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USER MANUAL - Master Hire

1. 45 2 58 REMOVED FROM GROUND YO ON STANDARD HARNESS J 95 d Grd y e Blue 3 4 FUEL FUEL BLACKEZ ETA SENDER PINK 25 PS A os FUEL LEVEL GAUGE B5 95 LOW FUEL LEVE CONNECT TO ALTERNATOR SHUTDOWN WIT D TERMINAL GAUGE OPTIO 31 125 130 49HP AND 185 USER MANUAL SECTION 2 2 12 WIRING DIAGRAM DEUTZ 23 IN 24 50 AMP FUSE 6C Oe GLOW PLUGS 55 pO RS T 1 0 21 ix T 30 AMP FUSE 02950 e eu GLOW PLUG 1A 2 1C m BELAN D BATTERY 50 AMP IGNITION 95 50 7 START 03 65 MS ELECTRIC SWITCH I3 STARTER STARTER i FUEL PUMP 92 Q6 e 6J 87 o E 4 3 284 30 40 12 2 7 ee p ee DIODE 9B ALTERNATOR Eh 4 10 Di 0 5 1 1 EE EEE ffir L P W 47
2. 15 15 15 15 maximum Electrical System 12 volt 12 volt 12 volt 12 volt Se Shutdown 250 F Shutdown 250 F Shutdown 250 F Shutdown 250 F 9 121 C 121 C 121 C 121 C Temperature Service Valves 2 3 4 2 3 4 2 3 4 2 3 4 Maximum Towing Speed 55 mph 88 kmph 55 mph 88 kmph 55 mph 88 kmph 55 mph 88 kmph Axle Rating 3700 Ibs 1678 kg 3700 Ibs 1678 kg 3700 Ibs 1678 kg 3700 Ibs 1678 kg Sound Level US EPA 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m 76 dBA at 7 m SULLAIR 39 125 130 49HP AND 185 USER MANUAL Table 3 9 Engine Specifcations John Deere SECTION 3 Engine 125 130 49HP 185 Type Diesel Diesel Diesel Diesel Make John Deere John Deere John Deere John Deere Model 4024TF270 4024TF270 4024TF281 4024TF270 Emission Level U S EPS Tier 2 U S EPS Tier 2 12 4 U S EPS Tier 2 European Stage II European Stage II European Stage IIIA European Stage II Displacement 149 cu in 2 44 L 149 cu in 2 44 L 149 cu in 2 44 L 149 cu in 2 44 L Cylinders 4 4 4 4 Bore x Stroke 3 40 x 4 10 in 3 40 x 4 10 in 3 40 x 4 10 in 3 40 x 4 10 in 86 0 x 104 0 mm 86 0 x 104 0 mm 86 0 x 104 0 mm 86 0 x 104 0 mm Rated Speed 2550 RPM 2650 RPM 2650 RPM 2800 RPM Rated Power 60 0 HP 44 8 kW 60 0 HP 44 8 kW 49 0 HP 36 kW 60 0 HP 44
3. Cooling Lubricating Compressor Fluid Pressurized Compressor Fluid See Section 3 4 Pressurized Compressor Fluid See Section 3 4 Pressurized Compressor Fluid See Section 3 4 Sump Capacity 3 US gallons 3 US gallons 3 US gallons 11 liters 11 liters 11 liters Track Width 50 9 1294 mm 50 9 1294 mm 50 9 1294 mm Tire Size Load Range ST175 80D13 ST175 80D13 ST175 80D13 Tire Pressure 50 psig 3 5 bar 50 psig 3 5 bar 50 psig 3 5 bar Wheel Size 13x4 5 13 x4 5 13 4 5 Lug Nut Torque 60 ft lbs 81 Nm 60 ft lbs 81 Nm 60 ft lbs 81 Nm Operating Tilt maximum 15 15 15 Electrical System 12 volt 12 volt 12 volt Compressor Discharge Temperature Shutdown 250 F 121 C 250 F 121 C 250 F 121 C Service Valves 2 3 4 2 3 4 2 3 4 Maximum Towing Speed 55 mph 88 kmph 55 mph 88 kmph 55 mph 88 kmph Axle Rating 3700 Ibs 1678 kg 3700 Ibs 1678 kg 3700 Ibs 1678 kg Sound Level US EPA 76 dBA at 7m 76 dBA at 7m 76 dBA at 7m SULLAIR 37 125 130 49HP AND 185 USER MANUAL Table 3 6 Engine Specifcations Deutz SECTION 3 Engine 125 130 185 Type Diesel Diesel Diesel Make Deutz Deutz Deutz Model TD2009L4 TD2009L4 TD2009L4 Emission Level U S EPA Interim Tier 4 European Stage IIIA U S EPA Interim Tier 4 European Stage IIIA U S EP
4. Follow the same procedure for stowing away the SECTION 1 wheeled jack as you would for the standard screw jack Raise the screw jack to its full upright position and pull the pin connecting the jack to the drawbar Rotate the screw jack to its stowed position parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing Disconnect coupling device keeping hands and fingers clear of all pinch points If the compressor is provided with a drawbar DO NOT attempt to lift the drawbar or if hinged to raise it to the upright position by hand if the weight is more than you can safely handle Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to yourself or others When possible stow hinged drawbar in the verti cal upright position Make certain it is securely latched in the vertical upright position Keep feet clear of drawbar at all times to avoid crushing accidents in case it should slip from your hands or otherwise fall to the ground 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 parked on or adjacent to public roads Park so as not to interfere with traffic While not towed in the usual sense of the word many of these instructions are directly applicable to skidmounted porta ble air compressors as well 1 3 PRESSURE RELEAS
5. Refer to Figure 5 1 1 Remove the old element with a strap wrench 2 Clean the gasket seating surface Apply a light coating of fluid to the new gas ket 4 Hand tighten the new element until the new gasket is seated 5 Continue tightening the element by hand an additional 1 2 to 34 turn 6 Restart the compressor and check for leaks Compressor Unit Thermal Valve Manifold 3 Fluid Filter Element P N 250028 032 SULLAIR 125 130 49HP AND 185 USER MANUAL AIR FILTER MAINTENANCE Refer to Figure 5 2 Air filter maintenance should be performed as often as conditions require If the filters are equipped with optional maintenance indicators change the filters every time the indicators show a change is necessary Filter Body Filter Cover Primary Element PF ON D gt Optional Safety Element Replacement Primary Element P N 02250102 158 Optional Replacement Safety Element P N 02250102 160 Figure 5 2 Air Filter AIR FILTER REPLACEMENT 1 Loosen and remove the air filter and cover 2 Remove the primary and optional secondary elements 3 Clean the body inside and out with a damp cloth 4 Reinstall if clean or replace the secondary element if installed 5 Replace the new primary filter element 47 125 130 49HP AND 185 USER MANUAL 6 Reposition the cover and lock it into the posi tion 7 Reset the filter restriction indicator if equipped ELEMENT INSP
6. SULLAIR USER MANUAL PORTABLE AIR COMPRESSOR 125 130 49HP AND 185 CATERPILLAR DEUTZ AND JOHN DEERE PART NUMBER 02250174 684 RO1 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 20080301 0000 and all subsequent serial numbers SULLAIR 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 CUSTOMER CARE TRAINING DEPARTMENT 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 Dep
7. i i 3 5 INTAKE L MANIFOLD LI TURBINE 7 FUEL SYSTE 9 2 INJECTOR RELIEF VALVE FILTER HEAD A 1 y S 3 O 8 Z INTERNAL IREL VLV i i _ MEN _ NND A 20 COOLING SYSTEM v pre Fees coser Bos 15 i 25 d p 19 H I 16 18 HEADS lt O n sssi CYLINDER 12 Y i i Y m i B LUBRICATION SYSTEM 26 17 i 14 ENGINE LUBE SYSTEM BLOCK AND TURBO 30 i L3 Y 53 115 4 ES ENGINE 12 EXHAUST LINE ETHYLENE 10 Sons D GLYCOL WATER gt FLUID LINE gt AIR LINE 32 26 SULLAIR SECTION 2 N O Q Turbocharger Compressor Muffler Engine Fuel Level Sender Rain Cap Exhaust System Fuel Filter W Water Separator Fuel Transfer Pump Internal To Engine Hand Operated Fuel Priming Pump Filter Fuel 10 11 12 14 15 16 17 18 19 Gauge Fuel Level Fuel Tank Cap W Vent Thermostat Thermocord Optional Oil Pump Integral To Engine By Pass Valve Internal To Engine Cooler Oil Internal To Engine Filter Oil Water Pump Integral To En
8. loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing cap completely Remove radiator filler cap only when cool enough to touch with a bare hand The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems optional is under pressure DO NOT puncture or incinerate those cylinders DO NOT attempt to remove the center valve core or side pressure relief valve from these cylinders regardless of whether they are full or empty If a manual blowdown valve is provided on the receiver open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air fluid system 1 4 FIRE AND EXPLOSION Do not attempt to operate the compressor in any classification of hazardous environ ment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty A Refuel at a service station or from a fuel tank designed for its intended purpose If this is not possible ground the compressor to the dis penser prior to refueling Clean up spills of fuel fluid battery electrolyte or coolant immediately if such spills occur Shut off air compressor and allow it to cool Then keep sparks flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel or when checking or adding electrolyte to
9. 33 BLANK PAGE SULLAIR 3 1 125 130 49HP AND 185 USER MANUAL Section 3 SPECIFICATIONS Table 3 1 Overall Specifications Caterpillar SPECIFICATIONS 125 130 AND 185 CATERPILLAR Length Width Height Weight wet Model Series in mm in mm in mm Ib kg 125 190 and 1888 130 8 3322 59 2 1504 53 8 1368 2130 966 Wheel 185 190900 TESESSS ig 1765 40 9 1040 41 7 1060 1885 855 Running Gear 1 Length over drawbar for 2 wheel version Table 3 2 Compressor Specifications Caterpillar Compressor 125 130 185 Type Rotary Screw Rotary Screw Rotary Screw Maximum Operating Pressure Pressure Delivery 125 psig 8 6 bar 125 Free CFM 59 L S 125 psig 8 6 bar 130 Free CFM 61 L S 125 psig 8 6 bar 185 Free CFM 87 L S Rated Pressure 100 psig 6 9 bar 100 psig 6 9 bar 100 psig 6 9 bar Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid Pressurized Compressor Fluid Lubricating Compressor Fluid See Section 3 4 See Section 3 4 See Section 3 4 Sump Capacity 3 US gallons 3 US gallons 3 US gallons 11 liters 11 liters 11 liters Track Width 50 9 1294 mm 50 9 1294 mm 50 9 1294 mm Tire Size Load Range ST175 80D13 ST175 80D13 ST175 80D13 Tire Pressure 50 psig 3 5 bar 50 psig 3 5 bar 50 psig 3 5 bar Wheel Size 13x4 5 13x4 5 13x4 5 Lug Nut Torq
10. 76 liters Radiator Capacity Engine Water Temperature 2 5 US Gallons 9 5 liters Shutdown 225 F 107 C 2 5 US Gallons 9 5 liters Shutdown 225 F 107 C 2 5 US Gallons 9 5 liters Shutdown 225 F 107 C Minimum Idle Speed 2550 RPM 2650 RPM 2200 RPM Alternator Rating 65 amp 65 amp 65 amp 1 DO NOT allow engine idle rpm to drop below minimum idle speed Compressor and or coupling damage will occur The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm 36 SULLAIR SECTION 3 3 2 Table 3 4 Overall Specifications Deutz 125 130 49HP AND 185 USER MANUAL SPECIFICATIONS 125 130 AND 185 DEUTZ Length Width Height Weight wet Model Series in mm in mm in mm Ib kg 129 130 and 18927 130 8 3322 59 2 1504 53 8 1368 2130 966 Wheel VE MET T 1765 40 9 1040 41 7 1060 1885 855 Running Gear Length over drawbar for 2 wheel version Table 3 5 Compressor Specifications Deutz Compressor 125 130 185 Type Rotary Screw Rotary Screw Rotary Screw Maximum Operating Pressure 125 psig 8 6 bar 125 psig 8 6 bar 125 psig 8 6 bar Pressure Delivery 125 Free CFM 59 L S 130 Free CFM 61 L S 185 Free CFM 87 L S Rated Pressure 100 psig 6 9 bar 100 psig 6 9 bar 100 psig 6 9 bar
11. Instrument Panel Group Optional Full Gauge Panel Shown 30 7 Engine voltage optional 8 Engine oil pressure optional 9 Engine coolant temperature optional 10 Engine RPM optional 11 Fuel level optional 12 Compressor discharge temperature optional SULLAIR SECTION 2 125 130 49HP AND 185 USER MANUAL 2 11 WIRING DIAGRAM CAT amp JD GLOW PLUGS 22 25 aN 24 FUEL e SOLENOID e 50 AMP FUSE b 9 JEg OL 21 30 AMP FUSE Fo EAS 1A 4 1B T MEME RELAY Em 50 AMP IGNITION 5 80 START 03 05 Li SWITCH 4 STARTER STARTER 1 Q2 06 RELAY e 86 87 ALTERNATOR 1 FAILURE LAMP 4 3 1 e K 40 12 DIODE 7 DIODE eB 10 Di b ALTERNATOR h ART DE ESS OM Spe ew 1 1 63 1 Heisan US San sinna 81 EOF 53 i 51 C D T LE REQUIRED FOR 3 PERKINS CAT ONLY E C T 4 5 5 DIODE INDIE d K 5 MODULE d e 55 SULLAIR P N 02250128 882 gt LED CONNECTED TO ON CAT PERKIN STARTER RED ICABLE 1A SULLAIR GROUN S ONL N C RELAY
12. 10 E COLD START ALTERNATOR FAILURE LAMP i 17 52 oF 15 14 phos EDP 51 5 3 SELL SWITCH Sp GROUND 54 O 66 14 1 E C T 4 i SSAM SOLENOID b Monu E a P N 02250126 682 2e e gt bB SJLED He 3 2 8 4 D 56 58 INSTRUMENT css Hn n 57 PANEL LIGHTS I 19 1 i 95 HOUR S UL GEN ze s METER KER se lt I P ZZ N TACHO TN VOLT 7 ae o ce 1 96 s DC MM STARTER 9 REMOVED FROM GROUND ON STANDARD HARNESS 1 6 6 1 1 95 86 87a RED CABLE 1A T 1 12 1 52 1 21 i BLUE 23 f i 1 FUBE Q JBLACKRA 1 SENDER 25 25 os i 55 FUEL LEVEL GAUGE 1 85 1 95 1 1 1 LOW FUEL LEVEL ALTERNATOR SHUTDOWN WITH i D TERMINAL GAUGE OPTION 32 SULLAIR SECTION 2 2 13 ELECTRICAL SYSTEM FUNCTIONAL DESCRIPTION The electrical system consists of the basic electrical elements required to operate the compressor and also has a system feature that automatically shuts down the compressor when a malfunction occurs The system s components include an engine starter battery alternator voltage regulator and a fuel solenoid It also has a compressor discharge temperature switch that will shut the compressor down if the compressor temperature exceeds 250 F 121 C It has an engine water temperature switch set to shut down the compressor when
13. 3 Fluid Fill Port Figure 3 1 Receiver Tank 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 SULLAIR 125 130 49HP AND 185 USER MANUAL Section 4 GENERAL 4 1 GENERAL While Sullair has built into this compressor complete set of controls and indicators that allow the operator to control and monitor the compressor s operation and performance Operators should learn to recognize indications which identify a service requirement or conditions that could lead to or show a current malfunction Before starting the compressor read this section thoroughly to gain familiarity with the controls and indicators their function and location 42 PURPOSE OF CONTROLS CONTROL OR INDICATOR PURPOSE ENGINE SWITCH Press this switch to the ON ignition position to energize the electrical system of the compressor Press the switch to the START position to momentarily engage the starter and start the compressor Press the switch to the OFF position to shut the compressor down This switch is located on the instrument panel COLD WEATHER STARTING AID BUTTON Push this button prior to compressor start up to allow the engine to pre heat for easier starting HOURMETER Indicates the accumulated hours of operation Useful for planning and logging service schedules AiR PRESSURE GAUGE Continuously mo
14. a lifting bail then lift by the bail provided If no bail is provided then lift by sling Compressors to be air lifted by helicopter must not be supported by the lifting bail but by slings instead In any event lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local State Military and Federal regulations that may apply Inspect lifting bail and points of attachment for cracked welds and for cracked bent corroded or otherwise degraded members and for loose bolts or nuts prior to lifting Make sure entire lifting rigging and supporting structure has been inspected is in good condi tion and has a rated capacity of at least the net weight of the compressor plus an additional 1096 allowance for weight of snow ice mud or stored tools and equipment If your are unsure of the weight then weigh compressor before lifting Make sure lifting hook has a functional safety latch or equivalent and is fully engaged and latched on the bail Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground DO NOT attempt to lift in high winds Keep all personnel out from under and away from the compressor whenever it is suspended Lift compressor no higher than necessary Keep lift operator in constant attendance when ever compressor is suspended Set compressor down only on a level surface capable of supporting at least its net weight p
15. if applicable in your area The air compressor should be operated only by those who have been trained and delegated to do so and who have read and understood this Operators Manual Failure to follow the instructions procedures and safety precautions in this manual can result in accidents and injuries NEVER start the air compressor unless it is safe to do so DO NOT attempt to operate the air compressor with a known unsafe condition Tag the air compressor and render it inoperative by disconnecting the battery so others who may not know of the unsafe condition will not attempt to operate it until the condition is corrected Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and or all pertinent Federal State and Local codes or requirements DO NOT modify the compressor except with written factory approval Each day walk around the air compressor and inspect for leaks loose or missing parts damaged parts or parts out of adjustment Perform all recommended daily maintenance Inspect for torn frayed blistered or otherwise deteriorated and degraded hoses Replace as required A CAUTION Estimated hose life based on a 5 day 8 hour work week is 3 years These conditions exist on an 8 hour shift only Any other operation of the equipment other than 8 hour shifts would shorten the hose life based on hours of operation 1 2 TOWING I PR
16. it is unbalanced from side to side or front to back Such unbalance will reduce the towability of this equipment and may increase the possibility of tipping rolling over jackknifing etc Loss of control of the towing vehicle may result TOWING A Observe all Federal State and Local laws while towing this equipment including those specifying minimum speed DO NOT exceed the towing speeds listed below under ideal conditions Reduce your speed SULLAIR according to posted speed limits weather traffic road or terrain conditions 1 Two axle four wheel or three axle six wheel steerable models 15 MPH 24 km h 2 All other models 55 MPH 88 km h C Remember that the portable air compressor may approach or exceed the weight of the towing vehicle Maintain increased stopping distances accordingly DO NOT make sudden lane changes U turns or other maneuvers Such maneuvers can cause the compressor to tip roll over jackknife or slide and cause loss of control of the towing vehicle Tipping rolling over etc can occur suddenly without warning U turns especially should be made slowly and carefully D Avoid grades in excess of 15 27 E Avoid potholes rocks and other obstructions and soft shoulders or unstable terrain F Maneuver in a manner that will not exceed the freedom of motion of the compressor s drawbar and or coupling device in or on the towing vehi cle s coupling device and or adjacent st
17. uncontrolled arcing which might serve as a source of ignition Positive battery terminals are usually identified by a plus sign on the terminal and the letters POS adjacent to the terminal Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative sign Connect one end of a jumper cable to the posi tive POS battery terminal in the starting vehicle When jump starting 24V compressors and if the starting vehicle is provided with two 2 12V batteries connected in series connect the jumper cable to the positive POS terminal of the ungrounded battery Connect the other end of the same jumper cable to the positive POS terminal of the starter motor battery in the compressor or when jump starting 24V compressor to the positive POS terminal of the ungrounded battery in the compressor Connect one end of the other jumper cable to the grounded negative NEG terminal of the bat tery in the starting vehicle When jump starting 24V compressors and if the starting vehicle is provided with two 2 12V batteries connected in series connect the jumper cable to the negative NEG terminal of the grounded battery Check your connections DO NOT attempt to start a 24V compressor with one 12V battery in the starting vehicle DO NOT apply 24V to one 12V battery in the compressor Connect the other end of this same jumper cable to a clean portion of
18. 8 kW F See Engine See Engine See Engine See Engine Type of Motor Oil Operator Manual Operator Manual Operator Manual Operator Manual Fuel Tank Capacit 20 Gallons 20 Gallons 20 Gallons 20 Gallons pacity 76 liters 76 liters 76 liters 76 liters Radiator Capacit 2 5 US Gallons 2 5 US Gallons 2 5 US Gallons 2 5 US Gallons pacity 9 5 liters 9 5 liters 9 5 liters 9 5 liters Engine Water Temperature Shutdown 225 F 107 C 225 F 107 C 225 F 107 C 225 F 107 C Minimum Idle Speed Alternator Rating 2000 RPM 70 amp 2000 RPM 70 amp 2000 RPM 70 amp 2000 RPM 70 amp 1 DO NOT allow engine idle rpm to drop below minimum idle speed Compressor and or coupling damage will occur The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed falls below 1500 rpm 3 4 LUBRICATION GUIDE COMPRESSOR AMBIENT TEMPERATURE FLUID TYPE CHANGE PERIOD HOURS RANGE F C Sullair AWF 1 1500 20 to 120 29 to 49 SAE 10W SE SF SG CD 250 0 to 100 18 to 38 MIL L 2104E 10W 250 0 to 100 18 to 38 I Sullair part numbers for Sullair AWF are 250030 757 5 gallons 18 9 liters and 250030 758 55 gallon drum 280 liters 40 SULLAIR SECTION 3 3 5 APPLICATION GUIDE Sullair air compressors are supplied with Sullair AWF which is a heavy duty multi viscosity all weather fluid w
19. A Interim Tier 4 European Stage IIIA Displacement 140 cu in 2 29 L 140 cu in 2 29 L 140 cu in 2 29 L Cylinders 4 4 4 Bore x Stroke 3 54 x 3 54 in 3 54 x 3 54 in 3 54 x 3 54 in 90 0 x 90 0 mm 90 0 x 90 0 mm 90 0 x 90 0 mm Rated Speed 2550 RPM 2650 RPM 2800 RPM Rated Power 67 HP 50 0 kW 67 HP 50 0 kW 67 HP 50 0 kW Type of Motor Oil See Engine Operator Manual See Engine Operator Manual See Engine Operator Manual Fuel Tank Capacity 20 Gallons 76 liters 20 Gallons 76 liters 20 Gallons 76 liters Radiator Capacity Engine Water Temperature Shutdown 2 5 US Gallons 9 5 liters 225 F 107 C 2 5 US Gallons 9 5 liters 225 F 107 C 2 5 US Gallons 9 5 liters 225 F 107 C Minimum Idle Speed 2550 RPM 2650 RPM 2200 RPM Alternator Rating 50 amp 50 amp 50 amp falls below 1500 rpm 1 DO NOT allow engine idle rpm to drop below minimum idle speed Compressor and or coupling damage will occur The compressor is equipped with a Low Speed Shutdown System that will shutdown the compressor if engine speed 38 SULLAIR SECTION 3 3 3 DEERE Table 3 7 Overall Specifications John Deere 125 130 49HP AND 185 USER MANUAL SPECIFICATIONS 125 130 49 HP AND 185 JOHN Length Width Height Weight wet Model Series in mm i
20. AL MUFFLER AND EXHAUST SYSTEM INSPECTION At least annually inspect muffler s and engine exhaust system to make sure all parts are securely mounted that all joints and connections are tight and that the muffler is in good condition DO NOT operate compressor with defective exhaust system Remove and replace any defective parts by ordering with part numbers indicated in the Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date 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 Maintenance Performed By Location Date Maintenance Performed By Location Date 56 SULLAIR SECTION 6 125 130 49HP AND 185 USER MANUAL 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 compres
21. D 185 CATERPILLAR SPECIFICATIONS 125 130 AND 185 DEUTZ SPECIFICATIONS 125 130 49 HP AND 185 JOHN DEERE LUBRICATION GUIDE COMPRESSOR APPLICATION GUIDE LUBRICATION GUIDE ENGINE GENERAL PURPOSE OF CONTROLS INITIAL STARTUP SHUTDOWN PROCEDURE RESTART PROCEDURE SECTION 5 MAINTENANCE 45 45 45 45 46 46 46 46 46 52 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 GENERAL ENGINE COOLANT REQUIREMENT FOR RADIATORS DAILY MAINTENANCE MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION MAINTENANCE EVERY 50 HOURS MAINTENANCE EVERY 100 HOURS MAINTENANCE EVERY 250 HOURS MAINTENANCE EVERY 1500 HOURS PART REPLACEMENT AND ADJUSTMENT PROCEDURES TROUBLESHOOTING SECTION 6 NOISE CONTROL 55 55 56 6 1 6 2 6 3 NOISE EMISSIONS WARRANTY TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED NOISE EMISSIONS MAINTENANCE AND MAINTENANCE RECORD LOG SULLAIR Section 1 SAFETY NOTE OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL 1 4 GENERAL Sullair Corporation designs and manufactures all of its products so they can be operated safely However the responsibility for safe operation rests with those who use and maintain these products The following safety precautions are offered as a guide which if conscientiously followed will minimize the possibility of accidents throughout the useful life of this equipment Read the CIMA Safety Manual prior to compressor operation and towing
22. E Open the pressure relief valve at least weekly to make sure it is not blocked closed obstructed or otherwise disabled Install an appropriate flow limiting valve between the compressor service air outlet and the shutoff throttle valve when an air hose exceeding 1 2 13 mm inside diameter is to be connected to the shutoff throttle valve to reduce pressure in case of hose failure per OSHA Standard 29 CFR 1926 302 b 7 or any applicable Federal State and Local codes standards and regulations When the hose is to be used to supply a mani fold install an additional appropriate flow limiting valve between the manifold and each air hose SULLAIR SECTION 1 exceeding 1 2 13 mm inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure Provide an appropriate flow limiting valve for each additional 75 feet 23 m of hose in runs of air hose exceeding 1 2 13 mm inside diameter to reduce pressure in case of hose failure Flow limiting valves are listed by pipe size and rated CFM Select appropriate valve accordingly DO NOT use tools that are rated below the maxi mum rating of this compressor Select tools air hoses pipes valves filters and other fittings accordingly DO NOT exceed manufacturer s rated safe operating pressures for these items Secure all hose connections by wire chain or other suitable retaining device to prevent tools or hose ends from being a
23. ECTION 1 Insert a bright light source into the element and look for any light leaks which indicate the presence of damage holes cracks etc 2 Inspect all gaskets and gasket contact sur faces of the housing and replace any dam aged ones 3 Store clean elements for later use in a clean container 4 After installing the element inspect and tighten all air inlet connections before operat ing the compressor SEPARATOR ELEMENT REPLACEMENT Refer to Figure 5 3 When compressor fluid carryover is evident after replacing or inspecting the fluid return line strainer and orifice and the blowdown valve and all are in satisfactory condition the separator element must be replaced with Kit number 250034 112 element for air fluid separator 1 Disconnect all sump cover piping connec tions to permit removal return line service line etc 2 Remove the fluid return line from the fitting on the cover 3 Remove the eight 8 cover bolts and wash ers and lift the cover off the sump 4 Remove the separator element Scrape the old gasket material from the cover and the flange on the sump Do not allow the scrapings to fall into the tank 6 Install the new element Replace the sump cover and bolts Lightly tighten all the bolts and then gradually tighten them alternating between bolts which 48 10 SECTION 5 are diagonally opposite each other Torque the bolts to 60 ft lbs 81 Nem Reconnect all pipi
24. EPARING TO TOW Do NOT tow the compressor should its weight exceed the rated limit of the tow vehicle as the vehicle may not brake safely with excess weight See rated limit in tow vehicle Operator s Manual and review its instructions and other requirements for safe towing 1 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 SULLAIR A Prior to hitching the air compressor to the tow vehicle inspect all attachment parts and equip ment checking for i signs of excessive wear or corrosion ii parts that are cracked bent dented or otherwise deformed or degraded and iii loose nuts bolts or other fasteners Should any such condition be present DO NOT TOW until the problem is corrected Back the tow vehicle to the compressor and posi tion it in preparation for coupling the compressor If the compressor is provided with a drawbar latched in the vertical upright position carefully unlatch drawbar and lower it to engage the cou pling device If not raise drawbar to engage cou pling device or otherwise couple the compressor to the towing vehicle This equipment may be tongue heavy DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury
25. ES B EEE EE T 1 16 d T i i x i cde ue SE S seede pec nc Shee i es ei eee T i oon n 09 T m lt 2 EN i T i 4 4 Ex Nu I bed 4 lt TROL LINE i Y b FLUID LINE AIRZFLUID LINE b Z N 4 AIR LINE PN Pan a 4 24 SULLAIR SECTION 2 1 Filter Air 2 Gauge Filter Restriction Optional 3 Inlet Valve 4 Compressor 5 Gauge Temperature 6 Switch Temperature 8 Valve Relief 9 Receiver Air Oil 10 Glass Sight Oil Level 12 Valve Minimum Pressure Check 13 Valve Ball 14 Engine Speed Control Cylinder 15 Regulator Blowdown Manifold SULLAIR 17 18 19 21 22 23 27 28 29 31 T1 125 130 49HP AND 185 USER MANUAL Orifice Valve Blowdown N C Strainer Valve Thermal Bypass Cooler Oil Filter Oil Gauge Pressure Valve Pressure Regulator Valve 3 Way Selector Valve Check Compressor Discharge Temperature Switch 25 125 130 49HP AND 185 USER MANUAL SECTION 2 2 8 PIPING AND INSTRUMENTATION ENGINE SYSTEM ENGINE SYSTEM 34 pu E AIR INTAKE AND EXHAUST SYSTEM 31 i COMPRESSOR 1 A 1
26. Faulty SSAM module Replace the module SSAM FLASH CODE Compressor temperature switch is open Check wiring connection to the switch and ONE FLASH tighten if loose Check switch continuity to ground and replace if necessary Low receiver tank fluid level Add fluid to receiver tank as required Loose or broken fan belt Tighten or replace belt Cooling air flow is insufficient dirty fluid Clean core thoroughly and check for proper cooler core ventilation Clogged compressor fluid filter Change fluid filter element Faulty fluid thermostat Change fluid thermostat element Plugged fluid cooler tube internal Replace cooler 52 SULLAIR SECTION 5 Table 5 1 Troubleshooting 125 130 49HP AND 185 USER MANUAL ENGINE STOPS DOES NOT CRANK OR CRANKS BUT DOES NOT START SYMPTOM PROBABLE CAUSE REMEDY SSAM FLASH CODE TWO FLASHES Engine coolant temperature switch is open Check wiring connection to the switch and tighten if necessary Check switch continuity to ground and replace if necessary Cooling air flow is insufficient Clean cooler and check for proper ventilation Loose or broken fan belt Tighten or replace belt Low engine coolant Fill with proper water glycol mixture as required Faulty water pump Defective engine thermostat Change pump Change thermostat element Engine problems might be present Refer to the Engine Opera
27. O NOT remove caps plugs and or other components when the compressor is run ning or pressurized Stop the compressor and relieve all internal pressure before removing these items 2 6 CAPACITY CONTROL SYSTEM FUNCTIONAL DESCRIPTION Refer to Figure 2 3 or Figure 2 4 The purpose of the control system is to regulate the amount of air intake and match it to the demand required output on the compressor The control system consists of a pressure regulating valve s air inlet valve system blowdown valve engine speed control and tubing connecting the various components of the compressor and engine The functional descriptions of the control system are described by relating them 1 Receiver Tank 2 Minimum Pressure Check Valve 3 Internal Air Oil Separator Element 125 130 49HP AND 185 USER MANUAL to four distinct phases of operation They apply to any control system with the exception of those with specified pressures which are dependent on pressure requirements The given values apply to a compressor with an operating pressure range of 100 to 110 psig 6 9 to 7 6 bar START 0 To 40 PsiG 0 2 8 BAR When the compressor is started the sump pressure quickly rises from 0 to 40 psig 0 to 2 8 bar During this period the pressure regulator valve is inactive At this pressure range the idle warm up control keeps the inlet valve closed for engine idle operation Within 30 seconds of starting th
28. O NOT us aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If the engine fails to start within 30 seconds release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again SULLAIR 125 130 49HP AND 185 USER MANUAL Section 5 MAINTENANCE WARNING DO NOT remove caps Plugs and or other components when the compressor is run ning or pressurized Shutdown the com pressor before removing any components 5 1 GENERAL Consistent and correctly performed maintenance will ensure the compressor s performance and extend its operational life See Part Replacement And Adjustment Procedures on page 46 for a detailed description of specific compressor components Before performing maintenance actions read the CIMA Safety Manual if applicable For engine maintenance requirements and procedures refer to the Engine Operator s Manual 5 2 ENGINE COOLANT REQUIREMENT FOR RADIATORS The coolant provided with Sullair portable air compressors is ethylene glycol based 50 50 mixture and should never be mixed with a different coolant type color or brand If radiator coolant is to be added for any reason be sure that the coolant added is the same as what is in the cooling system as well as what is recommended Refer to the Maintenance Section of the Engine Operator s Manual for
29. POINT TIE DOWN AIR COOLED OIL COOLER LIQUID COOLED OIL COOLER CONTROL BELOW TEMPERATURE AIR CIRCULATING FAN TEST SWITCH BELTS 24 HOURS PRESSURE CONTROL LOW PRESSURE HIGH PRESSURE LUBRICATION TRAILER TOWING 3 eee Safety Symbols 2 SULLAIR 15 A E EA A R U R L AAA WATER CONDENSATE mS DO NOT PLUG M A G EN E COOLANT DRA sam hy fener E OIL DRAIN ELECTRICAL SHOCK AIR FLOW DO NOT BREATH COMPRESSOR AIR WARNING HOT SURFACE PRESSURISED DO NOT REMOVE MANUAL VESSE DO NOT STAND ON SERVICE VALVE U L WARNING PRESSURISED COMPONENT DO NOT OPERATE COMPRSSOR WITH I DOORS OPE G R E WARNING N AN DANGEROUS OUTLET DO NOT OPE G L NIN GER T WARNIN VALVES N REMOTE N OA COMPRESSOR OIL DRAIN IN IN N OPEN AIR WITHOUT Y ED HOSES LED WARNING LOW TEMPERATURE WARNING CRUSH PINCH POINT CONNE DO NOT STACK DO NOT 1 CORROSIVE DO NOT TOW SIDE DOOR T LATCH BRAKES V DO NOT MIX BS COOLANTS AFTERCOOLER BYPASS VALVE MEM Gss NN SECTION 1 u SULLAIR 125 130 49HP AND 185 USER MANUAL Section 2 DESCRIPTION 2 1 INTRODUCTION The Sullair 125 130 49HP and 185 CFM Standard Portable Air Compressors offer superior performance reliability and require a minimal amount of maintenance Compared to other compressors Sullairs are unique i
30. U S Law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any persons other than for purposes of mainte nance repair or replacement of any device or element of design incorporated into any new compressor for the purpose of noise SULLAIR control prior to its sale or delivery to the ulti mate purchaser or while it is in use 2 The use of the compressor after such device or element of design has been removed or rendered inoperative by any person Among those acts included in the prohibition against tampering are the acts listed below 1 Removal or rendering inoperative any of the following a Engine exhaust system or parts thereof b Compressor air intake system or part thereof c Enclosure of part thereof 2 Removal of any of the following a Vibration isolators b Control silencer c Floor panel d Fan shroud e Acoustical materials foam or foam tape including fiberglass 3 Operation with canopy doors open for any purpose other than starting stopping adjust ment repair replacement of parts or mainte nance 55 125 130 49HP AND 185 USER MANUAL SECTION 6 6 3 NOISE EMISSIONS MAINTENANCE AND RECORD 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 AND MAINTENANCE RECORD LOG 1 ANNU
31. air flows to the service line and the fluid is cooled in preparation for re injection SULLAIR 125 130 49HP AND 185 USER MANUAL 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION Refer to Figure 2 2 The compressor cooling and lubrication system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor In addition to the fluid cooler and interconnecting piping the system consists also of three other components a fluid filter thermal valve and a fan which perform the following functions The fluid filter removes and collects any contami nants in the fluid The thermal valve functions as a temperature regu lator directing fluid either to the cooler or to the compressor unit The fan pushes air through the cooler dissipating the heat resulting from compression of the fluid The functions of the lubrication system are explained in more detail below Fluid is used in the system as a coolant and as a lubricant the sump serves as the fluid reservoir At start up fluid flows from the sump to the fluid thermal valve Fluid circulation is achieved by forcing the fluid from the high pressure region of the sump to a lower pressure area in the compressor unit A minimum pressure device See Compressor Discharge System Functional Description on page 20 is provided to assure adequate fluid flow under all conditions When entering the thermal valv
32. artment CO 9 10 10 10 11 12 13 14 gt SULLAIR TABLE OF CONTENTS SECTION 1 SAFETY 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 GENERAL TOWING PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING ENTRAPMENT JUMP STARTING IMPLEMENTATION OF LOCKOUT TAGOUT CALIFORNIA PROPOSITION 65 SYMBOLS AND REFERENCES SECTION 2 DESCRIPTION 17 17 19 19 20 21 24 26 28 29 31 32 33 33 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 INTRODUCTION DESCRIPTION OF COMPONENTS SULLAIR COMPRESSOR UNIT FUNCTIONAL DESCRIPTION COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTION AL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION CAPACITY CONTROL SYSTEM FUNCTIONAL DESCRIPTION PIPING AND INSTRUMENTATION COMPRESSOR SYSTEM PIPING AND INSTRUMENTATION ENGINE SYSTEM AIR INLET SYSTEM FUNCTIONAL DESCRIPTION INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION WIRING DIAGRAM CAT amp JD WIRING DIAGRAM DEUTZ ELECTRICAL SYSTEM FUNCTIONAL DESCRIPTION COMPRESSOR SHUTDOWN amp WARNING SYSTEM FUNCTIONAL DE TABLE OF CONTENTS SCRIPTION SECTION 3 SPECIFICATIONS 35 37 39 40 41 41 SECTION 4 GENERAL 43 43 44 44 3 1 3 2 3 3 3 4 3 5 3 6 4 1 4 2 4 3 44 SPECIFICATIONS 125 130 AN
33. as If the compressor is operated indoors discharge engine exhaust fumes outdoors Locate the compressor so that exhaust fumes are not apt to be carried towards personnel air intakes servicing personnel areas or towards the air intake of any portable or stationary compres sor Fuels fluids coolants lubricants and battery electrolyte used in the compressor are typical of the industry Care should be taken to avoid acci dental ingestions and or skin contact In the event of ingestion seek medical treatment promptly DO NOT induce vomiting if fuel is ingested Wash with soap and water in the event of skin contact Wear an acid resistant apron and a face shield or goggles when servicing the battery If electrolyte 1 8 10 is spilled on skin or clothing immediately flush with large quantities of water Ethyl ether used in diesel engine ether starting aid systems is toxic harmful or fatal if swallowed Avoid contact with the skin or eyes and avoid breathing the fumes If swallowed DO NOT induce vomiting but call a physician immediately Wear goggles or a full face shield when testing 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 If ethyl ether or air line anti icer system anti freeze compound enters the eyes or if fumes irri tate the eyes they should
34. ate and local regula tions 5 4 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation the following maintenance actions are required to eliminate contaminants from the system 1 Clean the return line orifice and change the strainer 2 Change the compressor fluid filter 45 125 130 49HP AND 185 USER MANUAL 3 Check the Engine Operator s Manual for ser vice requirements 4 Check the fuel filter for water Confirm that the receiver tank cover bolts are tightened to 60 Ib ft 81Nem 5 5 MAINTENANCE EVERY 50 HOURS 1 Inspect air filter elements and replace if nec essary 2 Check the fuel filter for water 5 6 MAINTENANCE EVERY 100 HOURS 1 Clean the radiator and cooler exterior sur faces 2 Check the Engine Operator s Manual for ser vice requirements 5 7 MAINTENANCE EVERY 250 HOURS 1 Check fan belt tension 2 Clean the radiator and cooler exterior sur faces Where dust and other atmospheric contaminants are present it might be neces sary to clean these parts more frequently 3 Check the Engine Operator s Manual for ser vice requirements 4 Change the engine oil and filter 5 Change the compressor fluid if it is not Sul lair AWF 10 11 12 SECTION 5 Change the fuel filter If the filter tends to clog more often than what is expected change the filter more frequently Change the engine fuel water separa
35. ated at least every 12 months or more to ensure proper performance and minimize wear Use a wheel bearing grease that conforms to MILSPEC MIL G 10924 or a high temperature one such as lithium complex NLGI consistency 2 Axles with the E Z Lube feature can be periodically lubricated without removing the hubs from the axle This feature consists of axle spindles that have been fitted with a grease zerk in their ends When grease is pumped into the zerk it is channeled to the inner bearing and then flows back to the outer bearing and then back out of the grease cap hold see Figure 5 5 125 130 49HP AND 185 USER MANUAL Remove the rubber cap from the grease cap s end Using a full charged grease gun place the gun onto the grease zerk located on the end of the spindle Make sure the nozzle is fully engaged on the fitting Pump grease into the zerk The old grease will be displaced and flow out of the cap around the grease gun nozzle When the new grease starts flowing out of the cap disengage the gun and wipe off any excess off the cap and replace the rubber plug Rubber Plug Outer Bearing Grease Flow mee m cm Grease Fitting SU 0000671 Metal End Cap Inner Bearing Spring Loaded Double Lip Seal Figure 5 5 Typical E Z Lube Axle SULLAIR 51 125 130 49HP AND 185 USER MANUAL 5 10 TROUBLESHOOTING The following Troubleshooting chart is based upon data obtained from factory tests and informa
36. batteries or when checking or add ing fluid or when checking diesel engine ether starting aid systems or replacing cylinders or when refilling air line anti icer systems antifreeze compound DO NOT permit liquids including air line anti icer system antifreeze compound or fluid film to accumulate on bottom covers or on under or around acoustical material or on any external or internal surfaces of the air compressor Wipe down using an aqueous industrial cleaner or steam clean as required If necessary remove acoustical material clean all surfaces and then replace acoustical material Any acoustical mate rial with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material DO NOT use flammable solvents for cleaning purposes Disconnect the grounded negative battery con nection prior to attempting any repairs or clean ing inside the enclosure Tag the battery connections so others will not unexpectedly reconnect it Keep electrical wiring including the battery ter minals and other terminals in good condition Replace any wiring that has cracked cut abraded or otherwise degraded insulation or ter minals that are worn discolored or corroded Keep all terminals clean and tight Turn off battery charger before making or break ing connections to the battery Keep grounded conductive objects such as tools away from exposed li
37. be washed with large quantities of clean water for 15 minutes A physi cian preferably any eye specialist should be contacted immediately DO NOT store ether cylinders or air line anti icer system antifreeze compound in operator s cabs or in other similar confined areas The antifreeze compound used in air line anti icer systems contains methanol and is toxic harmful or fatal if swallowed Avoid contact with the skin or eyes and avoid breathing the fumes If swallowed induce vomiting by administering a tablespoon of salt in each glass of clean warm water until vomit is clear then administer two tablespoons of baking soda in a glass of clean water Have patient lay down and cover eyes to exclude light Call a physician immediately ELECTRICAL SHOCK Keep the towing vehicle or equipment carrier compressor hoses tools and all personnel at least 10 feet 3 m from power lines and buried cables Keep all parts of the body and any hand held tools or other conductive objects away from exposed live parts of electrical system Maintain dry footing stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system Attempt repairs only in clean dry and well lighted and ventilated areas Stay clear of the compressor during electrical storms It can attract lightning 1 9 SECTION 1 LIFTING If the compressor is provided with
38. ccidentally disconnected and expelled 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 Vent all internal pressure prior to opening any line fitting hose valve drain plug connection or other component such as filters and line oilers and before attempting to refill optional air line anti icer systems with antifreeze compound Keep personnel out of line with and away from the discharge opening of hoses tools or other points of compressed air discharge DO NOT use air at pressures higher than 30 psig 2 1 bar for cleaning purposes and then only with effective chip guarding and personal protec tive equipment per OSHA Standard 29 CFR 1910 242 b or any applicable Federal State and Local codes standards and regulations DO NOT engage in horseplay with air hoses as death or serious injury may result This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve Lift the handle once a week to make sure the valve is functional DO NOT lift the handle while machine is under pressure If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non exposure DO NOT remove radiator filler cap until the cool ant temperature is below its boiling point Then SULLAIR
39. cells Check fluid level If low bring fluid to proper level before attempting to jump start not applicable to maintenance free batteries DO NOT attempt to jump start if fluid is frozen or slushy Bring batteries up to at least 60 F 16 C before attempting to jump start or it may explode Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start Attempt to jump start only with a vehicle having a negative ground electrical system with the same voltage and is also equipped with a battery or batteries of comparable size or larger than sup plied in the compressor DO NOT attempt to jump start using motor generator sets welders or other sources of DC power as serious damage may result Bring the starting vehicle alongside the compres sor but DO NOT permit metal to metal contact between the compressor and the starting vehicle Set the parking brakes of both the compressor if provided and the starting vehicle or otherwise block both sides of all wheels SULLAIR Place the starting vehicle in neutral or park turn off all non essential accessory electrical loads and start its engine Use only jumper cables that are clean in good condition and are heavy enough to handle the starting current Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of either the compressor or the starting vehicle to minimize the possibility of
40. d description of the engine The engine cooling system is comprised of a radiator high capacity fan and thermostat The high capacity fan pushes air through the radiator to maintain the engine s specified operating temperature The same fan also cools the fluid in the compressor cooling and lubrication system The engine radiator and the compressor fluid cooler are next to each other allowing the fan air to push through both simultaneously As air passes through the fluid cooler the heat of compression is removed from the fluid 2 3 COMPRESSOR UNIT FUNCTIONAL DESCRIPTION Sullair compressors are single stage positive displacement flood lubricated type compressors that provide continuous pulse free compression to meet various demand loads Sullair compressors require no routine maintenance or inspection of their internal parts or systems The compressor works by injecting fluid into the compressor unit where it mixes directly with the air as the rotors turn The fluid flow has three main functions 1 It acts as a coolant to control the rise of air temperature which is generated by compres sion heat of compression 2 Seals the leakage paths between the rotors and the stator and also between the rotors themselves 3 Lubricates the rotors allowing one rotor to directly drive the other After the air fluid mixture is discharged from the compressor unit the fluid is separated from the air At this time the
41. d range specified and are inflated to the specified pressures DO NOT change the tire size or type Also make sure wheel bolts lugs or nuts are tightened to the specified torques If provided make sure all dual stop tail direc tional and clearance lights are operating properly and that their lenses are clean and functional Also make sure all reflectors and reflecting sur faces including the slow moving vehicle emblem on compressors provided with same are clean and functional Make sure all service air hoses not air brake hoses are disconnected or are fully stowed and secured on hose reels if provided Make sure all access doors and tool box covers are closed and latched If the compressor is large enough to hold a man make sure all per sonnel are out before closing and latching access doors Make sure parking brakes in towing vehicle are set or that its wheels are chocked or blocked or that it is otherwise restrained from moving Then release the compressor parking brakes if pro vided Make sure the compressor wheels are not chocked or blocked and that all tie downs if any are free Test running brake operation including break away switch operation if provided before attempting to tow the compressor at its rated speed or less when conditions prevail DO NOT carry loose or inappropriate tools equipment or supplies on or in the compressor DO NOT load this equipment with accessories or tools such that
42. ddition 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 Maintenance Performed By Location Date Maintenance Performed By Location Date 58 SULLAIR BLANK PAGE SULLAIR SULLAIR WORLDWIDE SALES AND SERVICE SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekuo Shenzen Gunagdong PRV PRC POST CODE 518068 Telephone 755 6851686 Fax 755 6853473 www sullair asia com SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A www sullair com Telephone 1 800 SULLAIR U S A only Fax 219 874 1273 CUSTOMER CARE for PARTS and Service 1 888 SULLAIR 7855247 219 874 1835 SULLAIR EUROPE S A Zone Des Granges BP 82 42602 Montbrison France Telephone 33 477968470 Fax 33 477968499 www sullaireurope com Champion Compressors LTD Princess Highway Hallam Victoria 3803 Australia Telephone 61 3 9796 4000 Fax 61 3 9703 8053 www championcompressors com au Printed in the U S A Specifications subject to change without prior notice
43. e 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 the atmosphere at 43 125 130 49HP AND 185 USER MANUAL 4 3 INITIAL STARTUP SHUTDOWN PROCEDURE STARTUP Perform the following actions when starting the compressor for the first time 1 Ensure that the compressor is on a level sur face If the compressor is on an uneven sur face the fluid sight gauge readings will not be accurate and it will not be possible to determine if fluid levels are too low 2 Ensure that a minimum clearance of 3 feet is provided all the way around the machine to allow exhaust gas to ventilate before operat ing the machine Failure to ventilate hot exhaust gas can result in improper function ing of machine and the heat build up can result in melting of rubber and or plastic components 3 Check the oil and fluid levels in the engine and compressor add oil and or fluid if neces sary 4 Fill the fuel tank and drain any water from the fuel water separator 5 Crack open one service line Place the WARM UP control in the START position 7 Press the ENGINE SWITCH to the ON posi tion 8 In cold weather press the cold weather start ing aid button Hold button for 10 to 30 sec onds and then release 9 Momentarily press the ENGINE SWITCH to the START position to engage the starter release the switch when the engi
44. e compressor the instrument panel annunciator light goes off after 30 seconds turn the handle of the warm up selector valve located on the instrument panel from the START to the RUN position The inlet valve is fully open due to inlet pressure and the compressor operates at full capacity When the compressor operates at full capacity the engine runs at full speed 4 Compressor Unit 5 Service Air Outlets Figure 2 3 Compressor Discharge System SULLAIR 21 125 130 49HP AND 185 USER MANUAL SECTION 2 I e OOO lt 9050909050 0 0 MOR Q 0 1 Air Pressure Gauge 10 Fluid Filter 2 Idle Warm Up Valve 11 Compressor Unit 3 Inlet Valve 12 Air Filter 4 Orifice 13 Fluid Cooler 5 Regulator Blowdown Valve Manifold 14 Engine Speed Control Cylinder 6 Strainer 15 Instrument Panel 7 Minimum Pressure Check Valve 16 Air 8 Fluid Fill Fluid Level Sight Glass 17 Fluid Air 9 Thermal Valve 18 Fluid Figure 2 4 Control System with Piping and Instrumentation 22 SULLAIR BLANK PAGE SULLAIR 125 130 49HP AND 185 USER MANUAL SECTION 2 2 7 PIPING AND INSTRUMENTATION COMPRESSOR SYSTEM esee ere e a i TART
45. e upon start up the fluid temperature is cool and thus it is not necessary to route it through the cooler The fluid flows through the fluid filter and on to the compressor unit bypassing the cooler As the compressor continues to operate the temperature of the fluid rises and the thermostatic control opens allowing a portion of the fluid into the cooler When the temperature reaches 170 F 77 C the thermostat is fully open allowing all fluid entering the thermal valve to flow to the cooler The cooler is a radiator type that works in concert with the engine fan The fan pushes air through the cooler removing the heat from the fluid From the cooler the fluid is then routed back through the fluid 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 1 Fluid Cooler 2 Compressor 3 Thermal Valve SECTION 2 EN 4 Fluid Filter 5 Receiver Tank Figure 2 2 Compressor Cooling and Lubrication System 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION Refer to Figure 2 2 The Sullair compressor unit discharges a compressed air fluid mixture into the receiver tank The receiver tank has three functions 1 It acts as a primary fluid separator 2 Serves as t
46. ease the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again 29 125 130 49HP AND 185 USER MANUAL SECTION 2 20 40 60 ag 4 460 220 260 lt 49 90 ENG OIL PRESSURE ENG COOLANT TEMP 300 ud 120 kPa h PRESSURE TEMPERATURE 9 60 220 260 i mo TEMPERATURE 9 COMPR DISCHARGE TEMP N 7 START RUN START WARM U ON CONTROLN SZ S ON E x STOP OFF OPERATING HOURS AIR PRESSURE ENGINE SWITCH N P 1 4 PUSH A AR FUEL N W PRIOR TO 2 COLD LNG J WEATHER VOLTAGE ENGINE RPM FUEL LEVEL AS STARTING a QA pO Swutoown System amp Annunciation LIGHT ON 30 SECONDS AT STARTUP LIGHT OFF NORMAL OPERATION RUN FLASH CODE PROBLEM 1FLASH COMPRESSOR TEMP 2 FLASHES ENGINE TEMP 3 FLASHES ENGINE OIL PRESS FLASHES UNDERSPEED System air pressure Start stop switch Warm up control Shutdown indicator Hourmeter Wn gt Cold weather starting Glow plugs Figure 2 5
47. ed areas away from heat open flame or sparks DO NOT install store or otherwise expose ether cylinders to tem peratures above 160 F 71 C Remove ether cylinder from the compressor when operating in ambient temperatures above 60 F 16 C DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as serious personnel injury or property damage may result DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the compressor as serious damage to the com pressor or personal injury may result Antifreeze compound used in air line anti icer systems contains methanol which is flammable Use systems and refill with compound only in well ventilated areas away from heat open flames or sparks DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150 F 66 C Vapors from the antifreeze compound are heavier than air DO NOT store compound or discharge treated air in confined or unventilated areas DO NOT store containers of antifreeze compound in direct sunlight Store flammable fluids and materials away from your work area Know where fire extinguishers are and how to use them and for what type of fire they are intended Check readiness of fire suppression systems and detectors if so equipped 1 5 MOVING PARTS Keep hands arms and other parts of the body and also clothing away from belts pulle
48. ely handle Retract the front screw jack only after 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 the drawbar Rotate the screw jack to its stowed position parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position Rotate the screw jack to its stowed posi tion parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing H On two wheeled models fully retract front screw jack and any rear stabilizer legs If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack Pull the pin connecting the jack to the drawbar and raise the screw jack to its full upright posi tion Rotate the screw jack to its stowed position parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing SULLAIR SECTION 1 Make sure tires are in good condition and are the size loa
49. et floors controls and walking surfaces clean and free of fluid water antifreeze or other liquids to minimize possibility of slips and falls 1 6 HOT SURFACES SHARP EDGES AND SH RP CORNERS Avoid bodily contact with hot fluid hot coolant hot surfaces and sharp edges and corners Keep all parts of the body away from all points of air discharge and away from hot exhaust gases Wear personal protective equipment including gloves and head covering when working in on or around the compressor Keep a first aid kit handy Seek medical assis tance promptly in case of injury DO NOT ignore small cuts and burns as they may lead to infec tion SULLAIR 1 7 TOXIC AND IRRITATING SUBSTANCES A DO NOT use air from this compressor for respi ration breathing except in full compliance with OSHA Standards 29 CFR 1920 and any other Federal State or Local codes or regulations INHALATION HAZARD Death or serious injury can result from inhaling compressed air without using proper safety equipment See OSHA stan dards and or any applicable Federal State and Local codes standards and regulations on safety equipment DO NOT use air line anti icer systems in air lines supplying respirators or other breathing air utili zation equipment and DO NOT discharge air from these systems into unventilated or other confined areas Operate the compressor only in open or well ventilated are
50. gine Radiator Engine SULLAIR 20 25 26 29 125 130 49HP AND 185 USER MANUAL Engine Thermostat Integral To Engine Sensor Coolant Temperature Sensor Engine Oil Pressure Jacket Water Heater Optional 30 31 32 33 34 Oil Level Dipstick Filter Air Tank Fuel Engine Oil Pan Gauge Filter Restriction L1 Coolant Level L2 Fuel Level L3 Oil Level Dipstick P7 Oil Pressure T9 Coolant Temperature 27 125 130 49HP AND 185 USER MANUAL NORMAL OPERATION 80 TO 100 Psic 5 6 TO 6 9 BAR When the warm up control selector valve handle is moved to the RUN position the sump pressure rises above 80 psig 5 6 bar At this time the inlet valve remains fully open for maximum air output The engine will continue to run at full speed during this phase of operation MODULATION 100 To 110 PSIG 6 9 To 7 5 BAR If the demand on the compressor is less than its rated capacity the service line pressure will rise above 100 psig 6 9 bar The pressure regulating valve gradually opens applying pressure to the inlet valve piston and engine speed control This causes the inlet valve to partially close and reduces the engine speed As the pressure increases the inlet valve piston will further close the inlet valve and the engine speed will decrease until it reaches its preset idle speed When the demand on the compressor increases the sump pressure falls below 110 psig 7 6 bar The press
51. gine injector pump m Je pee E imi x 25 OD White 38 OD Blue 25 OD Black 38 OD Green 38 OD Orange 38 Yellow 38 OD Red 31 OD White To fitting at unit air filter rommoodu r Figure 5 4 Control System Adjustment Standard Pressure SULLAIR 49 125 130 49HP AND 185 USER MANUAL SECTION 5 4 Gradually open the service valve to atmo sphere until the engine comes up in speed and sump pressure is held at 100 psig 6 9 A WARNING bar At this point set the engine high speed to its specified setting by adjusting the high m idle threaded rod located on the engine Operating the compressor below its mini speed control To raise or lower the speed mum specified idle speed will damage the lengthen or shorten the rod respectively compressor Operating the compressor in this condition will cause coupling and or 5 Open the service valve to 100 psig 6 9 bar compressor failure rated full load pressure and recheck top engine speed and control response Close the service valve and allow the compressor 3 Adjust the pressure regulator so that the to cycle and re check low engine speed compressor maintains 115 psig 8 bar idle 50 SULLAIR SECTION 5 BEARING LUBRICATION Refer to Figure 5 5 Proper lubrication of the portable compressor s bearing axle is critical to its proper function and reduction of wear on this part Wheel bearings should be lubric
52. h Replace switch SULLAIR 53 125 130 49HP AND 185 USER MANUAL Table 5 1 Troubleshooting SECTION 5 ENGINE STOPS DOES NOT CRANK OR CRANKS BUT DOES NOT START SYMPTOM PROBABLE CAUSE REMEDY Compressor does not achieve full discharge pressure Run start switch not in run position For compressors with idle warm up controls switch toggle to RUN for full operation 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 Defective idle warm up control Replace control Improper unloading with an excessive pressure build up causing the pressure relief valve to open Pressure regulating valve is set too high Control system leak causing loss of pressure signal Readjust Check control lines Defective pressure regulating valve Repair valve kit available Inlet valve jammed Free or replace valve 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 pressure is too low Replace the pressure relief valve Defective pressure regulator Check the diaphragm and replace with kit if necessary Insufficient air delivery Run start switch not in run positio
53. he Authorized person is 1 13 CALIFORNIA notified of lock removal before returning PROPOSITION 65 to work 2 Tagout System Tags are warning devices affixed at points of power disconnect and are A not to be removed by anyone other that the WARNING person placing tag on power lockout Tags shall never be by passed ignored or CALIFORNIA PROPOSITION 65 WARNING defeated Diesel engine exhaust and some of its con stituents are known to the State of Califor nia to cause cancer birth defects and other reproductive harm Battery posts terminals and related acces sories contain lead and other compounds known to the State of California to cause cancer and birth defects and other repro ductive harm Wash hands after handling SULLAIR 13 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 SHUT OFF VALVE WITH SAFETY 14 SECTION 1 ENGINE COOLANT ENGINE COOLANT TEMPERATURE ENGINE ECM ENGINE RPM R O OA 9 lt lt m UD 2 2 GC lt 20 O gt lt 2 m AWF ENGINE SHUTDOWN COMPRESSOR SHUTDOWN Safety Symbols 1 SULLAIR 0 AU Ow SECTION 1 DIRECTION OF ROTATION Bar PRESSURE LIFT
54. he compressor fluid reservoir 3 Houses the air fluid separator The compressed air fluid mixture enters the receiver tank and is directed against the side of the sump Because of a change of direction and reduction of velocity large droplets of fluid separate and fall to the bottom of the sump The small amount of fluid remaining in the compressed air collects on the surface of the separator element as the compressed air flows through the separator As more fluid collects 20 on the element surface it then flows to the bottom of the separator A return line or scavenge tube leads from the bottom of the separator element to the inlet region of the compressor unit Fluid collecting on the bottom of the separator element is returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet An orifice protected by a strainer is included in this return line to assure proper and unobstructed flow The receiver tank is code rated at 200 psig 13 8 bar working pressure A minimum pressure device located downstream from the separator ensures a minimum receiver pressure of 80 psig 5 5 bar during all conditions Keeping this pressure level stable is necessary for proper air fluid separation and proper fluid circulation A pressure relief valve located on the wet side of the separator is set to open if the sump pressure exceeds 200 psig 13 8 bar SULLAIR SECTION 2 D
55. hich provides an extended change interval when compared to other fluids Detergent motor oils SAE 10W Class SE SF SG or CD can also be used Any of these oils are suitable under conditions where severe oil oxidation can occur Water must be drained from the receiver tank periodically In high ambient temperature and humidity conditions condensed moisture can emulsify with the oil forming a milky color SAE 10W is especially prone to this condition The fluid should be changed if this condition develops DO NOT mix different fluids Combinations of different fluids can lead to operational problems such as foaming plugged filters blocked orifices or lines When ambient conditions exceed the recommended ranges or if other conditions warrant the use of other extended life lubricants contact your local Sullair representative for recommendations Sullair encourages users to participate in a fluid analysis program The analysis might indicate a need for change intervals different from those recommended in this manual Sullair Corporation offers a fluid analysis for Sullair AWF Contact Sullair for details D A Lubricant amp Company Inc offers an analysis for users of Sullair AWF Contact your Sullair representative for details SULLAIR 125 130 49HP AND 185 USER MANUAL 3 6 LUBRICATION GUIDE ENGINE Refer to the Engine Operators Manual for oil specifications 1 Receiver Tank 2 Sight Glass
56. is pressed to the ON position to energize the electrical system and pressed momentarily to the START position to engage the starter and start the compressor The idle warm up control is turned from START to RUN after sufficient warm up is achieved for full compressor operation The shutdown indicator light indicates engine and compressor safety shutdown status The Hourmeter indicates the accumulated hours of operation The cold weather starting aid glow plugs should be used for starting in cold weather Press the button and hold for 10 30 seconds depending upon ambient temperature Release the button prior to starting The optional Engine Voltage Gauge monitors the voltage level of the engine storage bat tery SULLAIR 10 11 12 125 130 49HP AND 185 USER MANUAL The optional Engine Oil Pressure Gauge monitors the pressure of the lubricating oil in the engine The optional Engine Coolant Temperature Gauge monitors the temperature of the engine coolant in the engine The optional Tachometer monitors the oper ating speed of the engine The optional fuel level gauge indicates the fluid level in the fuel tank The optional Compressor Discharge Tem perature Gauge monitors the temperature of the air oil mixture in the sump DO NOT use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If the engine fails to start within 30 seconds rel
57. lus an additional 1096 allowance for the weight of Snow ice mud or stored tools and equipment If the compressor is provided with parking brakes make sure they are set and in any event block or chock both sides of all running wheels before disengaging the lifting hook 1 10 ENTRAPMENT A Make sure all personnel are out of compressor B before closing and latching enclosure doors If the compressor is large enough to hold a man and if it is necessary to enter it to perform service SULLAIR SECTION 1 adjustments inform other personnel before doing so or else secure the access door in the open position to avoid the possibility of others closing and possibly latching the door with per sonnel inside 1 11 JUMP STARTING A B Observe all safety precautions mentioned else where in this manual Batteries may contain hydrogen gas which is flammable and explosive Keep flames sparks and other sources of ignition away Batteries contain acid which is corrosive and poi sonous DO NOT allow battery acid to contact eyes skin fabrics or painted surfaces as serious personal injury or property damage could result Flush any contacted areas thoroughly with water immediately Always wear an acid resistant apron and face shield when attempting to jump start the compressor Remove all vent caps if so equipped from the battery or batteries in the compressor DO NOT permit dirt or foreign matter to enter the open
58. n For compressors with idle warm up controls switch toggle to RUN for full operation Plugged air filter Replace Defective idle warm up control Replace control Plugged air fluid separator Replace separator element and also change compressor fluid and fluid filter Defective pressure regulator Adjust or repair Engine speed too low Readjust engine speed Excessive compressor fluid consumption Clogged return line Clear orifice and return line strainer Lubrication system leak Check all pipes connections and components Separator element damaged or malfunctioning Change separator element 54 SULLAIR 125 130 49HP AND 185 USER MANUAL Section 6 NOISE CONTROL 6 1 NOISE EMISSIONS WARRANTY Sullair Corporation warrants to the ultimate purchaser and each subsequent purchaser that this air compressor was designed built and equipped to conform at the time of sale to the first retail purchaser with all applicable noise control regulations This warranty is not limited to any particular part component or system of the air compressor Defects in the design assembly or in any part component or system of the compressor which at the time of sale to the first retail purchaser caused noise emissions to exceed Federal standards are covered by this warranty for the life of the air compressor 6 2 TAMPERING WITH THE NOISE CONTROL SYSTEMIS PROHIBITED
59. n performing work Each person shall be provided with their own padlock and have possession of the only key If more than one person is working on a machine each person shall affix personal lock and tag using a multi lock device Tagout devices shall be used only when power sources are not capable of being locked out by use of padlocks and lockout hasp devices Name of person affixing tag to power source must be on tag along with date tag was placed on power source Release stored energy and bring the equipment to a zero mechanical state Verify Isolation Before work is started test equipment to ensure power is disconnected B General Security 1 The lock shall be removed by the Authorized person who put the lock on the energy isolating device No one other than the person persons placing padlock ad lockout hasp on power shall remove padlock and lockout hasps and restore power However when the authorized person who applied the lock is unavailable to remove it his her Supervisor may remove padlock padlocks and lockout hasps and restore power only if it is first a verified that no person will be exposed to danger b verified that the Authorized person who applied the device is not in the facility c noted that all reasonable efforts to con tact the Authorized person have been made to inform him or her that the lock out or tagout device has been removed SULLAIR SECTION 1 d ensured that t
60. n mm in mm Ib kg 125 130 49HP and 485 2 Wheel 130 8 3322 59 2 1504 53 8 1368 2130 966 125 130 49HP and 185 Less Running 69 1 1765 40 9 1040 41 7 1060 1885 855 Gear I Length over drawbar for 2 wheel version Table 3 8 Compressor Specifications John Deere Compressor 125 130 49HP 185 Type Rotary Screw Rotary Screw Rotary Screw Rotary Screw Maximum Operating Pressure 125 psig 8 6 bar 125 psig 8 6 bar 125 psig 8 6 bar 125 psig 8 6 bar Pressure Delivery 125 Free CFM 130 Free CFM 160 Free CFM 185 Free CFM 59 L S 61 L S 75 L S 87 L S Rated Pressure 100 psig 6 9 bar 100 psig 6 9 bar 100 psig 6 9 bar 100 psig 6 9 bar Cooling Pressurized Pressurized Pressurized Pressurized Compressor Fluid Compressor Fluid Compressor Fluid Compressor Fluid Lubricating Compressor Fluid See Section 3 4 See Section 3 4 See Section 3 4 See Section 3 4 Sump Capacit 3 US gallons 3 US gallons 3 US gallons 3 US gallons 11 liters 11 liters 11 liters 11 liters Track Width 50 9 1294 mm 50 9 1294 mm 50 9 1294 mm 50 9 1294 mm ise Load ST175 80D13 ST175 80D13 ST175 80D13 ST175 80D13 Tire Pressure Wheel Size 50 psig 3 5 bar 13x4 5 50 psig 3 5 bar 13x4 5 50 psig 3 5 bar 13x4 5 50 psig 3 5 bar 13 x 4 5 Lug Nut Torque 60 ft lbs 81 Nm 60 ft lbs 81 Nm 60 ft lbs 81 Nm 60 ft lbs 81 Nm Operating Tilt
61. n terms of reliability and durability Compressor internal components require no routine maintenance inspections SULLAIR 2 2 DESCRIPTION OF COMPONENTS Figure 2 1 shows the main components and subassemblies of the Sullair 125 130 49HP and 185 Standard Portable Air Compressors These packages include a heavy duty rotary screw air compressor a diesel engine fuel tank compressor 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 1 Minimum Pressure Check Valve 8 Compressor Air Filter 2 Radiator Fluid Cooler Assembly 9 Battery 3 Pressure Regulator amp Blowdown Manifold 10 Compressor Unit 4 Service Valves 11 Fluid Fill 5 Fuel Tank 12 Fluid Level Sight Glass 6 Engine Air Filter 13 Receiver Tank 7 Thermal Valve Compressor Fluid Filter Figure 2 1 Sullair Rotary Screw Portable Air Compressor 18 SULLAIR SECTION 2 The control system can easily be adjusted for pressures from 80 to 125 psig 5 6 to 8 6 bar The compressor unit is driven by an industrial diesel engine designed to provide enough horsepower to provide an adequate reserve under rated conditions Refer to the Engine Operator s Manual for a more detaile
62. ne starts 10 After 30 seconds the annunciator light will go off after 30 seconds Turn the IDLE WARM UP SWITCH from START to RUN to put the compressor in full operation 11 Close all doors to maintain proper noise level SHUTDOWN 1 Close the service valves and run the com pressor for approximately five minutes to allow the compressor to cool down 44 SECTION 4 2 Press the ENGINE SWITCH to the OFF position after five minutes 44 RESTART PROCEDURE After running and shutting down the compressor for the first time perform the following actions when restarting the compressor 1 Check engine oil engine coolant and fuel levels 2 Check the compressor fluid level sight glass and drain any water from the fuel water separator 3 Check the dust collectors and clean if neces sary 4 Crack open the service valve 5 Place the WARM UP control in the START position 6 Press the ENGINE SWITCH to the ON posi tion 7 n cold weather press the cold weather start ing aid button Hold button for 10 to 30 sec onds and then release 8 Momentarily press the ENGINE SWITCH to the START position to engage the starter release the switch when the engine starts 9 After 30 seconds the annunciator light will go off after 30 seconds Tum the IDLE WARM UP SWITCH from START to RUN to put the compressor in full operation 10 To shut down the compressor see Shutdown procedure on previous page D
63. ng The fluid return line tube should extend to the bottom of the sep arator element which will ensure proper return line flow Clean the fluid return line strainer and clear the orifice before starting the compressor After 24 hours of operation tighten the sump cover bolts to the value given in step 7 SU 0000670 Capscrew Washer Cover Separator Element with Gaskets m N gt Receiver Tank Air Fluid Separator Element P N 250034 112 Figure 5 3 Air Fluid Separator SULLAIR SECTION 5 PROCEDURE FOR SETTING SPEED AND PRESSURE CONTROLS ON PORTABLE COMPRESSORS EQUIPPED WITH POPPET VALVES Refer to Figure 5 4 Before adjusting the compressors control system the rated full load pressure and the high low rpm settings must be determined This information is provided in Section 3 or can be obtained by contacting a Sullair representative Receiver Tank Compressor Unit Engine Speed Control Cylinder 1 2 3 4 Pressure Regulator Blowdown Manifold Warm up Control Valve 6 Air Pressure Gauge 125 130 49HP AND 185 USER MANUAL The following procedure applies to a compressor with full load pressure rating of 100 psig 6 9 bar 1 Start the compressor and allow the engine to warm up to its normal operating temperature with the service valve closed 2 With the service valve closed set the engine low speed idle to its specified setting with the idle stop screw on the en
64. nitors the pressure inside the receiver tank at various load and unload conditions FLUID SIGHT LEVEL GLASS Indicates the fluid level in the receiver tank Proper level is marked halfway up the sight glass Check the level when the compressor is shutdown and on level ground SULLAIR COMPRESSOR DISCHARGE TEMPERATURE SWITCH Opens the electrical circuit to shut down the compressor when discharge temperature reaches a specific value See Specifications on page 35 THERMAL VALVE Functions as a temperature regulator by directing the compressor fluid either to the cooler or to the compressor unit MINIMUM PRESSURE DEVICE Maintains the minimum of 80 psig 5 6 bar in the compressor sump PRESSURE RELIEF VALVE Vents sump pressure to the atmosphere if pressure inside the sump exceeds 200 psig 13 8 bar AIR INLET VALVE Regulates the amount of air allowed to enter the air compressor inlet Regulation is determined by a signal from the pressure regulator s PRESSURE REGULATOR Allows the pressure signal to reach the engine speed control and the air inlet valve to control air delivery according to demand SHUTDOWN SYSTEM ANNUNCIATOR MODULE SSAM Monitors the compressor safety system for conditions requiring shutdown The annunciator on the instrument control will flash the applicable shutdown code BLOWDOWN VALVE Vents sump pressure to shutdown IDLE WARM UP CONTROL Keeps the compressor inlet valv
65. on any machine shall be locked out by each employee doing the work except when motion is necessary during setup adjustment or trouble shooting A 12 The established procedures for the application of energy control shall cover the following elements and actions and shall be initiated only by Autho rized Persons and done in the following sequence 1 Review the equipment or machine to be locked and tagged out 2 Alert operator and supervisor of which machine is to be worked on and that power and utilities will be turned off 3 Check to make certain no one is operating the machine before turning off the power 4 Tum off the equipment shutdown procedure using normal 5 Disconnect the energy sources a Air and hydraulic lines should be bled drained and cleaned out There should be no pressure in these lines or in the SECTION 1 reservoir tanks Lockout or tag lines or valves b Any mechanism under tension or pres sure such as springs should be released and locked out or tagged c Block any load or machine part prior to working under it d Electrical circuits should be checked with calibrated electrical testing equipment and stored energy and electrical capaci tors should be safely discharged Lockout and or Tagout each energy source using the proper energy isolating devices and tags Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each perso
66. proper engine coolant specifications and instructions Ensure that the proper coolant is used when adding engine coolant to the machine If you are not sure of the coolant that is installed originally or want to change to a different type the cooling system must be cleaned with a commercial cleaning agent and completely flushed and filled with distilled water several times to remove all traces of old coolant Then fill the system with the recommended coolant using only one brand type Cross contamination which is caused by adding different types of engine coolants may result in the coolant additives to deplete dropout thus leaving radiator surfaces unprotected SULLAIR Corrosion to radiator surfaces may occur thus reducing radiator life expectancy It is extremely important to evacuate purge all air within the cooling system before replacing the radiator cap 5 3 DAILY MAINTENANCE See Initial Startup Shutdown Procedure for general operation The radiator and engine cooling system must be drained and flushed periodically Refer to the OEM Engine Manual for more information Replace the coolant with a solution of 50 ethylene glycol and 50 water or as required for your geographic location DO NOT use a leak sealing type of antifreeze Should a 100 water solution be used a non chromate rust inhibitor must be added DO NOT mix coolant types Dispose of fluids in accordance with applicable federal st
67. ructure whether towing forward or backing up regard less of the terrain being traversed G DO NOT permit personnel to ride in or on the compressor H Make sure the area behind in front of and under the compressor is clear of all personnel and obstructions prior to towing in any direction l DO NOT permit personnel to stand or ride on the drawbar or to stand or walk between the com pressor and the towing vehicle PARKING OR LOCATING COMPRESSOR A Park or locate compressor on a level surface if possible If not park or locate compressor across grade so the compressor does not tend to roll downhill DO NOT park or locate compressor on grades exceeding 15 27 B Make sure compressor is parked or located on a firm surface that can support its weight C Park or locate compressor so the wind if any tends to carry the exhaust fumes and radiator heat away from the compressor air inlet open ings and also where the compressor will not be exposed to excessive dust from the work site D On steerable models park compressor with front wheels in straight ahead position E Set parking brakes and disconnect breakaway switch cable and all other interconnecting electri cal and or brake connections if provided Block or chock both sides of all wheels If provided unhook chains and remove them from the points of chain attachment on the towing vehicle then hook chains to bail on drawbar or wrap chains around the dra
68. sor with defective engine mounting system Remove and replace defective parts by ordering with part numbers indicated in Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date 4 ANNUAL FRAME CANOPY AND PARTS INSPECTION At least annually inspect frame canopy and parts for security of attachment Make sure there are not any missing or deformed members including all hinged doors covers and their fastening devices DO NOT operate compressor with defective frame canopy and parts Remove and replace defective parts by ordering with part numbers indicated in Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date 5 ANNUAL ACOUSTICAL MATERIALS INSPECTION At least annually inspect all acoustical materials if any for security of attachment Make sure that there is not any material missing or damaged refer to Parts List Clean or replace if necessary DO NOT operate compressor with defective acoustical material Remove and replace defective parts by ordering with part numbers indicated in the Parts List Maintenance Performed By Location Date Maintenance Performed By Location Date SULLAIR 57 125 130 49HP AND 185 USER MANUAL SECTION 6 6 ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS In a
69. the compressor engine block away from fuel lines the crank case breather opening and the battery Start the compressor in accordance with normal procedure Avoid prolonged cranking Allow the compressor to warm up When the compressor is warm and operating smoothly at 11 normal idle RPM disconnect the jumper cable from the engine block in the compressor then disconnect the other end of this same cable from the grounded negative NEG terminal of the battery in the starting vehicle Then disconnect the other jumper cable from the positive POS terminal of the battery in the compressor or if provided with two 2 12V batteries connected in series from the ungrounded battery in the com pressor and finally disconnect the other end of this same jumper cable from the positive POS terminal of the battery in the starting vehicle or from the positive POS terminal of the ungrounded battery in the starting vehicle if it is provided with two 2 12V batteries connected in series V Remove and carefully dispose of the dampened cloths as they may now be contaminated with acid then replace all vent caps 1 12 IMPLEMENTATION OF The energy control LOCKOUT TAGOUT procedure defines actions necessary to lockout a power source of any machine to be repaired serviced or set up where unexpected motion or an electrical or other energy source would cause personal injury or equipment damage The power source
70. the coolant temperature reaches 225 F 107 C and an oil pressure switch that will shut down the compressor if the engine oil pressure goes too low An underspeed sensor shuts down the compressor if the engine speed falls below 1500 rpm SULLAIR 125 130 49HP AND 185 USER MANUAL 2 14 COMPRESSOR SHUTDOWN amp WARNING SYSTEM FUNCTIONAL DESCRIPTION The Shutdown System and Annunciator Module SSAM continuously monitors the status of the compressor In the event of a shutdown condition the SSAM will shut down the compressor and display flashing the appropriate code on the instrument panel annunciator light The display will continue flashing until the ignition switch is turned OFF The shutdown codes are One flash high compressor discharge temperature Two flashes high engine coolant temperature Three flashes low engine oil pressure Four flashes low engine speed Five flashes low fuel level optional The SSAM also provides startup logic for the compressor When the ignition switch is in the ON position the annunciator light will illuminate for 30 seconds During this 30 second period pressing the ignition switch will engage the engine starter The low engine speed switch is inactive during this startup time interval By the end of these 30 seconds the annunciator light goes out and the engine START cycle is disabled At this time the system runs all safety checks including low fuel level if installed
71. tion from the field It lists symptoms probable causes and remedies This chart does not cover all possible malfunctions or cases of abnormal operation Before undertaking repairs or replacement actions analyze all of the available data Performing a detailed visual inspection in all cases can prevent additional damage or abnormal operation Table 5 1 Troubleshooting SECTION 5 Always 1 Check for loose wiring or connections 2 Check for damaged piping 3 Check for heat damage to parts electrical short circuits can cause heat damage which can appear as discolorations or the presence of a burnt odor If the troubleshooting remedy does not work or the malfunction is not covered in this Troubleshooting chart contact your nearest Sullair representative or Sullair for technical assistance ENGINE STOPS DOES NOT CRANK OR CRANKS BUT DOES NOT START SYMPTOM PROBABLE CAUSE REMEDY NO SSAM FLASH CODE Low voltage or battery disconnected Check battery cables and tighten if loose Check ground wire for proper attachment to frame Tighten if required Recharge or replace battery if required Blown fuse in wiring harness Remove and inspect fuse Replace if necessary disconnected Instrument panel connectors loose or Check instrument panel connectors and reattach if required Check instrument panel wires for broken connections or corrosion Clean and or replace if damaged
72. to yourself or others Keep hands and fingers clear of the coupling device and all other pinch points Keep feet clear of drawbar to avoid injury in case it should slip from your hands D Make sure the coupling device is fully engaged E closed and locked If chains are provided pass each chain through its point of attachment on the towing vehicle then hook each chain to itself by passing the grab hook over not through a link Cross chains under front of drawbar before passing them through points of attachment on towing vehicle to support front of drawbar in case it should acci dentally become uncoupled Make sure that the coupling device and adjacent structures on the towing vehicle and also if uti lized chain adjustment brake and or electrical interconnections DO NOT interfere with or restrict motion of any part of the compressor including its coupling device with respect to the towing vehicle when maneuvering over any anticipated terrain G SECTION 1 If provided make sure chain length brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering yet are supported so they cannot drag or rub on road terrain or towing vehicle sur faces which might cause wear that could render them inoperative AX WARNING This equipment may be tongue heavy DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can saf
73. tor Check the engine rpm idle speed The idle speed should be at the specified minimum idle speed listed in Section 3 The fluid change period varies by fluid brand Refer to Section 3 4 6 Clean or replace the return line strainer 7 Change the air filter primary elements 8 Change the compressor fluid filter 9 Clean the return line orifice 46 Operating the compressor below its mini mum specified idle speed will damage the compressor Operating the compressor in this condition will cause coupling and or compressor failure 5 8 MAINTENANCE EVERY 1500 HOURS If the compressor fluid is Sullair AWF change the fluid and replace the fluid filter element See Compressor Fluid Filter Ele ment Replacement on page 47 Service the engine cooling system Lubricate axle bearings on wheel mounted units 5 9 PART REPLACEMENT AND ADJUSTMENT PROCEDURES COMPRESSOR FLUID CHANGE PROCEDURE Run the compressor five to ten minutes to warm the fluid Shut the compressor down and relieve all internal pressure Drain the fluid sump by removing the plug or opening the valve at the bottom of the sump tank Change the compressor fluid and replace the fluid filter element For element replacement see the filter servicing procedure in this Sec tion Fill the sump with fluid in accordance with the specifications in Section 3 SULLAIR SECTION 5 COMPRESSOR FLUID FILTER ELEMENT REPLACEMENT
74. tor s Manual SSAM FLASH CODE THREE FLASHES Engine oil pressure switch is open Check wiring connection to switch and tighten if necessary Install gauge in parallel with the switch Replace the switch if the pressure exceeds 15 psig and stays open If the pressure is less than 15 psig refer to the Engine Operator s Manual SSAM FLASH CODE FOUR FLASHES Did not start compressor within the 30 seconds from turning the ignition switch to the ON position After turning the ignition switch to the ON position press the switch to the START position within 30 seconds Low battery voltage Check the battery cables and tighten if necessary Recharge or replace battery if necessary 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 Plugged air filter Clean and replace if necessary Plugged fuel filter Replace the fuel filter Engine problems Turn the compressor OFF See the Engine Warning Shutdown Table for probable causes 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 FIVE FLASHES No fuel Check fuel level and fill tank if empty Defective fuel switc
75. ue 60 ft Ibs 81 Nm 60 ft Ibs 81 Nm 60 ft Ibs 81 Nm Operating Tilt maximum 15 15 15 Electrical System 12 volt 12 volt 12 volt Compressor Discharge Temperature Shutdown 250 F 121 C 250 F 121 C 250 F 121 C Service Valves 2 3 4 2 3 4 2 3 4 Maximum Towing Speed 55 mph 88 kmph 55 mph 88 kmph 55 mph 88 kmph Axle Rating 3700 Ibs 1678 kg 3700 Ibs 1678 kg 3700 Ibs 1678 kg Sound Level US EPA 76 dBA at 7 m SULLAIR 76 dBA at 7 m 76 dBA at 7 m 35 125 130 49HP AND 185 USER MANUAL Table 3 3 Engine Specifcations Caterpillar SECTION 3 Engine 125 130 185 Type Diesel Diesel Diesel Make Caterpillar Caterpillar Caterpillar Model C2 2 C2 2 C2 2 U S EPA Tier 3 U S EPA Tier 3 U S EPA Tier 3 Emission Level European Stage IIIA European Stage IIIA European Stage IIIA Displacement 134 cu in 2 2 L 134 cu in 2 2 L 134 cu in 2 2 L Cylinders 4 4 4 EE 3 30 x 3 90 in 3 30 x 3 90 in 3 30 x 3 90 in 84 0 x 100 0 mm 84 0 x 100 0 mm 84 0 x 100 0 mm Rated Speed 2550 RPM 2650 RPM 2800 RPM Rated Power 60 HP 44 8 kW 60 HP 44 8 kW 60 HP 44 8 kW Type of Motor Oil See Engine Operator Manual See Engine Operator Manual See Engine Operator Manual Fuel Tank Capacity 20 Gallons 76 liters 20 Gallons 76 liters 20 Gallons
76. ure regulating valve closes the air inlet valve opens fully and the engine speed increases to its preset full load rating Between the pressure regulating valve and the inlet valve there is a small orifice that vents a small amount of air into the atmosphere when the pressure regulating valve is open This allows changes in air output to conform to air demand This orifice also discharges any accumulated moisture from the regulator SHUTDOWN The blowdown valve is normally closed At shutdown the back pressure in the compressor inlet signals the blowdown valve to vent the sump pressure into the atmosphere 28 SECTION 2 2 9 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION The air inlet system consists of two air filters a compressor air inlet valve and interconnecting piping to the engine and the compressor The air filters are two stage dry element type filters that are capable of cleaning extremely dirty air However when operating in dirty environments the filters should be checked more frequently See Air Filter Maintenance on page 47 for Air Filter Maintenance Procedures SULLAIR SECTION 2 2 10 Refer to Figure 2 5 for the locations of the following INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION indicators and controls 1 The air pressure gauge continuously moni tors the sump pressure under various load conditions The engine switch energizes the system and starts the compressor The engine switch
77. ve electrical parts such as terminals to avoid arcing which might serve as a source of ignition Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them DO NOT store or attempt to operate the compressor with any known leaks in the fuel sys tem Tag the compressor and render it inopera tive until repair can be made Remove any acoustical material or other material that may be damaged by heat or that may sup port combustion prior to attempting weld repairs Remove diesel engine ether starting aid cylin ders and air line anti icer system components containing antifreeze compound prior to attempting weld repairs in any place other than the fuel system DO NOT weld on or near the fuel system Keep a suitable fully charged class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor Keep oily rags trash leaves litter or other com bustibles out of and away from the compressor Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine SECTION 1 N DO NOT operate compressor under low over hanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas Ethyl ether used in diesel engine ether starting aid systems is extremely flammable Change cyl inders or maintain or troubleshoot these sys tems only in well ventilat
78. wbar and hook them to themselves to keep chains off the ground which might accelerate rusting Lower front screw jack and or any front and rear stabilizer legs Make sure the surface they con tact has sufficient load bearing capability to sup port the weight of the compressor Ay WARNING This equipment may be tongue heavy DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle CAUTION Retract the front screw jack only after 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 the drawbar Rotate the screw jack to its stowed position parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing On two wheeled models fully retract front screw jack and any rear stabilizer legs If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position Rotate the screw jack to its stowed posi tion parallel to the drawbar and reinsert the pin Make sure the jack is secured in place prior to towing If a caster wheel is provided on the screw jack it is part of the screw jack and cannot be removed
79. ys and other moving parts DO NOT attempt to operate the compressor with the fan or other guards removed Wear snug fitting clothing and confine long hair when working around this compressor especially SULLAIR SECTION 1 when exposed to hot or moving parts inside the enclosure Keep access doors closed except when making repairs or adjustments performing service or when starting or stopping the compressor Make sure all personnel are out of and clear of the compressor prior to attempting to start or operate it Shut off engine before adding fuel fluid coolant lubricants air line antifreeze compound or bat tery electrolyte or before replacing ether starting aid cylinders 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 When adjusting the controls it may require oper ation of the equipment during adjustment DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM Make all other adjustments with the engine shut off When necessary make adjustment other than setting control regulator and engine RPM with the engine shut off If nec essary start the engine and check adjustment If adjustment is incorrect shut engine off readjust then restart the engine to recheck adjustment Keep hands fe

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