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Documente Cultură
SULLAIR
PARTS LIST
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PPORTABLE
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ompressor
600H,600HH,
600H, 750, 750H,750,750HH,
750H
750HH,825,
825,900H,
900, 900H,
1050 1050
Caterpillar
Caterpillar
M ANU ALAND
O PERATO R’SMANUAL
OPERATOR’S
PartNUMBER:
PART Number:
02250167-521 REV. 02
02250167-521
keepFOR
KEEP for
future
FUTURE
reference
REFERENCE
©©SullairCORPORATION
SULLAIR corporation
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The informationininthis
this document
document is
is correct
correct attime
at the the time of printing
of printing for
for utility
portable compressor
compressor serial number
serial number
200612200101
20061215XXXX
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and subsequentserial
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numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenance
and service of Sullair equipment. Individual seminars on portable compressors are presented at regular intervals
throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the
most common problems, and actual equipment operation. The seminars are recommended for Rental House,
Contractor Maintenance and Service Personnel.
: 1-888-SULLAIR or
219-879-5451 (ext. 5363)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
TABLE OF CONTENTS
1 - SAFETY............................................................................................................ 1
General............................................................................................................ 1
Towing (I) ....................................................................................................... 1
Preparing To Tow....................................................................................... 1
Towing ...................................................................................................... 3
Parking Or Locating Compressor.............................................................. 3
Pressure Release............................................................................................ 4
Fire And Explosion........................................................................................... 5
Moving Parts.................................................................................................... 6
Hot Surfaces, Sharp Edges And Sharp Corners.............................................. 6
Toxic And Irritating Substances........................................................................ 6
Electrical Shock............................................................................................... 7
Lifting............................................................................................................... 7
Entrapment...................................................................................................... 8
Jump Starting................................................................................................... 8
Implementation of Lockout/Tagout................................................................... 9
California Proposition 65 . ................................................................................. 9
Symbols and References............................................................................... 10
2 - DESCRIPTION................................................................................................ 13
Introduction ................................................................................................... 13
Description Of Components........................................................................... 13
Sullair Compressor Unit, Functional Description........................................... 16
Compressor Cooling And Lubrication System, Functional Description . ....... 17
Capacity Control System, Functional Description.......................................... 19
Start - 0 to 65 psig (0 to 4.5 bar) ............................................................ 19
Low Pressure - 80 to 100 psig(5.5 to 6.9 bar) ........................................ 19
High Pressure - 80 to 150 psig (5.5 to 10.3 bar) for “H” models or 80
to 175 psig (5.5 to 12.1 bar) for “HH” models ......................................... 19
Shutdown ............................................................................................... 19
Compressor Discharge System, Functional Description................................ 22
aftercooled air System, Functional Description.............................................. 23
Air Inlet System, Functional Description ....................................................... 24
Piping and Instrumentation Diagram—Compressor...................................... 26
Instrument Panel Group, Functional Description........................................... 30
Engine Control Module, Functional Description............................................. 31
Electrical System, Functional Description...................................................... 34
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List iii
SECTION 7
3 - Specifications.......................................................................................... 43
Table Of Specifications – 600h, 750, 750h, 750hh........................................ 43
Table Of Specifications—825, 900, 900h, 1050............................................. 45
Lubrication Guide – Compressor................................................................... 46
Application Guide........................................................................................... 47
Lubrication Guide – Engine............................................................................ 47
Identification, Tandem Axle............................................................................ 48
Identification, 4-Wheel................................................................................... 50
Identification, Less Running Gear.................................................................. 52
4 - OPERATION................................................................................................... 55
General.......................................................................................................... 55
Purpose Of Controls...................................................................................... 55
Compressor Start-Up Procedure .................................................................. 57
Shutdown Procedure..................................................................................... 58
5 - MAINTENANCE.............................................................................................. 59
General.......................................................................................................... 59
Daily Operation.............................................................................................. 59
Engine Coolant.............................................................................................. 59
Maintenance After Initial 50 Hours Of Operation........................................... 60
Maintenance Every 100 Hours....................................................................... 60
Maintenance Every 250 Hours....................................................................... 60
Maintenance Every 300 Hours....................................................................... 60
Maintenance Every 600 Hours....................................................................... 60
Maintenance Every 1000 Hours..................................................................... 60
Maintenance Every 1500 Hours..................................................................... 60
Parts Replacement And Adjustment Procedures........................................... 61
Compressor Fluid Change Procedure..................................................... 61
Running Gear Lubrication........................................................................ 61
Wheel Bearing Lubrication...................................................................... 62
Main Fluid Filter Servicing....................................................................... 62
Air Filter Maintenance.............................................................................. 63
Main Fluid Filter Assembly and Thermostat ........................................... 63
Element Removal.................................................................................... 64
Element Inspection.................................................................................. 64
Primary Element Replacement................................................................ 64
Control System Adjustment..................................................................... 65
Control System Components................................................................... 66
Separator Element Replacement............................................................ 67
Troubleshooting Guide................................................................................... 68
6 - NOISE CONTROL.......................................................................................... 71
Noise Emissions Warranty............................................................................. 71
Tampering with the Noise Control System is Prohibited................................ 71
Noise Emissions Maintenance and Maintenance Record Log....................... 72
7 - ILLUSTRATIONS AND PARTS LIST............................................................. 75
Procedure for Ordering Parts......................................................................... 75
Recommended Spare Parts List.................................................................... 78
Engine Assembly And Mounting.................................................................... 84
Exhaust System............................................................................................. 88
Cooler Assembly, Standard............................................................................ 90
Cooling System, Non-Aftercooled.................................................................. 94
Cooling System, Aftercooled.......................................................................... 98
Compressor Oil Filter Sub-Assembly With Thermostat............................... 102
Air Controls Manifold, Single Pressure........................................................ 104
Air Controls Manifold, dual Pressure........................................................... 106
iv 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Table of Contents
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List v
SECTION 7
vi 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 1
SAFETY
DO NOT modify the compressor except with written
NOTE factory approval.
Each day, walk around the air compressor and inspect for
leaks, loose or missing parts, damaged parts or parts out
of adjustment. Perform all recommended daily
maintenance.
Inspect for torn, frayed, blistered or otherwise deteriorated
and degraded hoses. Replace as required.
(I) While not towed in the usual sense of the word, many of these instructions are directly applicable to skid-mounted portable air
compressors as well.
1
SECTION 1
A. Prior to hitching the air compressor to the tow vehicle, G. If provided, make sure chain length, brake and
inspect all attachment parts and equipment, checking electrical interconnections provide sufficient slack to
for (i) signs of excessive wear or corrosion, (ii) parts prevent strain when cornering and maneuvering, yet
that are cracked, bent, dented or otherwise deformed are supported so they cannot drag or rub on road,
or degraded, and (iii) loose nuts, bolts or other terrain or towing vehicle surfaces which might cause
fasteners. Should any such condition be present, DO wear that could render them inoperative.
NOT TOW until the problem is corrected.
B. Back the tow vehicle to the compressor and position WARNING
it in preparation for coupling the compressor.
This equipment may be tongue heavy.
C. If the compressor is provided with a drawbar latched
in the vertical upright position, carefully unlatch DO NOT attempt to raise or lower the
drawbar and lower it to engage the coupling device. If drawbar by hand if the weight is more
not, raise drawbar to engage coupling device or than you can safely handle.
otherwise couple the compressor to the towing
vehicle.
CAUTION
WARNING Retract the front screw jack only
after attaching the compressor to the
This equipment may be tongue heavy. tow vehicle. Raise the screw jack to
DO NOT attempt to raise or lower the its full up position and pull the pin
drawbar by hand if the weight is more connecting the jack to the drawbar.
than you can safely handle. Rotate the screw jack to its stowed
position, parallel to the drawbar, and
Use the screw jack provided or a reinsert the pin. Make sure the jack is
chain fall if you cannot lift or lower secured in place prior to towing.
it without avoiding injury to yourself
or others. Keep hands and fingers If a caster wheel is provided on the
clear of the coupling device and all screw jack it is part of the screw jack
other pinch points. Keep feet clear and can not be removed. Follow the
of drawbar to avoid injury in case it same procedure for stowing away
should slip from your hands. the wheeled jack as you would for
the standard screw jack. Pull the pin
connecting the jack to the drawbar
D. Make sure the coupling device is fully engaged, and raise the screw jack to its full
closed and locked. up position. Rotate the screw jack
E. If chains are provided, pass each chain through its to its stowed position, parallel to the
point of attachment on the towing vehicle; then hook drawbar, and reinsert the pin. Make
each chain to itself by passing the grab hook over sure the jack is secured in place prior
(not through) a link. Cross chains under front of to towing.
drawbar before passing them through points of
attachment on towing vehicle to support front of H. On two-wheeled models, fully retract front screw jack
drawbar in case it should accidentally become and any rear stabilizer legs. If a caster wheel is
uncoupled. provided on the screw jack it is part of the screw jack,
F. Make sure that the coupling device and adjacent and can not be removed. Follow the same procedure
structures on the towing vehicle (and also, if utilized, for stowing away the wheeled jack as you would for
chain adjustment, brake and/or electrical the standard screw jack. Pull the pin connecting the
interconnections) DO NOT interfere with or restrict jack to the drawbar and raise the screw jack to its full
motion of any part of the compressor, including its upright position. Rotate the screw jack to its stowed
coupling device, with respect to the towing vehicle position, parallel to the drawbar, and reinsert the pin.
when maneuvering over any anticipated terrain. Make sure the jack is secured in place prior to towing.
I. Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire size or
type. Also, make sure wheel bolts, lugs or nuts are
tightened to the specified torques.
2
SAFETY
J. If provided, make sure all dual stop, tail directional F. Maneuver in a manner that will not exceed the
and clearance lights are operating properly and that freedom of motion of the compressor’s drawbar and/
their lenses are clean and functional. Also, make sure or coupling device, in or on the towing vehicle’s
all reflectors and reflecting surfaces, including the coupling device and/or adjacent structure whether
slow moving vehicle emblem on compressors towing forward or backing up, regardless of the
provided with same, are clean and functional. terrain being traversed.
K. Make sure all service air hoses (not air brake hoses) G. DO NOT permit personnel to ride in or on the
are disconnected or are fully stowed and secured on compressor.
hose reels, if provided.
H. Make sure the area behind, in front of, and under the
L. Make sure all access doors and tool box covers are compressor is clear of all personnel and obstructions
closed and latched. If the compressor is large enough prior to towing in any direction.
to hold a man, make sure all personnel are out before
closing and latching access doors. I. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compressor
M. Make sure parking brakes in towing vehicle are set, and the towing vehicle.
or that its wheels are chocked or blocked, or that it is
otherwise restrained from moving. Then, release the Parking Or Locating Compressor
compressor parking brakes, if provided. A. Park or locate compressor on a level surface, if
N. Make sure the compressor wheels are not chocked possible. If not, park or locate compressor across
or blocked, and that all tie-downs, if any, are free. grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on
O. Test running brake operation, including breakaway grades exceeding 15̊ (27%).
switch operation if provided, before attempting to tow
the compressor at its rated speed or less when B. Make sure compressor is parked or located on a firm
conditions prevail. surface that can support its weight.
P. DO NOT carry loose or inappropriate tools, C. Park or locate compressor so the wind, if any, tends
equipment or supplies on or in the compressor. to carry the exhaust fumes and radiator heat away
from the compressor air inlet openings, and also
Q. DO NOT load this equipment with accessories or where the compressor will not be exposed to
tools such that it is unbalanced from side to side or excessive dust from the work site.
front to back. Such unbalance will reduce the
towability of this equipment and may increase the D. On steerable models, park compressor with front
possibility of tipping, rolling over, jackknifing, etc. wheels in straight-ahead position.
Loss of control of the towing vehicle may result. E. Set parking brakes and disconnect breakaway switch
Towing cable and all other interconnecting electrical and/or
brake connections, if provided.
A. O
bserve all Federal, State, and Local laws while
towing this equipment (including those specifying F. Block or chock both sides of all wheels.
minimum speed). G. If provided, unhook chains and remove them from the
B. DO NOT exceed the towing speeds listed below points of chain attachment on the towing vehicle,
under ideal conditions. Reduce your speed according then hook chains to bail on drawbar or wrap chains
to posted speed limits, weather, traffic, road or terrain around the drawbar and hook them to themselves to
conditions: keep chains off the ground which might accelerate
rusting.
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 15̊ (27%).
E. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain.
3
SECTION 1
H. Lower front screw jack and/or any front and rear K. When possible, stow hinged drawbar in the vertical
stabilizer legs. Make sure the surface they contact upright position. Make certain it is securely latched in
has sufficient load bearing capability to support the the vertical upright position. Keep feet clear of
weight of the compressor. drawbar at all times to avoid crushing accidents in
case it should slip from your hands or otherwise fall
WARNING to the ground.
L. Move the towing vehicle well clear of the parked
This equipment may be tongue heavy. compressor and erect hazard indicators, barricades
DO NOT attempt to raise or lower the and/or flares (if at night) if compressor is parked on or
drawbar by hand if the weight is more adjacent to public roads. Park so as not to interfere
than you can safely handle. with traffic.
NOTE
CAUTION
While not towed in the usual sense of
Retract the front screw jack only the word, many of these instructions
after attaching the compressor to the are directly applicable to skid-
tow vehicle. Raise the screw jack to mounted portable air compressors as
its full up position and pull the pin well.
connecting the jack to the drawbar.
Rotate the screw jack to its stowed
position, parallel to the drawbar, and 1.3 Pressure Release
reinsert the pin. Make sure the jack is A. Open the pressure relief valve at least weekly to
secured in place prior to towing. make sure it is not blocked, closed, obstructed or
On two-wheeled models, fully otherwise disabled.
retract front screw jack and any rear B. Install an appropriate flow-limiting valve between the
stabilizer legs. If a caster wheel is compressor service air outlet and the shutoff (throttle)
provided on the screw jack it is part valve, when an air hose exceeding 1/2" (13 mm)
of the screw jack and can not be inside diameter is to be connected to the shutoff
removed. Follow the same procedure (throttle) valve, to reduce pressure in case of hose
failure, per OSHA Standard 29 CFR 1926.302 (b) (7)
for stowing away the wheeled jack or any applicable Federal, State and Local codes,
as you would for the standard screw standards and regulations.
jack. Pull the pin connecting the jack
to the drawbar and raise the screw C. When the hose is to be used to supply a manifold,
install an additional appropriate flow-limiting valve
jack to its full up position. Rotate the between the manifold and each air hose exceeding
screw jack to its stowed position, 1/2" (13 mm) inside diameter that is to be connected
parallel to the drawbar, and reinsert to the manifold to reduce pressure in case of hose
the pin. Make sure the jack is secured failure.
in place prior to towing. D. Provide an appropriate flow-limiting valve for each
additional 75 feet (23 m) of hose in runs of air hose
I. If a caster wheel is provided on the screw jack, it is exceeding 1/2" (13 mm) inside diameter to reduce
part of the screw jack and cannot be removed. Follow pressure in case of hose failure.
the same procedure for stowing away the wheeled
jack as you would for the standard screw jack. Raise E. Flow-limiting valves are listed by pipe size and rated
the screw jack to its full upright position and pull the CFM. Select appropriate valve accordingly.
pin connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the F. DO NOT use tools that are rated below the maximum
drawbar and reinsert the pin. Make sure the jack is rating of this compressor. Select tools, air hoses,
secured in place prior to towing. pipes, valves, filters and other fittings accordingly. DO
NOT exceed manufacturer’s rated safe operating
J. Disconnect coupling device, keeping hands and pressures for these items.
fingers clear of all pinch points. If the compressor is
provided with a drawbar, DO NOT attempt to lift the G. Secure all hose connections by wire, chain or other
drawbar or if hinged, to raise it to the upright position suitable retaining device to prevent tools or hose
by hand, if the weight is more than you can safely ends from being accidentally disconnected and
handle. Use a screwjack or chain fall if you cannot lift expelled.
or raise the drawbar without avoiding injury to H. Open fluid filler cap only when compressor is not
yourself or others. running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to zero
internal pressure before removing the cap.
4
SAFETY
I. Vent all internal pressure prior to opening any line, B. Clean up spills of fuel, fluid, battery electrolyte or
fitting, hose, valve, drain plug, connection or other coolant immediately if such spills occur.
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems C. Shut off air compressor and allow it to cool. Then
with antifreeze compound. keep sparks, flames and other sources of ignition
away and DO NOT permit smoking in the vicinity
J. Keep personnel out of line with and away from the when adding fuel, or when checking or adding
discharge opening of hoses, tools or other points of electrolyte to batteries, or when checking or adding
compressed air discharge. fluid, or when checking diesel engine ether starting
aid systems or replacing cylinders, or when refilling
K. DO NOT use air at pressures higher than 30 psig (2.1 air line anti-icer systems antifreeze compound.
bar) for cleaning purposes, and then only with
effective chip guarding and personal protective D. DO NOT permit liquids, including air line anti-icer
equipment per OSHA Standard 29 CFR 1910.242 (b) system antifreeze compound or fluid film, to
or any applicable Federal, State and Local codes, accumulate on bottom covers or on, under or around
standards and regulations. acoustical material, or on any external or internal
surfaces of the air compressor. Wipe down using an
L. DO NOT engage in horseplay with air hoses as death aqueous industrial cleaner or steam clean as
or serious injury may result. required. If necessary, remove acoustical material,
M. This equipment is supplied with an ASME designed clean all surfaces and then replace acoustical
pressure vessel protected by an ASME rated relief material. Any acoustical material with a protective
valve. Lift the handle once a week to make sure the covering that has been torn or punctured should be
valve is functional. DO NOT lift the handle while replaced immediately to prevent accumulation of
machine is under pressure. liquids or fluid film within the material. DO NOT use
flammable solvents for cleaning purposes.
N. If the machine is installed in an enclosed area it is
necessary to vent the relief valve to the outside of the E. Disconnect the grounded (negative) battery
structure or to an area of non-exposure. connection prior to attempting any repairs or
cleaning inside the enclosure. Tag the battery
O. DO NOT remove radiator filler cap until the coolant connections so others will not unexpectedly
temperature is below its boiling point. Then loosen reconnect it.
cap slowly to its stop to relieve any excess pressure
and make sure coolant is not boiling before removing F. Keep electrical wiring, including the battery terminals
cap completely. Remove radiator filler cap only when and other terminals, in good condition. Replace any
cool enough to touch with a bare hand. wiring that has cracked, cut abraded or otherwise
degraded insulation or terminals that are worn,
P. The ethyl ether in the replaceable cylinders used in discolored or corroded. Keep all terminals clean and
diesel ether starting aid systems (optional) is under tight.
pressure. DO NOT puncture or incinerate those
cylinders. DO NOT attempt to remove the center G. Turn off battery charger before making or breaking
valve core or side pressure relief valve from these connections to the battery.
cylinders regardless of whether they are full or empty. H. Keep grounded conductive objects such as tools
Q. If a manual blowdown valve is provided on the away from exposed live electrical parts such as
receiver, open the valve to ensure all internal terminals to avoid arcing which might serve as a
pressure has been vented prior to servicing any source of ignition.
pressurized component of the compressor air/fluid I. Replace damaged fuel tanks or lines immediately
system. rather than attempt to weld or otherwise repair them.
DO NOT store or attempt to operate the compressor
1.4 Fire And Explosion with any known leaks in the fuel system. Tag the
compressor and render it inoperative until repair can
WARNING be made.
Do not attempt to operate the J. Remove any acoustical material or other material that
may be damaged by heat or that may support
compressor in any classification of combustion prior to attempting weld repairs. Remove
hazardous environment or potentially diesel engine ether starting aid cylinders and air line
explosive atmosphere unless the anti-icer system components containing antifreeze
compressor has been specially compound, prior to attempting weld repairs in any
designed and manufactured for that place other than the fuel system. DO NOT weld on or
duty. near the fuel system.
A. Refuel at a service station or from a fuel tank K. Keep a suitable, fully charged class BC or ABC fire
designed for its intended purpose. If this is not extinguisher or extinguishers nearby when servicing
possible, ground the compressor to the dispenser and operating the compressor.
prior to refueling.
5
SECTION 1
L. Keep oily rags, trash, leaves, litter or other G. Turn the battery disconnect switch to the off position
combustibles out of and away from the compressor. to prevent accidental engine operation prior to
attempting repairs or adjustments. Tag the battery
M. Open all access doors and allow the enclosure to connection so others will not unexpectedly reconnect
ventilate thoroughly prior to attempting to start the it.
engine.
H. When adjusting the controls, it may require operation
N. DO NOT operate compressor under low overhanging of the equipment during adjustment. DO NOT come
leaves or permit such leaves to contact hot exhaust in contact with any moving parts while adjusting the
system surfaces when operating the compressor in control regulator and setting the engine RPM. Make
forested areas. all other adjustments with the engine shut off. When
O. Ethyl ether used in diesel engine ether starting aid necessary, make adjustment, other than setting
systems is extremely flammable. Change cylinders, control regulator and engine RPM, with the engine
or maintain or troubleshoot these systems only in shut off. If necessary, start the engine and check
well-ventilated areas away from heat, open flame or adjustment. If adjustment is incorrect, shut engine off,
sparks. DO NOT install, store or otherwise expose readjust, then restart the engine to recheck
ether cylinders to temperatures above 160 ̊F (71 ̊C). adjustment.
Remove ether cylinder from the compressor when I. Keep hands, feet, floors, controls and walking
operating in ambient temperatures above 60 ̊F (16 ̊C). surfaces clean and free of fluid, water, antifreeze or
P. DO NOT attempt to use ether as a starting aid in other liquids to minimize possibility of slips and falls.
gasoline engines or diesel engines with glow plugs as
serious personnel injury or property damage may 1.6 Hot Surfaces, Sharp Edges
result.
And Sharp Corners
Q. DO NOT spray ether into compressor air filter or into
an air filter that serves both the engine and the A. Avoid bodily contact with hot fluid, hot coolant, hot
compressor as serious damage to the compressor or surfaces and sharp edges and corners.
personal injury may result.
B. Keep all parts of the body away from all points of air
R. Antifreeze compound used in air line anti-icer discharge and away from hot exhaust gases.
systems contains methanol which is flammable. Use
systems and refill with compound only in well- C. Wear personal protective equipment including gloves
ventilated areas away from heat, open flames or and head covering when working in, on or around the
sparks. DO NOT expose any part of these systems or compressor.
the antifreeze compound to temperatures above
150 ̊F (66 ̊C). Vapors from the antifreeze compound D. Keep a first aid kit handy. Seek medical assistance
are heavier than air. DO NOT store compound or promptly in case of injury. DO NOT ignore small cuts
discharge treated air in confined or unventilated and burns as they may lead to infection.
areas. DO NOT store containers of antifreeze
compound in direct sunlight. 1.7 Toxic And Irritating
S. Store flammable fluids and materials away from your Substances
work area. Know where fire extinguishers are and
how to use them, and for what type of fire they are A. DO NOT use air from this compressor for respiration
intended. Check readiness of fire suppression (breathing) except in full compliance with OSHA
systems and detectors if so equipped. Standards 29 CFR 1920 and any other Federal, State
or Local codes or regulations.
1.5 Moving Parts
A. Keep hands, arms and other parts of the body and DANGER
also clothing away from belts, pulleys and other
moving parts.
B. DO NOT attempt to operate the compressor with the
fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair when
working around this compressor, especially when
exposed to hot or moving parts inside the enclosure. INHALATION HAZARD!
D. Keep access doors closed except when making Death or serious injury can result
repairs or adjustments, performing service or when
starting or stopping the compressor. from inhaling compressed air without
using proper safety equipment.
E. Make sure all personnel are out of and clear of the See OSHA standards and/or any
compressor prior to attempting to start or operate it.
applicable Federal, State, and Local
F. Shut off engine before adding fuel, fluid, coolant codes, standards and regulations on
lubricants, air line antifreeze compound or battery safety equipment.
electrolyte, or before replacing ether starting aid
cylinders.
6
SAFETY
B. DO NOT use air line anti-icer systems in air lines B. Keep all parts of the body and any hand-held tools or
supplying respirators or other breathing air utilization other conductive objects away from exposed live
equipment and DO NOT discharge air from these parts of electrical system. Maintain dry footing, stand
systems into unventilated or other confined areas. on insulating surfaces and DO NOT contact any other
portion of the compressor when making adjustments
C. Operate the compressor only in open or well- or repairs to exposed live parts of the electrical
ventilated areas. system.
D. If the compressor is operated indoors, discharge C. Attempt repairs only in clean, dry and well-lighted and
engine exhaust fumes outdoors. ventilated areas.
E. Locate the compressor so that exhaust fumes are not D. Stay clear of the compressor during electrical storms!
apt to be carried towards personnel, air intakes It can attract lightning.
servicing personnel areas or towards the air intake of
any portable or stationary compressor.
1.9 Lifting
F. Fuels, fluids, coolants, lubricants and battery
electrolyte used in the compressor are typical of the A. If the compressor is provided with a lifting bail, then
industry. Care should be taken to avoid accidental lift by the bail provided. If no bail is provided, then lift
ingestions and/or skin contact. In the event of by sling. Compressors to be air lifted by helicopter
ingestion, seek medical treatment promptly. DO NOT must not be supported by the lifting bail, but by slings
induce vomiting if fuel is ingested. Wash with soap instead. In any event, lift only in full compliance with
and water in the event of skin contact. OSHA Standards 29 CFR 1910 subpart N or any
other Local, State, Military and Federal regulations
G. Wear an acid-resistant apron and a face shield or that may apply.
goggles when servicing the battery. If electrolyte is
spilled on skin or clothing, immediately flush with B. Inspect lifting bail and points of attachment for
large quantities of water. cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts or
H. Ethyl ether used in diesel engine ether starting aid nuts prior to lifting.
systems is toxic, harmful or fatal if swallowed. Avoid
contact with the skin or eyes and avoid breathing the C. Make sure entire lifting, rigging and supporting
fumes. If swallowed, DO NOT induce vomiting, but structure has been inspected, is in good condition
call a physician immediately. and has a rated capacity of at least the net weight of
the compressor plus an additional 10% allowance for
I. Wear goggles or a full face shield when testing ether weight of snow, ice, mud or stored tools and
starting aid systems or when adding antifreeze equipment. If your are unsure of the weight, then
compound to air line anti-icer systems. Keep weigh compressor before lifting.
openings of valve or atomizer tube of ether starting
aid system pointed away from yourself and other D. Make sure lifting hook has a functional safety latch or
personnel. equivalent, and is fully engaged and latched on the
bail.
J. If ethyl ether or air line anti-icer system antifreeze
compound enters the eyes or if fumes irritate the E. Use guide ropes or equivalent to prevent twisting or
eyes, they should be washed with large quantities of swinging of the compressor once it has been lifted
clean water for 15 minutes. A physician, preferably clear of the ground.
any eye specialist, should be contacted immediately. F. DO NOT attempt to lift in high winds.
K. DO NOT store ether cylinders or air line anti-icer G. Keep all personnel out from under and away from the
system antifreeze compound in operator’s cabs or in compressor whenever it is suspended.
other similar confined areas.
H. Lift compressor no higher than necessary.
L. The antifreeze compound used in air line anti-icer
systems contains methanol and is toxic, harmful or I. Keep lift operator in constant attendance whenever
fatal if swallowed. Avoid contact with the skin or eyes compressor is suspended.
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt in each J. Set compressor down only on a level surface capable
glass of clean warm water until vomit is clear, then of supporting at least its net weight plus an additional
administer two tablespoons of baking soda in a glass 10% allowance for the weight of snow, ice, mud or
of clean water. Have patient lay down and cover eyes stored tools and equipment.
to exclude light. Call a physician immediately. K. If the compressor is provided with parking brakes,
make sure they are set, and in any event, block or
1.8 Electrical Shock chock both sides of all running wheels before
disengaging the lifting hook.
A. 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.
7
SECTION 1
8
SAFETY
V. Remove and carefully dispose of the dampened of person affixing tag to power source must be on
cloths, as they may now be contaminated with acid, tag along with date tag was placed on power
then replace all vent caps. source.
8. Release stored energy and bring the equipment
1.12 Implementation of to a “zero mechanical state”.
Lockout/Tagout 9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
The energy control procedure defines actions necessary
to lockout a power source of any machine to be repaired, B. General Security
serviced or set-up, where unexpected motion, or an
1. The lock shall be removed by the “Authorized”
electrical or other energy source, would cause personal
person who put the lock on the energy-isolating
injury or equipment damage. The power source on any device. No one other than the person/persons
machine shall be locked out by each employee doing the placing padlock ad lockout hasp on power shall
work except when motion is necessary during setup, remove padlock and lockout hasps and restore
adjustment or trouble-shooting. power. However, when the authorized person
A. The established procedures for the application of who applied the lock is unavailable to remove it
energy control shall cover the following elements and his/her Supervisor may remove padlock/padlocks
actions and shall be initiated only by Authorized and lockout hasps and restore power only if it is
Persons and done in the following sequence: first:
1. Review the equipment or machine to be locked a. verified that no person will be exposed to
and tagged out. danger.
2. Alert operator and supervisor of which machine is b. verified that the “Authorized” person who
to be worked on, and that power and utilities will applied the device is not in the facility.
be turned off.
c. noted that all reasonable efforts to contact
3. Check to make certain no one is operating the the “Authorized” person have been made to
machine before turning off the power. inform him or her that the lockout or tagout
4. Turn off the equipment using normal shutdown device has been removed.
procedure. d. ensured that the “Authorized” person is
5. Disconnect the energy sources: notified of lock removal before returning to
work.
a. Air and hydraulic lines should be bled,
drained and cleaned out. There should be no 2. Tagout System—Tags are warning devices
pressure in these lines or in the reservoir affixed at points of power disconnect and are not
to be removed by anyone other that the person
tanks. Lockout or tag lines or valves.
placing tag on power lockout. Tags shall never be
b. Any mechanism under tension or pressure, by-passed, ignored, or otherwise defeated
such as springs, should be released and
locked out or tagged. 1.13 California Proposition 65
c. Block any load or machine part prior to
working under it.
d. Electrical circuits should be checked with
WARNING
calibrated electrical testing equipment and
CALIFORNIA PROPOSITION 65
stored energy and electrical capacitors
should be safely discharged. WARNING
6. Lockout and/or Tagout each energy source using Diesel engine exhaust and some of its
the proper energy isolating devices and tags. constituents are known to the State
Place lockout hasp and padlock or tag at the of California to cause cancer, birth
point of power disconnect where lockout is defects and other reproductive harm.
required by each person performing work. Each Battery posts, terminals and related
person shall be provided with their own padlock accessories contain lead and other
and have possession of the only key. If more compounds known to the State of
than one person is working on a machine each
person shall affix personal lock and tag using a California to cause cancer and birth
multi-lock device. defects and other reproductive harm.
Wash hands after handling.
7. 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
9
SECTION 1
Safety Symbols-1
10
SAFETY
Safety Symbols-2
11
SECTION 1
Safety Symbols-3
12
Section 2
DESCRIPTION
2.1 Introduction electrical system. The machine is also supplied with sound
deadening insulation to lower noise emissions to meet EPA
Sullair Portable Air Compressor models offer superior or CE, and/or any Federal, State, or local noise requirement.
performance and reliability while requiring only minimal The Sullair compressor unit is driven by an industrial engine
maintenance. designed to provide enough horsepower at rated conditions.
Refer to Engine Operator’s Manual for a more detailed
The compressor is equipped with a Sullair rotary screw description of the engine.
compressor unit. Compared to other compressors, the
Sullair is unique in mechanical reliability and compressor The engine cooling system is comprised of a radiator, high
durability. No inspection is required of the working parts capacity fan and thermostats. The high capacity fan draws
within the compressor unit. air through the radiator, keeping the engine at the proper
operating temperature.
As you continue reading this manual and come to learn
how the compressor operates and is cared for, you will see The same fan also cools the fluid in the compressor
how surprisingly easy it is to keep a Sullair compressor in cooling and lubrication system. While passing through the
top operating condition. radiator, the fan air also passes through the compressor
fluid cooler (which is mounted adjacent to the radiator). As
Read Section 5 - MAINTENANCE to keep your air passes through the cooler, the heat of compression is
compressor in top operating condition. Should any removed from the fluid.
problem or question arise which cannot be answered in
this text, contact your nearest Sullair representative or the The same fan also cools the engines intake air supply by
Sullair Corporation Service Department. passing air through an air to air aftercooler. As air passes
through the aftercooler heat is removed which was
2.2 Description Of Components introduced by the engine’s turbo charger. The engine is
coupled to the compressor unit with a non-lubricated,
Refer to Figures 2-1A and 2-1B. The components and vulcanized rubber disk and a drive flange-type coupling. All
assemblies of the Sullair Portable Air Compressor models compressor models are supplied with a fuel tank large
are clearly shown. The package includes a compressor, enough to keep the compressor running through a full
diesel engine, compressor inlet system, compressor 8-hour shift.
cooling and lubrication system, compressor discharge
system, capacity control system, instrument panel and
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 13
SECTION 2
SU_0000145
14 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
SU_0000146
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 15
SECTION 2
2.3 Sullair Compressor Unit, Fluid is injected into the compressor unit hoses and mixes
directly with the air as the rotors turn, compressing the air.
Functional Description The fluid flow has three basic functions:
Sullair compressors feature the Sullair compressor unit, a 1. As coolant, it controls the rise of air temperature
single-stage, positive displacement, flood lubricated-type normally associated with the heat of compression.
compressor. This unit provides continuous compression to 2. Seals the clearance paths between the rotors and the
meet your needs. stator and also between the rotors themselves.
NOTE 3. Acts as a lubricating film between the rotors allowing
one rotor to directly drive the other, which is an idler.
With a Sullair compressor, there is
After the air/fluid mixture is discharged from the
no maintenance or inspection of the compressor unit, the fluid is separated from the air. At this
internal parts of the compressor unit time, the air flows through an aftercooler and separator
permitted in accordance with the then to your service line while the fluid is being cooled in
terms of the warranty. preparation for reinjection.
16 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
2.4 Compressor Cooling Before the temperature of the fluid reaches the valve set
point, cooled fluid is mixed with warmer fluid. When the
And Lubrication System, temperature of the fluid reaches 170°F (77°C), the thermal
Functional Description element shifts completely causing all fluid to flow to the
cooler. The thermal valve incorporates a pressure relief
Refer to Figure 2-2 and Figure 2-3B. The compressor valve, which allows fluid to bypass the cooler, if the cooler
cooling and lubrication system is designed to provide becomes plugged or frozen. This helps assure that fluid
adequate lubrication as well as maintain the proper will continue to be provided to the compressor for
operating temperature of the compressor. In addition to the lubrication. After the fluid passes through the thermal valve
cooler and fan, the system consists of a main filter and it is then directed through the main fluid filter. There, the
thermal valve. fluid is filtered in preparation for injection into the
compression chamber and bearings of the compressor
Fluid is used in the system as a coolant and a lubricant. unit. The filter has a replaceable element and a built-in
The fluid is housed in the receiver tank. bypass valve which allows the fluid to flow even when the
Upon start up, the fluid temperature is cool, and routing to filter element becomes plugged and requires changing or
the cooler is not required. The fluid first enters the thermal when the viscosity of the fluid is too high for adequate flow.
valve and then flows on to the compressor unit, bypassing After the fluid is properly filtered, it then flows on to the
the cooler. As the compressor continues to operate, the compressor unit where it lubricates, seals and cools the
temperature of the fluid rises and the thermal valve compression chamber as well as lubricates the bearings
element begins to shift. This forces a portion of the fluid to and gears.
the fluid cooler. The cooler is a radiator-type that works in
conjunction with the engine fan. The fan draws air through
the cooler removing the heat of compression from the
fluid. From the cooler, the fluid is routed back to the
thermal valve.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 17
SECTION 2
Fluid
SU_0000144
3. Receiver Tank
4. Fluid Cooler
5. Thermal Valve
6. Fluid Filler
18 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
2.5 Capacity Control System, High Pressure - 80 to 150 psig (5.5 to 10.3
Functional Description bar) for “H” models or 80 to 175 psig (5.5 to
12.1 bar) for “HH” models
Refer to Figure 2-3A. The purpose of the control system is
When the HIGH/LOW switch is switched to the “HIGH”
to regulate the amount of air intake in accordance with the
position, the low pressure regulator is blocked off allowing
amount of compressed air demand. The control system
the high pressure regulator to take over control of the
consists of an inlet valve, the high and low pressure
machine. The 60 psig (4.1 bar) reducing regulator fully
regulators, the pressure reducing regulator, the blowdown/
opens the inlet valve and the Compass Controller
running blowdown valve, the Compass Controller, a
commands maximum speed (1800 rpm) from the engine.
START/RUN selector switch, and the HIGH/LOW selector
As the pressure reaches the set point of the system the
switch.
high pressure regulator cracks open and closes the inlet
Start - 0 to 65 psig (0 to 4.5 bar) valve and the Compass Controller returns the engine back
to idle, until a demand for air is seen.
Push OFF/ON/START switch to “ON” position to initialize
the Compass Controller. Once the Compass Controller Shutdown
says “READY” on LCD, press OFF/ON/START switch to
The blowdown valve is normally closed. When the
the “START” position. In the “START” position, the inlet
compressor is shutdown, system pressure backs up to the
valve is held closed by the springs in the inlet valve. The
inlet valve causing the check spring in the inlet valve to
valve is cracked open by vacuum in the compressor and is
close the air inlet valve. This sends a pressure signal to
allowed to build up to 65 psig (4.5 bar). The reason for
the blowdown valve causing it to open and vent the
keeping the valve closed during start is to allow the engine
pressure in the system. After the pressure is vented, the
to warm up without being loaded by the compressor. Air
blowdown valve spring returns the blowdown valve to the
pressure is contained in the receiver tank by the minimum
closed position.
pressure valve which has a set point of 65 psig (4.5 bar).
At this point the valve opens allowing the air to pass to the
service valve. After engine has warmed up the machine
automatically transfers to “RUN” mode.
Low Pressure - 80 to 100 psig
(5.5 to 6.9 bar)
With the HIGH/LOW switch in the “LOW” position, and the
controller in “RUN” mode, the service valve can now be
opened. Pressure from the 60 psig (4.1 bar) reducing
regulator opens up the inlet valve and the Compass
Controller increases the engine speed to full load (1800
rpm). As the demand for air decreases, the Compass
Controller commands the engine to reduce speed to idle
(1400 rpm) and the inlet valve closes, where it stabilizes
until the air demand is required again. If the machine is not
marked with an “H” or “HH”, it is a single presure machine
and will not have a HIGH/LOW switch. The machine will
run as if it is in the “LOW” position.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 19
SECTION 2
5 4
8
12
10
11 13 1
A B C D E
SU_0000203
20 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
A B C D E
FLUID
AIR
1 AIR/FLUID
19 18
20
2
7
17
16
15
13
10
14
12
3 4
8
11
5
6 9
SU_0000204
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 21
SECTION 2
2.6 Compressor Discharge The receiver tank is code rated. A minimum pressure/
check valve, located downstream from the separator,
System, Functional helps assure a minimum receiver pressure during all
Description conditions. This pressure is necessary for proper air/fluid
separation and proper fluid circulation.
Refer to Figure 2-3B. The Sullair compressor unit A minimum pressure/check valve at the outlet of the
discharges compressed air/fluid mixture into the receiver receiver is installed to prevent compressed air in the
tank. service line from bleeding back into the receiver on
The receiver tank has three functions: shutdown when the compressor is being run in parallel
with other compressors tied to a large air system.
1. It acts as a primary fluid separator.
Fluid is added to the receiver tank via a capped fluid filler.
2. Serves as the compressor fluid storage sump. A fluid level gauge glass enables the operator to visually
3. Houses the final fluid separator. monitor the receiver tank fluid level.
The compressed air/fluid mixture enters the receiver tank
and is directed against the tank side wall. By change of WARNING
direction and reduction of velocity, large droplets of fluid
separate and fall to the bottom of the receiver tank. The DO NOT remove caps, plugs, and/or
fractional percentage of fluid remaining in the compressed other components when compressor
air collects on the surface of the final separator element as is running or pressurized.
the compressed air flows through the separator. As more
and more fluid collects on the element’s surface, the fluid Stop compressor and relieve all
descends to the bottom of the separator. A return line (or internal pressure before doing so.
scavenge tube) leads from the bottom of the separator
element to the inlet region of the compressor unit. Fluid
collecting on the bottom of the separator element is
returned to the compressor by the pressure difference
between the area surrounding the separator element and
the compressor inlet. An orifice (protected by a strainer) is
included in this return line to help assure proper flow.
22 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
2.7 aftercooled air System, should never be plugged or closed off in any way. From
the moisture separator the compressed air goes through
Functional Description the discharge filters (if equipped) and on to the service
valve.
Refer to Figure 2-5. The purpose of the aftercooled air
system is to operate the air compressor in conditions when NOTE
compressed air temperatures are required to be 10 to 25
̊F (5 to 13 ̊C) over ambient temperature. Two discharge Aftercooled system should not be
valves are provided on all aftercooled compressor models. operated in ambient conditions
One valve is labeled standard air and one valve is labeled below 32°F (0°C). If it is necessary to
aftercooled air. Closing the standard air (non- aftercooled)
operate in these conditions, Sullair
valve completely forces the air flow from the receiver tank
to the aftercooler. The ambient air, which is drawn through can supply optional equipment to
the aftercooler by the engine fan, cools the compressed air accommodate this requirement.
as it passes through the aftercooler core. Cooled air enters To operate in the non-aftercooled
the moisture separator where condensation is removed mode, close the aftercooler service
from the cooler air and discharged. This condensation valve completely and open non-
does carry some oil and it should be disposed of properly aftercooled valve.
in accordance with local regulations. A condensation drain
port is located in the frame on the front of the machine for
convienence of condensate removal. This drain port
Air
Air/Fluid SU_000141
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 23
SECTION 2
2.8 Air Inlet System, Functional engine air filter restriction gauge or the compressor air filter
restriction gauge will indicate when restriction of the air
Description passing through the filter becomes too high.
Refer to Figure 2-6. The compressor inlet system consists of At this time, change the air filter element. Refer to Air Filter
one air filter, a compressor air inlet valve and interconnecting Maintenance on page 63. These indicators should be
piping to the engine and compressor. Also, air filter restriction checked daily, after start-up under normal conditions.
indicator gauges are located next to the air filter housings.
The compressor air inlet valve controls the amount of air
The air filter is a 2-stage unit with a safety element dry intake of the compressor in response to the air demand.
element-type filter. This filter is capable of cleaning extremely
dirty air. However, in such cases, frequent checks of the air
filter will be required. Referring to the instrument panel, the
SU_0000152
24 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 25
SECTION 2
02250170-299-2-R00
26 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
1 filter, air 1
2 gauge, air filter restriction 1
3 inlet valve 1
4 compressor 1
5 valve, relief 2
6 switch, temperature 2
7 sensor, temperature 1
8 sensor, pressure 3
9 valve, discharge check 1
10 receiver, air/oil 1
11 glass, sight oil level 12
12 valve, minimum pressure 1
13 valve, ball 2
14 cooler, air (optional) 1
15 separator, moisture 1
16 trap, drain 1
17 orifice 8
18 valve, blowdown n.c. 2
19 strainer 2
20 sightglass, orifice block 1
21 valve, thermal bypass 1
22 cooler, oil 1
23 filter, oil 1
24 valve, oil stop 1
25 valve, pilot actuated recirc sol. 1
26 valve, regulator backpressure 2
27 gauge, pressure 1
28 valve, pressure regulator 1
29 valve, check 3
30 valve, solenoid 3-way run/start 1
31 valve, solenoid 2-way elect 3
32 seperator, element 3
33 valve, spiral 1
34 vent, air 2
35 cylinder, air (optional) 1
36 valve, pressure diff. bypass 2
37 valve, back pressure regulator 1
38 manifold, oil control 1
39 manifold, air control 1
Component Description
P1 Dry Side Pressure
P2 Control Pressure
P3 Wet Side Pressure
T1 Compressor Discharge Temperature Sensor
T3 Receiver Tank Temperature Switch (RTT)
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 27
SECTION 2
02250170-299-1-R00
28 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
Component Description
L1 COOLANT LEVEL
L2 FUEL LEVEL
L3 OIL LEVEL (DIPSTICK)
P5 INLET MANIFOLD AIR PRESSURE
P6 FUEL PRESSURE
P7 OIL PRESSURE
T7 INLET AIR TEMPERATURE
T8 FUEL TEMPERATURE
T9 COOLANT TEMPERATURE
S1 CAM SPEED
S2 CRANK SPEED
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 29
SECTION 2
1 3 7 4
02250159-203-R05
2
5
1. HI/LO Switch
2. Diagnostic Service Port
3. Reset Switch
4. Pressure Gauge
5. Temp/Tach/Fuel Gauge
6. Warning Bank
7. START/ON/OFF Switch
30 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
2.11 Engine Control Module, The lamp is not required for engine operation, however, it
can be useful to determine Active diagnostic codes. The
Functional Description lamp will illuminate (ON) at initial ECM power-up to test the
lamp operation (self test).
Diagnostic Fault Codes are provided to indicate an
electrical or electronic problem has been detected by the Count the first sequence of flashes to determine the first
ECM (Engine Control Module). In some cases, the engine digit. After a two-second pause, count the second
performance can be affected when the condition causing sequence of flashes to determine the second digit. Any
the code exists. More frequently, however, the operator additional flash code diagnostics will follow (after a pause)
cannot detect any difference in the engine performance. and will be displayed in the same manner.
The Compass Controller indicates a performance problem In addition to the flash codes described above, the
has occurred whenever the Engine Warning Lamp is Compass Controller should display a brief text message in
flashing. The diagnostic code may indicate the cause of the LCD of the master gauge. This message helps to
the problem, and should be corrected. pinpoint the source of the problem and aid in
troubleshooting the compressor.
If the Compass Controller does not indicate a problem with
the engine performance but a diagnostic code is logged by
the ECM, the ECM detected an abnormal condition that
NOTE
did not affect performance. Only Active diagnostic codes can
If this is the case, unless there are several occurrences of be read in this manner. Logged
the code in a very short period of time, or, the ECM is diagnostic codes must be retrieved
indicating an Active Code at the present time, there is most with an Electronic Service Tool.
likely nothing wrong with the system.
The diagnostic FLASH CODE may be retrieved using this Refer to Table 2-1 on page 32 for possible performance of
lamp. active diagnostic codes.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 31
SECTION 2
Reduced
Flash CID-FMI SPN-FMI Engine Low Engine
Description of Code Engine
Code Code Code Misfires Power Shutdown
Speed
12 Incorrect crank-without-inject inputs 266-02 266-02
13 Fuel Temperature open/short to +batt 174-03 174-03
Fuel temperature short to ground 174-04 174-04
21 5-volt sensor DC power supply short to 262-03 620-03
+batt
5-volt sensor DC power supply short to 262-04 620-04
ground
Digital sensor supply short to +batt 262-03 678-03
Digital sensor supply short to ground 263-04 678-04
24 Engine oil pressure open/short to +batt 100-03 100-03
Engine oil pressure open/short to ground 100-04 100-04
25 Turbo outlet pressure above normal 273-00 102-00 x
Turbo outlet pressure open/short to +batt 273-03 102-03 x
Turbo outlet pressure short to ground 273-04 102-04 x
26 Atmospheric pressure open/short to +batt 274-03 108-03
Atmospheric pressure short to ground 274-04 108-04
27 Engine coolant temperature open/short to 110-03 110-03 x x x
+batt
Engine coolant temperature short to ground 110-04 110-04 x x x
28 Throttle position calibration required 91-13 91-03 x x
32 Throttle position signal abnormal 91-08 91-08 x x
34 Speed/timing sensor loss of signal 320-02 190-02 x x (I)
Speed/timing sensor mechanical failure 320-11 190-11 x x (I)
Loss of secondary engine speed signal 342-02 723-02 x x (I)
Secondary engine speed sensor 342-11 723-11 x x (I)
mechanical failure
35 Engine overspeed shutdown 004 0190-16
Engine overspeed warning 190 0190-00
37 Fuel pressure open/short to +batt 94-03 94-03
Fuel pressure short to ground 94-04 94-04
Engine oil temperature open/short to +batt 175-03 175-03
Engine oil temperature short to ground 175-04 175-04
38 Intake manifold air temp open/short to +batt 172-03 172-03 x x x
Intake manifold air temp short to ground 172-04 172-04 x x x
42 Engine timing calibration required 261-13 228-13 x x x x
46 Low engine oil pressure warning 100 0100-17
Low engine oil pressure derate 039 0100-18
Low engine oil pressure shutdown 040 0100-01 x (I) x (I) x (I)
51 System voltage internittent/erratic 168-02 168-02 x x x
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier
32 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
Reduced
Flash CID-FMI SPN-FMI Engine Low Engine
Description of Code Engine
Code Code Code Misfires Power Shutdown
Speed
53 Electronic Control Module error 254-12 No code x x x x
56 Personality Module mismatch 253-02 234-02 x (II)
Check programmable parameters 268-02 111-02 x x
58 J1939 Data Link communications 247-09 639-09
61 High engine coolant temperature derate 015 0110-16
High engine coolant temperature shutdown 016 0110-00
High engine coolant warning 017 0110-15
62 Fuel filter restriction derate 005 0094-15
Fuel filter restriction shutdown 006 0094-16
Fuel filter restriction warning 095 0094-00
High fuel pressure 096 0094-00
64 HIgh inlet temperature derate 025 0172-16
High inlet temperature shutdown 027 0172-05
65 High fuel temperature derate 054 0174-16
High fuel temperature shutdown 055 0174-00
High fuel temperature warning 056 0174-15
72 Injector cylinder #1 fault 1-11 651-11 x x
Injector cylinder #2 fault 2-11 652-11 x x
73 Injector cylinder #3 fault 3-11 653-11 x x
Injector cylinder #4 fault 4-11 654-11 x x
74 Injector cylinder #5 fault 5-11 655-11 x x
Injector cylinder #6 fault 6-11 656-11 x x
00 Either start relay open/short to +batt 545-05 545-05
Either start relay short to ground 545-06 545-06
(I) The engine will shut down if both speed/timing sensors are lost.
(II) Fuel injection will not occur and the engine will not start. NOTE: Sullair engines are programmed to shut down.
CID = Component Identifier SPN = Suspect Parameter Number FMI = Failure Mode Identifier
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 33
SECTION 2
2.12 Electrical System, prevent it from being started if the engine coolant level
drops too low. In addition, there is a starter protection relay
Functional Description which prevents accidental starter engagement after the
engine is running or whenever there is pressure in the
Refer to Figures 2-8A and 2-8B. The electrical system is receiver tank. Also, should fuel supply level drop near the
comprised of not only the necessary equipment required to bottom of the fuel tank, the Compass Controller will shut
operate the compressor, but also a system to shut it down down the machine before the engine runs out of fuel.
in the event of a malfunction. The components of the There are also several connectors in the main harness
electrical system are an engine starter (with an integral that are designed to receive wiring for factory options such
solenoid), battery, a breaker protected alternator with a as remote start, cold weather louvers, engine air stop
built-in voltage regulator, a breaker protected engine air valve, and ether start system. The electrical system also
inlet heater (for cold weather starting), a compressor incorporates a lockable battery disconnect to be utilized for
discharge temperature sensor and receiver tank extended periods of non use and during machine
temperature switch (both will shut down the compressor maintenance. In case of emergency, an emergency stop
should the compressor temperature exceed 250°F switch is located just above the Compass Controller on the
[121°C]), an ambient temperature sensor, and a fuel level canopy of the machine. Figures 2-9A and 2-9B show the
sensor. This compressor also incorporates an engine wiring diagram for the Compass Control.
coolant level sensor. This device is located in the top of the
engine radiator. It will shut the compressor down or
34 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 35
SECTION 2
D
2
D
25
D
1 D D
7 8
D
26
D
19
D
20
D
21
D
27
D
22
D
23
D
24
02250163-092-R08
36 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
D
3 D
5
D
4
D
6
D
12
D D D D
7 8 8 10
D D
9 11 D
13
D
15
D
14
D
17
D
18
D
27
D D D
29 30 31
02250163-092-R08
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 37
SECTION 2
38 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 39
SECTION 2
02250172-331-1-R00
40 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
DESCRIPTION
02250172-331-2-R00
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 41
SECTION 2
42 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 3
Specifications
3.1 Table Of Specifications – 600h, 750, 750h, 750hh
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 43
SECTION 3
44 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
SPECIFICATIONS
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 45
SECTION 3
(I) Sullair part numbers for multi-viscosity lubricants are 250030-757 (5 gallons/18.9 liters), 250030-758 (55 gallons/208 liter drum).
46 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
SPECIFICATIONS
CAUTION
SU_0000142
*If fluid is seen in the sight glass when the machine is not
running, no fluid is needed.
When ambient conditions exceed those noted or if
conditions warrant use of other extended life lubricants,
contact Sullair for recommendations. 3.5 Lubrication Guide – Engine
Sullair encourages the user to participate in a fluid analysis Refer to the Engine Operator’s Manual for oil
program. This could result in a fluid change interval specifications.
differing from that stated in the manual. Sullair Corporation
offers a fluid analysis program for Sullair AWF. Contact
your local Sullair representative for details.
D-A Lubricant® Company Inc. offers an analysis program
for users of D-A products and Sullair AWF. Contact your
D-A Lubricant® representative for details.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 47
SECTION 3
02250162-745-R01
48 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
SPECIFICATIONS
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 49
SECTION 3
02250162-746-R01
50 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
SPECIFICATIONS
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 51
SECTION 3
02250165-379-R01
52 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
SPECIFICATIONS
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 53
SECTION 3
54 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 4
OPERATION
4.1 General interpret the readings which will call for service or indicate
the beginning of a malfunction. Before starting your Sullair
While Sullair has built into this compressor a compressor, read this section thoroughly and familiarize
comprehensive array of controls and indicators to assure yourself with the controls and indicators—their purpose,
that it is operating properly, you will want to recognize and location and use.
NOTE
When restarting the compressor, the
Compass Controller will not allow
restart until system pressure falls
below 10 psig (0.7 bar) or less. More
than 10 psig (0.7 bar) can put extra
load on the starter.
Voltmeter Monitors the condition of the batteries and the charging circuit.
The normal reading is 24 to 48 volts.
Air Pressure Gauge Continually monitors the pressure inside the receiver tank at
various load and unload conditions.
Engine Coolant Temperature Gauge Monitors the temperature of the engine coolant. The normal
operating temperature should read approximately 160ºF to
210ºF (71ºC to 99ºC).
Compass Controller Depicts system related diagnostics. Can be used for system
performance monitoring.
Compressor Discharge Temperature Gauge Monitors the temperature of the air/fluid mixture leaving the
compressor unit. The normal reading should be approximately
210ºF to 230ºF (99ºC to 110ºC).
System Pressure Sensor Prevents starter engagement when the air system is
pressurized.
Fluid Level Sight Glass Monitors the fluid level in the receiver tank. Proper level is
always visible in the sight glass. Check the level when the
compressor is shutdown.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 55
SECTION 4
56 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
GENERAL
&
Once the compressor has started, the unit will enter a
warm-up phase. At this point, the unit is not producing
usable compressed air and the service valve should
still be closed. The following message will be
displayed on the LCD panel:
SU_0000044
SU_0000047
SU_0000045
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 57
SECTION 4
SU_0000048
SU_0000049
WARNING
The E-Stop (emergency stop switch)
should be used only in the event of an
emergency. Refrain from using the E-Stop
to shut the machine down during normal
operations. All usage of the E-Stop is
logged in permanent memory for use by
service technicians when troubleshooting
a machine. Non-emergency use of E-Stop
is considered equipment abuse and could
void the manufacturer’s warranty.
58 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 5
MAINTENANCE
5.1 General After a routine start has been made, it is necessary to
perform an inspection to ensure all operations are
A good maintenance program is the key to long performing correctly. Perform the following inspections to
compressor life. Below is a program that when adhered prevent unnecessary problems.
to, should keep the compressor in top operating condition. 1. Observe the instrument panel gauges and be sure
For engine maintenance requirements, refer to the they monitor the correct readings for their particular
Engine Operator’s Manual for a detailed description of phase of operation.
service instructions.
2. After the compressor has warmed up, it is
Refer to Description of Components on page 13 for a recommended that a general check on the overall
detailed description of specific compressor system compressor and instrument panel be made to assure
components. Prior to performing maintenance, read the that the compressor is running properly.
CIMA Safety Manual, if applicable.
3. Check the air filter restriction gauges. Should they
indicate restriction, replace the elements immediately.
CAUTION Refer to Air Filter Maintenance on page 63 .
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 59
SECTION 5
60 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
MAINTENANCE
SU_0000079
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 61
SECTION 5
3
1
2
5
7
6
SU_0000076
1. Rubber Plug 5. Grease Fitting
2. Outer Bearing 6. Metal End Cap
3. Inner Bearing 7. Spring-loaded Double Lip Seal
4. Grease Flow
Figure 5–2:Typical E-Z Lube Axle
62 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
MAINTENANCE
4 2
SU_0000126
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 63
SECTION 5
1 CAUTION
3 6
5
SU_0000077
64 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
MAINTENANCE
Control System Adjustment 4. For 175 psig (12.1 bar) “HH” machines, turn the “HI/
LO” switch to “HI” position. Close the service valve
Refer to Figure 5-5. Prior to adjusting the control system, it and set the “HI” pressure control regulator to maintain
is necessary to determine the desired operating pressure 190 to 200 psig (13.1 to 13.8 bar) discharge pressure.
range as well as the maximum pressure at which the Open the service valve to maintain 175 psig (12.1 bar)
machine is to operate. This pressure must not exceed the and check for 1800 RPM full-load speed. If lower
maximum operating pressure which is stamped on the speed is observed, raise the setting of the low
machine serial number plate. pressure control regulator until rated speed is
1. Start the machine and let it warm-up and enter full achieved.
“RUN” mode.
2. Open service valve slightly until engine tries to speed
up. Slowly close the service valve. With service valve
closed, check and adjust the pressure at the reducing
regulator to a minimum of 60 psig (4.1 bar) and not to
exceed 75 psig (5.2 bar). With service valve still
closed, and the “HI/LO” switch in the “LO” position,
adjust the low-pressure back-pressure regulator so the
service pressure is between 115 to 125 psig (7.9 to 8.6
bar) with the engine at 1400 rpm. Open the service
valve to load the compressor to maintain 100 psig (6.9
bar) discharge pressure. Operating speed should be
1800 RPM on the instrument panel. If not, repeat step,
but adjust the unload service pressure up or down as
needed until 100 psig (6.9 bar) is maintained when
engine speed is 1800 rpm.
3. For 150 psig (10.3 bar) “H” machines, turn the “HI/LO”
switch to “HI” position. Close the service valve and set
the “HI” pressure control regulator to maintain 165 to
175 psig (11.4 to 12.1 bar) discharge pressure. Open
the service valve to maintain 150 psig (10.3 bar) and
check for 1800 RPM full-load speed. If lower speed is
observed, raise the setting of the low pressure control
regulator until rated speed is achieved.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 65
SECTION 5
SU_0000153
66 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
MAINTENANCE
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 67
SECTION 5
68 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
MAINTENANCE
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 69
SECTION 5
NOTE
70 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 6
NOISE CONTROL
6.1 Noise Emissions Warranty ultimate purchaser or while it is in use.
2. The use of the compressor after such device or element of
Sullair Corporation warrants to the ultimate purchaser and design has been removed or rendered inoperative by
each subsequent purchaser that this air compressor was any person.
designed, built and equipped to conform at the time of sale
to the first retail purchaser, with all applicable U.S. EPA,
Among those acts included in the prohibition against
European CE, and/or any Federal, State or Local noise
tampering are the acts listed below:
control regulations.
1. Removal or rendering inoperative any of the following:
This warranty is not limited to any particular part, a. Engine exhaust system or parts thereof
component, or system of the air compressor. Defects in the
design, assembly, or in any part, component, or system of b. Compressor air intake system or part thereof
the compressor which, at the time of sale to the first retail c. Enclosure of part thereof
purchaser, caused noise emissions to exceed applicable
standards are covered by this warranty for the life of the air 2. Removal of any of the following:
compressor. a. Vibration isolators
b. Control silencer
6.2 Tampering with the Noise
c. Floor panel
Control System is
d. Fan shroud
Prohibited
e. Acoustical materials including fiberglass foam or foam
Federal Law prohibits the following acts or the causing tape
thereof: 3. Operation with canopy doors open for any purpose other
1. The removal or rendering inoperative by any persons, than starting, stopping, adjustment, repair,
other than for purposes of maintenance, repair, or replacement of parts or maintenance.
replacement, of any device or element of design
incorporated into any new compressor for the purpose
of noise control prior to its sale or delivery to the
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 71
SECTION 6
Maintenance Performed
By
Location
Date
Maintenance Performed
By
Location
Date
72 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
NOISE CONTROL
Maintenance Performed
By
Location
Date
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
Maintenance Performed
By
Location
Date
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 73
SECTION 6
Maintenance Performed
By
Location
Date
74 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
Section 7
ILLUSTRATIONS AND
PARTS LIST
7.1 Procedure for Ordering Parts
When ordering parts, always indicate the Serial Number of the compressor. This can be obtained from the Bill of Landing
for the compressor or from the Serial Number Plate located on the compressor. Refer to Figure 7-1.
xxxxxxx
xxxx-xxxxx
xxxx/xxxxxxx
2007XXXXXXXX
xxx/xx
xxxxxxx
xxxx-xxxxx xxxx/xxxxxxx
2007XXXXXXXX
xxxx-xxxxx xxxx/xxxxxxx
2007XXXXXXXX xxxxxxx
SU_0000471
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 75
SECTION 7
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was
purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, phone
or fax numbers listed.
76 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 77
SECTION 7
78 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
CAUTION
Mixing of other lubricants within
the compressor unit will void all
warranties.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 79
SECTION 7
02250162-747-1-R07
80 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 81
SECTION 7
02250162-747-2-R07
82 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1: PART NUMBERS 02250127-557; ADAPTER, DISCHARGE 3”, 826502-236; O-RING, VITON 3 1/4 X 1/8, & 828306-125;
CAPSCREW, SOCKET HEAD 3/8-16 X 1 1/4 ARE INCLUDED WITH THE UNIT.
A2: TO BLUE HOSE ON HOSE BUNDLE.
A3: TO RED HOSE ON HOSE BUNDLE.
A4: TO YELLOW HOSE ON HOSE BUNDLE.
A5: TO WHITE HOSE ON HOSE BUNDLE.
A6: TO PURPLE HOSE ON HOSE BUNDLE.
A7: TO SCAVANGE LINE ON TOP OF REC TANK.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 83
SECTION 7
02250162-748-R03
84 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 85
SECTION 7
02250162-752-R04
86 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 87
SECTION 7
02250162-753-R02
88 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 89
SECTION 7
02250165-334-R02
90 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 91
SECTION 7
02250162-757-R02
92 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 93
SECTION 7
02250165-333-R05
94 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 95
SECTION 7
02250165-333-R05
96 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 97
SECTION 7
02250162-754-R06
98 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 99
SECTION 7
02250162-754-R06
100 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 101
SECTION 7
02250073-035R03
02250073-035-R03
102 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
(I) For maintenance on filterstat (thermostat), order replacement kit no. 02250087-682.
(II) For maintenance on fluid filter, order replacement element no. 250025-526, quantity of two.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 103
SECTION 7
02250162-843-R02
104 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 105
SECTION 7
02250144-497-R03
106 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 107
SECTION 7
02250054-762R06
02250054-762-R06
108 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
NOTE
For maintenance on inlet valve
assembly, order repair kit no.
02250073-277, and replacement
gasket no. 040696.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 109
SECTION 7
02250159-190-R01
110 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 111
SECTION 7
02250160-092-R11
112 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 113
SECTION 7
02250160-092-R11
114 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 REAR VIEW.
A2 WIRING HARNESS CONNECTOR.
A3 USE ON OPEN FRAMES MACHINES ONLY.
A4 MOUNT TO PEM NUTS IN 02250157-351.
A5 START/RUN
A6 RECIRC
A7 HI/LOW
A8 WIRING HARNESS DETAILS.
A9 DECAL LOCATION.
A10 P2
Controller Model
02250165-490 Single Pressure
02250159-203 Dual Pressure
Manifold Model
02250162-843 Single Pressure
02250144-497 Dual Pressure
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 115
SECTION 7
02250165-250-R04
116 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 To frame
A2 To air end discharge
A3 Air discharge
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 117
SECTION 7
02250165-249-1-R06
118 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 119
SECTION 7
02250165-249-2-R06
120 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 121
SECTION 7
02250162-755-1-R06
122 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 123
SECTION 7
02250162-755-2-R06
124 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 To aftercooler.
A2 Mounted to fuel tank.
A3 To bail valve.
A4 To flex tube.
A5 To lower AC cooler.
A6 AC air outlet.
A7 To frame.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 125
SECTION 7
02250162-760-R08
126 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 127
SECTION 7
02250162-760-R08
128 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 129
SECTION 7
02250085-191-R01
130 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 131
SECTION 7
02250162-774-1-R05
132 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 133
SECTION 7
02250162-774-2-R05
134 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 135
SECTION 7
02250162-759-R05
136 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 137
SECTION 7
02250162-756-R02
138 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 139
SECTION 7
02250162-758-R03
140 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 Inlet
A2 Outlet
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 141
SECTION 7
02250165-659-R04
142 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 143
SECTION 7
7.27 Frame, Running Gear And Parts, Tandem Axle, Electric Brakes
Standard
02250162-749-1-R04
144 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 145
SECTION 7
02250162-749-2-R04
146 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 147
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7.28 Frame, Running Gear And Parts, Tandem Axle, Hydraulic Brakes
02250162-750-1-R05
148 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 149
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02250162-750-2-R05
150 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 151
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02250162-751-R03
152 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 153
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02250163-621-R03
154 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 155
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02250162-473-1-R08
02250162-473-2-R08
156 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 157
SECTION 7
02250162-473-3-R08
158 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 159
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02250162-473-4-R08
160 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 If column part number left blank for color assembly, refer to the base part number in first column.
A2 For stainless steel hardware refer to kit number: 02250142-504.
A3 To sides.
A4 To lifting bail.
A5 To side panel.
A6 To top panel.
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 161
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02250159-939R03
02250159-939-R03
162 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 163
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02250161-268R01
02250161-268-R01
164 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 165
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02250166-422R01
02250166-422-R01
166 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 167
SECTION 7
02250164-056R01
02250164-056-R01
168 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 169
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02250165-441-1-R03
170 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 Coolers
A2 Front of the machine
A3 Viewed from bottom of the machine
A4 View is shown without baffles
Foam to be put on both curb side and street side
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 171
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02250165-441-2-R03
172 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 Coolers
A2 Front of the machine
A3 Viewed from bottom of the machine
A4 View is shown without baffles
Foam to be put on both curb side and street side
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 173
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02250165-441-3-R03
174 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 Coolers
A2 Front of the machine
A3 Viewed from bottom of the machine
A4 View is shown without baffles
Foam to be put on both curb side and street side
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 175
SECTION 7
02250165-441-4-R03
176 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
A1 Coolers
A2 Front of the machine
A3 Viewed from bottom of the machine
A4 View is shown without baffles
Foam to be put on both curb side and street side
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 177
SECTION 7
02250162-761-R01
178 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 179
SECTION 7
02250162-775-1-R05
180 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 181
SECTION 7
02250162-775-2-R05
182 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 183
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1 3 7 4
5
02250159-203-1-R05
184 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 185
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02250159-203-2-R05
186 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 187
SECTION 7
02250165-490-1-R02
188 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 189
SECTION 7
02250165-490-2-R02
190 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 191
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35
37
825 1050
38
39
40
41
42
43
44
45
SU_0000489
192 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 193
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02250172-879
194 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 195
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02250172-880
196 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 197
SECTION 7
02250172-881
198 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 199
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02250101-293-R05
200 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
• Locations and type of lights and reflectors per Canadian transport directive CMVSS108
• All lights must have S.A.E. marking
• All reflex reflectors must have D.O.T. and S.A.E. approval
• All conspicuity tape must meet D.O.T. & S.A.E. specifications
• All dimensions position/location tolerance ±.25 (6.4)
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 201
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202 600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List
ILLUSTRATIONS AND PARTS LIST
WARNING
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects and other
repoductive harm.
Battery posts, terminals and
related accessories contain lead
and other compounds known to
the State of California to cause
cancer and birth defects and
other reproductive harm. Wash
hands after handling.
02250118-633
600H, 750, 750H, 750HH, 825, 900, 900H, 1050 Operator’s Manual and Parts List 203
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