder assembly. All parts are now accessible for cleaning or ra placement. Replace worn or damaged pars ‘with repair kit number 250018-870 for best re- sults. 5, Reassemble in raverse order of disassembly. COIL REPLACEMENT KIT (P/N 250018-971) 1. Remove the retaining clip. 2. Slip the yoke containing the coil and sleeves off the sclenci¢ base sub-assembly. 3, Reassamole in reverse order of disassembly. 6.7 TROUBLESHOOTING The information contained in the Troubleshocting chart is based upon both the repor's about actual field applications. and extensive testing cone at tne factory. It contains symptoms and usual Section 6 MAINTENANCE ‘causes for the described problems. However 00 NOT assume that these are the only problems that may occur. alla trouble should be systematically ar Uncerteking any repairs cr component repiace- ment procedures. ‘A detailed visual inspection is worn pertorming for almost all problems. Doing so can prevent un necessary damage. Always remember tc) a. Check for loose wiring 5. Check fer damaged piping. . Check for parts damaged by heat or an electri- Cal shor circuit. usually apparent by ciscolora- tion or a Burnt order, ‘Should your problem persist after making the rec- ‘ommended check, consult your nearest Suliair representative or the Sullair Corporation factory toll ree at 1-800-348-2722. Figure 6-12 Solenoid Vaive (PIN 250017-993) SOLENOID: BASE. SUBASSEMBLY FLUXPLATE-D ‘CORE seaincef] cone’ ASSEMBLY os HOLDER OsK ‘Spnina’ 00" ony Sooo + par pn 28008-379 ++ Repacement Kit P/N 250018-97f (coi)Section 6 MAINTENANCE ‘TROUBLESHOOTING ‘SyMerom PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT START Main Disconnect Switen Open Lune Fuse Bown Control Transformer Fuse Blown Replace fuse, Motor Starter Overloads Troped Reset, Shou trouble pera. check Rnetonng prover” Lew Incoming Line Vettage Check voltage. Should voltage check ow, Santa sower compary COMPRESSOR SHUTS DOWN STAIR DEMAND PRESENT Love of Contrel Vottage Reset; trouble persists, check that ine Sree des Pa eed marr Soerating pressure of thw compressor {Sbeciieg on namepiate). Lew Incoming Voltage ‘Consult power company. Excessive Operating Pressure Detect In tne pressure switch: check ressure ar wricn somtact poms eben, Separator raquras maintenance: check ‘maintenance gauge under ful load Conattone- ig pressure shut-down ewten ie acusted 00 low: reachat to 138 PSIG (S9TKPa). Detective solenoid valve: tolencd valve Shotid sauve contrat aver to move 12 {nica stop whan the pressure swtch ‘ontacts open. Rapa i'aetestve. 2etacve loncown av! low va noua exhaust suo pressure to 30 t0 38 PRS to tere) wren masimor Operating pressure is reaches. Repal # Setecuv Dlacharge Temperature Switch Cooling water temperature too Nah: pen IMerease water flow (water-cooled oni). Cooling water tow msuffclart: check water lies and vatves (water-cooed ony. ‘Cooler puaged: clean tubes, If uging Deraats natal water conctioner ‘raterecooted ony) ae flow restricted: clean cociar and ‘Sheek for proper vertiation Ampient temperature a too Hoh: prove ‘Niticare vertiaton | ‘Water tow ragdatng vave not functioning SrSpenyeratge fwaterceosl ory Datectve ancnarge emoeratire scr Shack tora snot or open over t0 probe Sd corect wenaSection 6 MAINTENANCE TROUBLESHOOTING (continued) Berom COMPRESSOR WILE NOT BUILD ES ECTESSEuaaGe Pressure LINE PRESSURE fISES ABOVE EDEUi paessune SeTTING (GN PRESSURE SWITCH EXCESSIVE COMPRESSOR FLUIO EGNSUMPTION PRESSURE AELIEF VALVE ‘OPEN REPEATEDLY PROBABLE CAUSE AA Gemand ia Tee Gra ley Ale Fite Proagure Reguator Out of eustment Detective Pressure Requator Detects or Diy et Valve Leak in Control Sygtem Causing of Pressure Signals Detactve Solenoid Valve Detective Blowdown Vaive Higa prams sputdown Suh isBetecive ar Acute Clogged Return Line or Crew ‘Separator Elemart Damaged or RetEanetoning Property Leak in the Lubrieation System Excess Fuld Fearing Flu Level Too High ign Pressure shutdown Switch Ia SSagive or Out ot Aclstrmert (138 Sia (s02Kra)) Detective Pressure Ralf Vatve Check Separator Ditterantia (eioggeat REMEDY Check service ines for leaks or open vues e Check the ter nceater and change, Freeured ‘Agust reguator according 19 contr agbeisek Ratructora in the Mantenance Check aasrragm and reslace it necess (ativan ge Check tnat vane tuly opens wen ful ar Sleands sresert. Ropar or clean a necessary check for leaks [Check that alaphragm ang contacts are not GEinages: Aesiace t necessary Repair et avaiable, {Check that sump pressure Ie exhausted 12 SarStnceohere wren the preenure switch Bence seen oe reparror reviace Regeeeary tit avalape). aaguat or repiace. Clean strainer (screen and o-ring rei mane it avalanie) Caan orien change siement. Check al pipes, connections and Semponert Drain and change rain to correct lave Rendust eiow oressure rata valve setting Soo bid T737stPals er ‘eiace! Replace pressure reset vaveSection 1 ILLUSTRATIONS AND PARTS LIST TABLE OF CONTENTS A ORDERING PARTS PARTS UST SSMPRESSOR, FRAME ANO PARTS. system COOLING ANO LUBRICATICN SYSTEM 3 \Ps-s0He) SR COOLING AND LUBRICATION S¥STEit - SSS SueD 128 bOHP) {GA COOLING AND LUBRICATION SYSTEM ~ Sue sone) INSTRUMENT PANEL - CPEN AND ENCLOSURE OPT'C* 12 AIR-COOLED AFTERCOOLING CATION (25 AND 30h! (SENG Sine 14 WATER-CCOLED AFTERCOOLING OPTION ( 49HP) 15 WATER-COGLED AND AIR-COOLED ENCESSUSE AND PARTS OPTION 18 HEAVY CUTY FILTER OPTION 17 CATIONAL AIR TANK = 120 AND 200 GALLON 1.18 CE2AL GROUP1.1 PROCEDURE FOR ORDERING PARTS Paris should be crcered from the nearest Su! ‘chased. i for any reason Greatly at the address or phone numbers Ii compressor was ou: nrot De obtained in this manner. c Number of the compressor. This can ne oo: ill of Laging for te compressor or from tne Seriai Numoer Plate located on the comsresscr. when ordering parts always indicate the Ser SULLAIR CORPORATION Subsidiary of Sundstrand Corpors 3700 East Michigan Boulevard Michigan City, Indiana 46360 (219) 879-5451 See Toll-free Number Below (218) 874-1273 SULLAIR CORPORATION Parts istribution Division and Service Department 4628 E. Second Street ty. Indiana 46360 Telephone: 1-800-348-2722 or (219) 873-5451 (219) 874-1835 (Parts) (219) 874-1808 (Service) RECOMMENDED SPARE PARTS LIST ILLUSTRATIONS AND PARTS LIST cr the Representative ment fer main fluid filter 250025-521 repair kit for Separator element 260034—111 repair kit for separator element 250034112 feplacemant element for air fiter 410036 repair kit for pressure regulator 250017-280 repair kit for Solenoid valve 250017-983 feplacement call tor sclenoig valve 250017. feplacement Gasket for flexible coupling 040" replacement Gasket for flexible coupling 25° repair kit for raturn line strainer 24177" repair kit for thermal vaive 250025-820 repair kit for air inlet vaive 250025-654 ‘seal kit for minimum pressure vaive 24158 repair kit for Clowdown vi repair kit for shaft seal repair kit for separator/trap 040847 feslacement spring for check valve 049905 7/8000 fluid (8 gallons) 24K7 fluid (5 gallons) Sullupe 32 fluid (5 galfons) fe 250025-655 = PLEASE NOTE: WHEN ORDERING PARTS. KIT NUMBER. 250025-525 (std. & 24KT) 250034-112 (std.) 280034114 (24K7) 250034-114 (std. & 25KT) 042448 (std. & 28KT) 250019-853 (std. & 25KT) 250018-970 (std. & 25KT) 250018-971 (std. & 24KT) (040517 (std.) 250007-559 (24KT) 241772 (std. & 24K7) 250028-621 (std. & 25KT) 250019-451 (std. & 2sKT) 250026-758 (std. & 24KT) 250031-772 (std. & 23K7) 001836-007 (std. & 24K) (044374 (sta. & 24KT) 25003-8557 250019-662 (std.) 046850-001 (24KT) '250022-663, INDICATE SERIAL NUMBER OF COMPRESSOR mm whom the nec from thepecuon + ILLUSTRATIONS AND PARTS LIST 1.3 MOTOR, COMPRESSOR, FRAME AND PARTSECC ILLUSTRATIONS AND PARTS LIST ree Ee aes 2,0 1 be jessie erent roa Alf acta ager Salas 3 Lan ne finget astray 64 se ecient amuse eee Ria: sree 4 ctatitaten Ceanicepo ats amas SG cea ae ease aman se nana Ee eae 8 capscrew. hex mead grS %" x 1% 828606-125, - Seat Tene ES ae 8 capscrew. hex nead gr5 "x 2%" 828608. Fa hces ES ees Sa weed naam teat aes aero se eames melee haat a ee tee go lie an ee Se Ss SNS EEE EE oct Sig Bcoeeclaat asa een Berm ee Coeah roo, | Seer eee | ie) Ue ee renee, eens le Sd eee ones Tie eee cmeein 1) OSE Sueoie pee laues 4 ic paca fee pa cee ee aanenene Satan ee aera nel ae ee aa eee ee Be Grains oe Pe se eee oe ee ee reeee cain 2 eerie = fas ee ee be rem Se Continues on Page 5) PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSORILLUS INATIUING AINE 1.3 MOTOR, COMPRESSOR, FRAME AND PARTSSection 1 ILLUSTRATIONS AND PARTS LIST 1.3 MOTOR, COMPRESSOR. FRAME AND PARTS (Continued) fey stanaara 2aKT number deseriation par numoer rumoer ua: 25 comaressor unit, 108 Seriestl) - 28 acapter, SAE 5 25000s-s42 ar grile. coupling guarc (2! 250038-883, 23 screw, ser wasner ¥_" xX" 829705-075 829705-07: 28 wasner. )$" 837208-112637208-1" 30 washer, %° 938206-071 a36208-0 (I) There is an exchange program whereby a remanufactured compressor unit can be cbtened trom Suilair eistributors or the factory at less cost tnan the owner could reoai the unt. For v arcing tha unt exchange program. contact your nearest Sullair renre: Coreeration. ‘The shait seal is not consideree part of the comeressor unt in regara to tne 2 year warranty. Th normal Sula parts warranty applies. Fer snaft seal repairs, orger snait seal recar wit no 001836-007. PLEASE NOTE: WHEN ORDERING PAATS, INDICATE SERIAL NUMBER OF COMPRESSORILLUSTRATIONS AND PARTS LIST 4.4 AIR INLET SYSTEMSECTION ILLUSTRATIONS AND PARTS LIST 1.4 AIR INLET SYSTEM hey stancare number descriotion part rumoer 1 air fiter assemaly (0) 410038 (incluces tems 2. 3, 4. 2 rut, wing 47-29 e2ag1s-004 —824818-co8 3 hood. air fiter 043392 043392 4 element, air titer 042s oes, 1 5 ase, filter 017888 on7se8 1 6 ripple. pipe 4° x 3° 23102-0320 823102-030 1 7 coupling. pipe galvanizec % g03z1s-005 _803215-005 2 8 connector. tuse start %"mret x 813604125 13604-1258 1 3 tubing, plastic "00 25002¢-785 250024-745 Deh 10 capscrew. nex gr5 47-7 x 1/67 828610-125 828610-125, 4 " washer. springicck $4" $37510-156 4 12 valve. air inlet 2:4" (IN) 25025-6654 1 13 connector. tuse-l "mst x i6"t 813704-125 1 14 onring. 3%" x 4" 826502-238 826502-238 ' 15 elbow. pine galvanized 1 801515-005 -801515-005 1 18 indicator. air fiter maintenance 045757 048757 1 7 wasner. flat }" 838206-071 836208-071 1 (1) For maintenance on air filter assemo'y no. 410036, order replacement element no. 042845 (ID For maintenance on air iniet valve no, 25028-6854, order repair kit 0. 250019-451 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSORILLUSTRATIONS AND PARTS LIST 4.5 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED (25-40HP)Section 1 ILLUSTRATIONS AND PARTS LIST 4.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED (25-40HP) hey 2sKT number description part number quantity 1 elbow. 90° > x %" (25. 3047) g10512-075 = elbow. 80° 4" x%" (4OHP) 810812-075 2 elbow, tube-m %” x 4" (40HP) 810808-050 3 screw, hax head ser washer He" xX" (25, SOHP) 829708-075 wscrew, hex head ser wasner He" < X" (a0#°) 829708-074 ut, hax ser washer plated %4"~1 (25, CHP) 825305-283 825305-283 snut, nex ser washer plated (a0HP) 825305-283 825305-283 brace. cooler/starter 250018-805 250018-605 ut, hex locking plated Ka"=18 (25, 30HP) 25505-1668 825505-166 ‘snut, locking 47-18 (40HP) 825508-188 825508-198 fan, cooling (25, 30HP) o42es2 042492 fan, cooling (40H?) 249012 249012 guara, fan 22896 225982 ub, fan (25, 20H Gey 023350 + hub. fan (40HP) : 231981 capscrew. ferry He" x 147 (25. 20HP) 82840-1580 _§28408-150 SCapscrew. ferry %" x 1%" (20H?) —628406-175 828406-175 elbow, 90° recucing 1" x %"(25. 30HP) 801605-030 801 604-030 ripple, pice 1%." x 8" 822120-060 82120-0860 ripple, close 1” (25, 30HP) a22216-000 622216-000 elbow. 80° reducing 1% x % g0160s-030 801605-030 tube, fia step 232823 232823 eloow. 45° sine 201615-030 801415-020 ripple. pine X” x 247 922112-025 82112-0285 elbow, tuse-m 3%" x %* (40H) g10808-038 810506-038 tubing, cooner %" (40HP) g40115-008 84015-0086 jople, close %" (25. 30HP) 222212-000 822212-000 Snigele, cose %” (40HP) 822212-000 822212-000 connector, tube %" x %" (25. 30HP) B10212-075810212-075 sconnecier, ube %" x %" (40HF) g10212-075 810212-075 tee. reducing %" x 4" xX" (ZS. OHP) 802203-023 802203-023 ste. requeng %" x 47 xX" 1s0r=) 802203 0203-023 nipple. close 822208-000 (continued on gage t PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR