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550RH-750HCUMMINS ENGINE

I

We appreciate for both your purchasing and utilizing

this portable screw compressor made by

Shenzhen Sullair Asia Industrial Co. Ltd.

Suzhou Sullair Air Equipment Co., Ltd.

The various types of portable screw compressors made by Shenzhen

Sullair Asia Industrial Co. Ltd. and Suzhou Sullair Air Equipment Co.,

Ltd. (hereinafter “Sullair”) are expected to work to your satisfaction.

Before operating and maintaining the portable rotary screw air

compressor of Sullair, please do read this Operating and Maintenance

Manual carefully.

Sullair reserves the right of research and improvement of its products, and

is not responsible for modifications and improvements on its previous

products.

License No:

Compressor Model:

Compressor Serial Number:

Diesel Engine Model:

Diesel Engine Serial Number:

III

PREFACE

This Operating and Maintenance Manual describes in detail the safety precautions,

structural functions of each system, and operation & maintenance method for 550RH,

600XH and 750H portable screw air compressors designed and produced by Sullair,

and driven by Dongfeng CUMMINS diesel engine.

Operators shall carefully read this Operating and Maintenance Manual and the

Operating and Maintenance Manual of Dongfeng CUMMINS C engine and may carry

out machine operation and maintenance only after fully understanding the structural

functions and safety precautions of each system and component. Unless otherwise

specified in this Manual, if the user doesn’t operate and maintain in accordance with

the operation and maintenance regulations of this Manual, or disassembles and

modifies the machine without authorization, or uses the parts not designated by Sullair,

then it will lose the right of claim.

This Manual does not include parts list. If you need to order parts from Sullair, please

see Parts List (88291004-642). It is important to note that your product may differ

from the one described in this Manual because Sullair always puts efforts on research

and improvement of its products. Consult Sullair Service Department before ordering

parts.

If you encounter any problem during operation that is not clearly described in this

Manual, contact local Sullair authorized dealer, or directly Sullair branches or Sullair

Service Department. Solution to your problem can be assured.

——Editor

June 2009

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SAFETY PRECAUTIONSRead carefully before operating the compressor.

▲ WARNING

Compressed air and air compression system are dangerous!

Failure to follow the instructions, procedures and safety precautions in thisManual may result in accidents and injuries to you or others!

Read this Manual carefully and make sure you fully understand every part ofthis Manual before operating and servicing the compressor!

User is responsible for appropriate care of the machine!

For details of safety precautions and potential hazards when operating the compressor, refer to

Safety Precaution section in this Manual. Before shipment, conspicuous warning labels have

been attached on the locations where precautions and hazards should be taken into account.

In this Manual, operations involving safety issue will be in bold font and indicated as Caution,

Warning, or Danger, depending on the degree of damage to the compressor or personal injury.

Caution indicates a potentially hazardous situation, which, if not avoided, may result in generaldamage to the machine.

Warning indicates a potentially hazardous situation, which, if not avoided, may result in damageto the machine or personal injury.

Danger indicates an imminently hazardous situation, which, if not avoided, may result in majoraccident, death or injury.

1. You must read this Manual carefully and fully understand this Manual prior to any operationand maintenance of the compressor.

2. Never operate the compressor when it exceeds the rated discharge pressure, otherwise, theengine may be damaged due to overload.

3. Each protection and control function has been properly set up at factory. Never modify orremove control parts of the machine, otherwise it may cause severe damage to machine orinjury.

4. Never remove or loosen any piping components, connectors, plugs, and connections when thecompressor is running. DO NOT operate the relief valve. The thermal substance inside themachine is pressurized and may cause severe personal injury.

5. Prior to any maintenance, you have to make sure that: The compressor is shut down; Internal pressure has been released completely.

6. Only use safe solution to clean the compressor and accessories.7. Any part that is found defective must be changed immediately to avoid irreparable damage.

VII

TABLE OF CONTENTS

PREFACE....................................................................................................................... III

SAFETY PRECAUTIONS ..............................................................................................V

Section 1 SPECIFICATIONS

1.1 Technical Parameters ......................................................................................................................1

1.2 Dimensions(DPQ550RH-750H) .....................................................................................................2

1.3 Dimensions(DLQ550RH-750H).....................................................................................................2

1.4 Compressor Fluid............................................................................................................................3

1.5 Engine Oil .......................................................................................................................................3

1.6 Engine Coolant ...............................................................................................................................4

1.7 Diesel Fuel ......................................................................................................................................5

Section 2 SAFETY

2.1 General............................................................................................................................................6

2.2 Towing and Parking........................................................................................................................6

2.3 Pressure Release .............................................................................................................................8

2.4 Fire and Explosion ..........................................................................................................................8

2.5 Moving Parts...................................................................................................................................9

2.6 Hot surfaces, sharp edges and sharp corners...................................................................................9

2.7 Toxic and Irritative Substances.......................................................................................................9

2.8 Electrical Shock ............................................................................................................................10

2.9 Battery...........................................................................................................................................10

2.10 Lifting .........................................................................................................................................10

2.11 Miscellaneous .............................................................................................................................10

Section 3 DESCRIPTION

3.1 Introduction...................................................................................................................................11

3.2 Machine Layout ............................................................................................................................11

3.3 Compressor unit & Diesel Engine Assembly................................................................................12

3.4 Compressor Inlet System ..............................................................................................................13

3.5 Diesel engine inlet system ............................................................................................................14

3.6 Compressor Discharge System .....................................................................................................15

3.7 Compressor Cooling and Lubrication System ..............................................................................16

3.8 Control System .............................................................................................................................17

3.9 Auto Protection System ................................................................................................................19

VIII

3.10 Engine Fuel System ....................................................................................................................19

3.11 Engine Lubrication System.........................................................................................................20

3.12 Engine Cooling System...............................................................................................................20

3.13 Engine Discharge System ...........................................................................................................21

3.14 Instrument Control System .........................................................................................................22

3.15 Electrical System ........................................................................................................................29

3.16 Frame-Moving System................................................................................................................29

3.17 Enclosure Assembly....................................................................................................................29

Section 4 OPERATION

4.1 General..........................................................................................................................................32

4.2 Purpose of Controls and Indicators ...............................................................................................32

4.3 Initial Start-up Procedure..............................................................................................................33

4.4 Subsequent Start-up Procedure .....................................................................................................33

4.5 Shutdown Procedure .....................................................................................................................34

4.6 Mode Setting Procedure................................................................................................................34

4.7 Jump Start Procedure ....................................................................................................................34

4.8 Storage ..........................................................................................................................................35

Section 5 MAINTENANCE

5.1 General..........................................................................................................................................36

5.2 Maintenance of Rotary Screw Compressor ..................................................................................36

5.3 Maintenance of Diesel Engine ......................................................................................................38

5.4 Parts Replacement and Adjustment Procedures............................................................................41

5.5 Troubleshooting ............................................................................................................................43

Section 6 NOISE CONTROL

6.1 Noise Emission .............................................................................................................................49

6.2 Prohibited Operation.....................................................................................................................49

6.3 Service Record..............................................................................................................................49

PARTS ORDERING ...................................................................................................... 50

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

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Section 1SPECIFICATIONS

1.1 Technical ParametersTechnical parameters and overall dimensions of the compressor are shown in the table below:

MODEL 550RH 600XH 750H

General

Nominal Delivery m3/min (cfm) 15.5(550) 17.0(600) 21.2(750)

Rated Discharge Pressure –bar (psi) 17(250) 13.8(200) 10(150)

Pressure Range-bar 6.5-17 3.5-13.8 3.5-10

Max Towing Speed-km/h 35 (Only for DPQ550RH-750H)

Noise level @ 7m, ±3dB (A) 79

Gross Weight-kg (DPQ550RH-750H) 3200

Gross Weight-kg (DLQ550RH-750H) 3000

Dimensions:L×W×H – mm (DPQ550RH-750H)

4560×2150×2050 (to the top of casing)4560×2150×2170 (total height of machine)

Dimensions:L×W×H – mm (DLQ550RH-750H)

3480×1680×1680 (to the top of casing)3480×1680×1806 (total height of machine)

Tire Size 7.5-16-14PR ( only for DPQ550RH-750H)

Tire Pressure - kPa (psi) 690-760 (100-110) (only for DPQ550RH-750H)

Max Altitude - m 3048

Engine

Mamufacturer Dongfeng CUMMINS

MODEL 6CTA8.3-C240 6CTA8.3-C260

Speed, full-load/no-load - rpm 1800/1400 1800/1400

Rated Power - BHP (kW) 240(179) 260(194)

Displacement - L (in3) 8.3(136)

Coolant Tank Capacity - L (U.S.gal) 9.8(2.6)

Engine Oil Capacity - L (U.S.gal) 18(4.8)

Fuel Tank Capacity - L (U.S.gal) 375(99)

Fuel consumption at full-loadL/h (U.S.gal/h)

38.6(10.2) 37.4(10.0) 40.4(10.7)

Electrical System Voltage -V 24

Battery Capacity 210Ah/ea.

Compressor

Service valve spec. One Rp2 and one Rp3/4

Fluid Capacity - L (U.S.gal) 26 (6.8)


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1.2 Dimensions (DPQ550RH-750H)

Air Inlet

Air Outlet

Control Panel

Maintenance Portof Control Valve

Air Inlet

Fluid Sight-glassHole

Maintenance doorof Cooler

Lifting Orifice

Mounting Plateof Silencer

MaintenancePort of Fluid/airseparator

Figure 1-1 Dimensions

1.3 Dimensions (DLQ550RH-750H)

Figure 1-2 Dimensions


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1.4 Compressor Fluid

The fluids as shown in the table below can be used in the portable rotary screw compressor

designed and made by Sullair. These fluids are suitable under conditions where severe oil oxidation

can occur. Suitable ambient temperature, load condition, as well as change interval vary from fluid

to fluid. Two-year warranty service is only available when Sullair ® AWF ® fluid designated

by Sullair is used.

Fluid Type Change Interval, Hours Ambient Temperature, oC Model

Sullair® AWF® 500 -29～49

RH ModelMobil 1 Synthetic AFT 800 -29～49

Mobil Rarus SHC 1026 800 10～52

Mobil Rarus SHC 1024 1000 -29～38

Fluid Type Change Interval, Hours Ambient Temperature, oC Model

Sullair® AWF® 2500/1800/1200 -29～38/39～44/45～50

XH and HModel

D-A Torque Fluid 1000 -12～43

SAE 10W SE,SF,SG,CD 300 -18～38

MIL-L-2104E 10W 300 -18～38

DexronⅢ 550 -18～38

Note: Part numbers for Sullair AWF are 250030-757(5gal/19 liter package) and 250030-758(55

gal/208 liter package).

Normally, portable rotary screw air compressor designed and manufactured by Sullair is equipped

with Sullair®AWF® fluid. This fluid is a kind of heavy-duty, multi-viscosity all-weather fluid,

applicable for various climate conditions, being the special portable rotary screw compressor oil

supplied by the manufacturer, having good application performance.Periodically remove the condensate at the bottom of the fluid/air separator sump. In high ambienttemperature and high humidity conditions, condensed moisture may emulsify with the oil forming a“milk” color. The fluid should be changed if this condition develops.DO NOT mix different types of fluid. Mixing different fluids may lead to problems such asfoaming, filter plugging, orifice or line plugging. If serious, it will cause cooler plugging or air-endlocking.When ambient temperature exceeds specification or if conditions require use of other extended-lifefluid, contact Sullair. Sullair encourages the user to participate in a fluid analysis program. Thiscould result in a fluid change interval differing from that stated in the manual. Sullair offers a fluidanalysis program for Sullair®AWF®. Contact your local Sullair representative for details.

1.5 Engine Oil

Diesel engine shall use multi-grade oil of API CH-4, API-CG-4 conforming to American PetroleumInstitute (API) categories. Using nonconforming engine oil will seriously affect the service life ofengine and may cause accidents such as scuffing or bush-burning, etc.

Engine oil gradeAmbient temperatureAPI CH-4, API CG-4

SAE 0W30 Engine oil for ultra low temperature (-40℃~-25℃)

SAE 5W30 Engine oil for low temperature (-30℃~-15℃)

SAE 10W30 Engine oil for low temperature (-20℃~-5℃)

SAE 15W40 Engine oil for normal temperature (-10℃~+38℃)

SAE 20W40 Engine oil for high temperature (above +38℃) or undersevere load condition

Caution: Using low-viscosity engine oil, e.g. 10W-30, will be helpful for engine startup and


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providing sufficient oil volume under low ambient temperature. However, continuous use oflow-viscosity engine oil will reduce engine service life.

70506-J Premium Blue engine oil provided by Sullair (equivalent to CH-4 grade 15W-40 engine oilof API classification) can ensure normal operation of the diesel engine under normal temperature.The Sullair part number for premium blue engine oil is: 88290003-329.

1.6 Engine Coolant

Antifreeze & antirust coolant not only prevents the water jacket of cylinder block/head and watertank from cracking due to freezing in winter, it also prevents the rust and removes the scale.Moreover, the boiling point of the antifreeze & antirust solution is higher than that of the ordinarywater, which also has certain advantage on the cooling system. Therefore, this engine seriesrequires antifreeze & antirust coolant throughout the year and never use ordinary coolingwater.Coolant also acts as fluid in water pump of the engine.Antifreeze & antirust coolant normally consists of three compositions: water, additive and glycol(or ethylene glycol), and the three compositions are concocted in certain proportion. The proportionmust be controlled precisely, because different proportions will have different effects.It is recommended to use distilled water or de-ionized water in engine cooling system. If there is nodistilled water or de-ionized water, please use water that meets the requirements in the followingtable:

Minimum requirement of water acceptable to diesel engineItem Upper limit

Chloride (CL-1) 40mg/l

Sulfate (SO-2) 100mg/l

Total hardness 170mg/lTotal solid 340mg/l

Acidity Ph5.5～9.0

Sullair offers DCA60L-J antirust additive to supplement the concentration of antifreeze & antirustsolution, ensuring the service life of diesel engine cooling system. No antirust additive is requiredfor new machine. Only add when experiment indicates that the SCA (supplementary coolant additive)concentration is lower than 6%. It is suggested to use 6%-8% SCA in the coolant. Sullair partnumber for DCA60L-J antirust is 88290002-597.Sullair offers the concentrated antifreeze liquid (glycols). Through different mixing ratio with water,it can make the freezing point and boiling point of the cooling system to various points. Glycolconcentration in Sullair coolant is 50%.Sullair’s part number of condensed antifreeze antirust liquid is 88290002-598.

Glycol concentration

Concentration Antifreeze protection Boiling protection

50% -32℃ 106℃

60% -50℃ 108℃

▲Warning

If the machine is intended to be stored or operated in cold region, the lowest localambient temperature should be available to make sure the antifreeze protection temperatureis lower than lowest ambient temperature so as to avoid damage to diesel engine and coolingsystem.


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1.7 Diesel Fuel

User can choose light diesel fuel of different grades based on the local ambient temperature:

0# light diesel fuel Ambient temperature above 4℃

－10# light diesel fuel Ambient temperature above -5℃

－20# light diesel fuel Ambient temperature -14 ~℃ -5℃

－35# light diesel fuel Ambient temperature -29 ~℃ -14℃

▲Warning

Since diesel will separate out the paraffin crystal first before solidification, blocking thefuel line and fuel filter, causing the diesel engine unable to start. Therefore, appropriate lightdiesel must be used at low temperature. Before the wax is formed from diesel, thoroughlydrain diesel not conforming to environment requirement, including all diesels in engine fuelline and fuel filter.

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

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Section 2 SAFETY

2.1 GeneralSullair designs and manufactures its rotary screw air compressors so that they can be operatedsafely and reliably. However, the responsibility for safe operation rests with those who use andmaintain these products. The following safety precautions, if consciously followed, will minimizethe possibility of accident.Only those who have been trained and delegated to do so, and who have read andunderstood this Manual should operate the air compressor. Failure to follow the instructions,procedures and safety precautions in this Manual can result in accidents and personal injuries oreven death.NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the aircompressor with a known unsafe condition. Tag the air compressor and render it inoperative bydisconnecting the power at source so others who may not know of the unsafe condition will notoperate it accidentally until the condition is corrected.Compressed air is dangerous. Maintain or repair the air compressor unit only when allcompressed air in the whole compressor system has been bled empty.DO NOT modify internal structure or control mechanism of the compressor except with writtenapproval from Sullair.Perform daily maintenance of the air compressor and check for leaks, loose or missing parts,damaged parts or parts out of adjustment. Correct problem without delay.Check hoses frequently to see if there is any damage that may affect its performance, e.g., scratch,wear, crack, hardening, bulge, etc. Replace if any of the conditions is evident. Use time of hoseshall not exceed its nominal service life.Caution: Use time of hose is 2000 hours. User shall calculate the service life based on actualconditions.

2.2 Towing and Parking2.2.1 Preparation

▲Warning

DO NOT tow the compressor should its weight exceed the rated limit of the towing vehicle, as the

vehicle may not brake safely with excess weight. See rated limit in towing vehicle operator’smanual, and review its instructions and other requirements for safe towing.

1) Prior to hitching the air compressor to the tow vehicle, check all attaching parts for: (1) signsof excessive wear or corrosion; (2) parts that are cracked, bent, dented or otherwise deformedor degraded; (3) loose nuts, bolts or other fasteners; (4) Check if the stay bolt (marked in red )for transport on the fluid/air separator base is in place and secure; (5) check if the stay bolt(marked in red ) for transport on the diesel engine and air end support is in place and secure.Should any such condition be present, do not tow until the problem has been corrected.

2) Before coupling, turn the handle of drawbar leg of the machine to adjust the machine to anappropriate position (lean forward a little).

3) During the coupling, have the tow vehicle slowly backed to a proper position when attachingthe compressor.

4) If the lug of compressor’s drawbar is not at the same height of tow vehicle’s hook, change themounting position of direction of lug or adjust the height of the leg to achieve desirableheight.

5) Make sure the tow pin is secured and the connection mechanism is absolutely engaged,fastened and locked.

6) Make sure the safety chain is securely fastened to tow vehicle to avoid the connection systemgoes off by accident.

7) Fold the leg before towing once the machine is connected to the tow vehicle.

▲Warning

Fold the leg of drawbar only after the compressor is connected to tow vehicle. Secure the leg with pin.


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8) Make sure the towing mechanism and adjustment device of towing vehicle and the machine

do not interfere with or disturb each other when moving on any kind of terrain.

9) Make sure the tyres are in good condition. Do not change the size of tyre. Tighten the bolts of

tyre to specified torque.

10) Make sure the lights of towing vehicle are in good condition. The reflective surface of

compressor shall be clean and intact.

11) Make sure the air service hose has been unraveled.

12) Make sure all doors of the machine are closed and secured. Make sure there is nobody inside

the machine before closing doors.

13) Make sure the wheels of the machine are not blocked and the machine can move freely.

14) Test the performance of towing vehicle’s brake before driving at rated speed.

15) DO NOT carry loose or inappropriate tools or equipment on or in the compressor unit.

16) DO NOT load this equipment with accessories or tools that is likely to cause unit unbalance.

Such unbalance may reduce the tow-ability of this equipment and may increase the

possibility of tipping, rolling over, jackknifing, etc.

2.2.2 Towing

Caution: The compressor is a specially designed construction equipment and is not recommended

on road at normal situation. If it is necessary, please do follow the requirements below:

1) DO NOT exceed the Max. Towing speed of 35 km/h under ideal conditions. Reduce runningspeed according to posted speed limits, weather, traffic, roads or terrain conditions.

2) Remember that the portable air compressor may approach or exceed the weight of the towingvehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lanechanges, U-turns, or other similar dangerous maneuvers. Avoid excessive deviation whenback the towing vehicle. Slow down speed when make U-turns.

3) Avoid grades in excess of 15o (27%).4) Avoid potholes, rocks and other obstructions and soft shoulders or unstable terrain.5) Maneuver in a manner that will not exceed the freedom of motion of the compressor’s

drawbar and/or coupling device, in or on the towing vehicle’s coupling device and/oradjacent structure whether towing forward or backing up, regardless of the terrain beingtraversed.

6) Make sure all service doors are closed and locked.7) DO NOT permit personnel to ride in or on the compressor. No personnel are allowed

standing between the towing vehicle and the compressor unit.8) Make sure no personnel are near the compressor.9) Make sure that the stay bolt (marked in red) for transport on the fluid/air separator base is in

place and secure.10) Make sure that the stay bolt (marked in red) for transport on the diesel engine and air end

support is in place and secure.

2.2.3 Parking

1) Park or locate the compressor on a level and firm surface, if possible. Otherwise park or

locate the compressor across grade so the compressor does not tend to roll down hill.

2) When parking, the compressor should be leaning forward a little. Support the rear end if

necessary.

Caution: DO NOT park or located the compressor on grades in excess of 15o (27%).

3) Park or locate the compressor in such a place that the exhausted hot air and radiator heat is

away from the compressor air inlet openings. Avoid the compressor be exposed to excessive

dust environment.

4) Loose the chain on towing vehicle. The chain shall not make contact with ground to avoid

rust.

5) Block both directions of wheel using stone blocks.

6) Disengage connection mechanism. Do not stick your hand.

7) Unfold the leg of drawbar and pin the leg.


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Caution: The leg must rest on solid ground. Never put your feet under the drawbar.8) Turn the handle of drawbar leg of the machine to adjust the machine to an appropriate

position (lean forward a little).9) The towing vehicle should be parked in a place that will not disturb the operation of

compressor, preferably away from the compressor.10) If the compressor is parked at the midst of road or nearby, install signs, barriers as well as

indication lights during night to warn other vehicles.11) Make sure that the stay bolt for transport on the fluid/air separator base and the stay bolt

(marked in red) for transport on the diesel engine and air end support are loosened prior topower-on.

2.3 Pressure Release

1) Make sure the working pressures in hoses, pneumatic devices, lines, valves, filters, and otheraccessories are not in excess of the rated pressure.

2) Make sure to shut down the compressor and bleed the sump to zero before removing the cap.3) Make sure to bleed the internal pressures when disconnecting any piping, connector, valve, oil

plug, filter and separator.4) Keep personnel out of line with and away from any discharge openings, regardless of service

air end, compressor or pneumatic devices.5) Pressure of air used for dust cleaning purpose should not be in excess of 30psi (2.1bar), and

dust protection equipment should be provided in working.

2.4 Fire and Explosion

1) Allow the compressor to cool before adding fluid. Ground the compressor and fluid/airseparator together before adding fluid and keep sparks, flames and other sources of ignitionaway.

2) Clean up spills of fluid immediately should such spills occur. Do not permit fluid on acousticmaterial or the surface of other components. Wipe down using a cleaner or steam clean asrequired. If necessary, replace contaminated acoustic material. Any acoustic material with aprotective covering that has been torn or punctured should be replaced immediately to preventaccumulation of fluid within the material.

Caution: DO NOT use flammable solvents for cleaning purpose.

3) Disconnect the ground line (negative) of power supply prior to any repairs or cleaning inside

the enclosure. Tag the disconnected location so others will not unexpectedly reconnect it.

4) Make sure the electrical system is in good condition, i.e. the connection is clean and secure.Change whenever damage occurs.

5) Keep grounded conductors (e.g. tools) away from exposed live electrical parts (e.g. terminals)to avoid arcing.

6) Disconnect charger before servicing or wiring the battery.7) Change damaged fuel tank and pipes immediately.8) If the fuel system is leaking, it must be corrected before starting the machine. Install warning

signs until the problem has been corrected.9) If welding is required during the repair, remove any acoustical material and other materials

inflammable or vulnerable to heat.

▲Warning

Do not weld near fuel or lubrication system.

10) Keep sufficient and reliable fire extinguishers available and check regularly.11) Keep oily rags, trash, leaves, litter or other inflammables out of and away from the

compressor.12) Open all access doors before starting the compressor for full ventilation.13) DO NOT operate the compressor under low over hanging leaves or permit such leaves to

contact with hot surfaces of the compressor when working in forested areas.


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2.5 Moving Parts

1) Keep hands, arms and other parts of the body and also clothing away from couplings, fans,belts and other moving parts.

2) DO NOT attempt to operate the compressor with the fan, coupling or other guards removed.3) Wear snug-fitting clothes and confine long hair when working around the compressor,

especially when exposed to hot surface or moving parts inside.4) Keep access doors closed except when making maintenance.5) Make sure all personnel are out of and clear of the compressor prior to attempting to start the

compressor.6) Shut down the engine prior to following operations: adding fuel, fluid, coolant, or changing

electrolyte.7) Disconnect the negative terminal of battery when servicing and render it inoperative so others

who may not know of the condition will not connect wire accidentally.8) Sometimes it might be necessary to adjust the pressure regulator or engine speed when the

compressor is running. In such a case, do not touch other moving parts or the terminal ofengine starter. Other adjustment operation can only be carried out after the compressor is shutdown.

9) Clean the oil and water contaminant on hand, foot, machine parts and ground near themachine, to avoid slipping.

2.6 Hot surfaces, sharp edges and sharp corners

1) Avoid body contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.2) Keep all parts of the body away from all points of air discharge and exhaust port of cooling

fan.3) Wear personal protective equipment including gloves and head covering when working in, on

or around the compressor.4) Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore

small cuts and burns as they may lead to infection.

▲Danger

NEVER remove the heat insulation sleeve of engine tail pipe. Replace immediately if damaged.Otherwise, it may cause serious accidents such as machine fire or burn!

2.7 Toxic and Irritative Substances

1) Do not use air from the compressor for respiration.

▲Danger

Death or serious injury can result from inhaling compressed air without using proper safetyequipment!

2) Operate the compressor only in open or well-ventilated areas. If the compressor is operatedindoors, fully discharge engine exhaust fumes outdoors.

3) Locate the compressor so that personnel or compressor is not likely to ingest or intake exhaustfumes.

4) Care should be taken to avoid accidental ingestion and/or skin contact with fuel, fluid andcoolant. Wash with soap and water in the event of skin contact. In the event of ingestion, seekmedical treatment promptly.

5) Wear an acid-proof apron and a face mask when servicing the battery. If electrolyte is spilledon skin or clothes, immediately flush with large quantity of water.

6) If eyes are spilled by coolant or irrigated by volatile gas, flush with water for 15 minutes andsee a doctor, preferably ophthalmologist.

7) Do not store coolant in a closed space.8) Coolant is toxic. Never swallow, contact with skin or inhale its volatile. If swallowed, drink

large amount of salty water to wash the stomach. After the puke is clear, drink a cup of sodawater and lie down. Call a doctor immediately.


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2.8 Electrical Shock

1) Keep the compressor, towing vehicle and personnel at least 3m away from electric wire.

2) Keep all parts of the body and any hand-held tools or other conductive objects away from

exposed live parts of electrical system. When servicing and adjusting these parts, stand on

insulation surface. Do not wet the feet and do not contact other parts of the compressor.

3) Maintain the compressor at a clean, dry and well-lighted place.

4) Stay away from the compressor during lightning.

2.9 Battery

1) The battery may contain hydrogen. Since hydrogen is highly inflammable and explosive, no

sparks, flames and other sources of ignition shall be present near the compressor.

2) Electrolyte in battery is highly corrosive and toxic. Never contact it with eyes, skin or fabrics.

Otherwise, it may cause injury or loss of property. In case of electrolyte spill, flush with large

amount of water immediately.

3) If the electrolyte is frozen or has ice in it, never start the compressor. Otherwise, the battery

may explode.

4) Avoid contact of leads and wire clamp with other metal parts to prevent the electric arc, which

may cause fire.

2.10 Lifting

1) Before lifting, inspect points of attachment for cracked welds and for cracked, bent, corroded

or otherwise degraded members and for loose bolts or nuts.

2) Make sure the entire lifting, rigging and supporting structure has been inspected, is in good

condition and has a rated capacity of at least the weight of the compressor. If you are unsure of

the weight, then weigh compressor before lifting.

3) Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and

latched on the bail or slings.

4) Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has

been lifted.

5) Do not attempt to lift in high winds.

6) Keep all personnel out from under the compressor whenever it is suspended.

7) Keep lift operation in constant attendance whenever compressor is suspended.

8) Lift compressor no higher than necessary.

9) Do not drive the crane while lifting to avoid damage to compressor.

10) Set the machine down only on a surface capable of supporting the machine.

11) Block both directions of compressor’s wheels before releasing the hook.

12) Use steel cable or wire to secure wheel axle and drawbar before transporting the compressor.

2.11 Miscellaneous

1) If it is necessary to enter the enclosure to perform service adjustment, you must inform other

personnel before doing so, and secure and tag the access door in the open position to avoid the

possibility of others closing the door with personnel inside.

2) Make sure all personnel are out of the machine before closing the door.

3) Air spring used to support doors is a high air pressure product. Never put it over flame or

bump or dismember it.

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

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Section 3 DESCRIPTION

3.1 Introduction

The 550RH, 600XH and 750H diesel engine driven portable screw compressor designed and

manufactured by Sullair will provide you with improved reliability and greatly reduced maintenance.

Your compressor, a diesel engine driven, air-cooled fluid injection screw portable type, is convenient

to travel depending on operation requirement.

The compressor is designed and manufactured by Sullair, offering great power performance, cost

effectiveness and reliability. It can be operated 24x7 at full load.

Driver of the compressor is Dongfeng CUMMINS 6C diesel engine. Its excellent performance

guarantees power supply to the compressor.

The compressor features logical layout, comprehensive functions, ease of use & operation and elegant

appearance. The enclosed silent design minimizes noise of the compressor. Display instruments and

indicators on instrument panel give abundant messages and diagnostic functions.

In reading this Manual, you will know how to use and maintain the compressor. With attention, you

will find out that it is easy to maintain the machine at its top performance.

Read Section 5 Maintenance to keep your portable screw compressor in top operating condition.

Should any problem or questions arise which cannot be answered in this Manual, contact your local

Sullair representative or Sullair Service Department.

3.2 Machine Layout

Cooling andlubrication system

Engine DischargeSystem

Inlet System

Discharge system

Diesel engine andCompressor unit assembly

Frame-moving System

Electrical System

Fig. 3-1 DPQ550RH, 600XH and 750H portable rotary screw compressor


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Fig. 3-2 DLQ550RH, 600XH and 750H series screw compressor

See Fig. 3-1 and Fig3-2 for parts and layout of 550RH, 600XH and 750H diesel engine drivenportable screw compressor of Sullair. The machine consists of compressor unit & diesel engineassembly, compressor inlet system, engine inlet system, compressor discharge system, cooling andlubrication system, control system, engine discharge system, fuel system, electrical system,frame-moving system, etc. Sound insulation enclosure of the machine is equipped with acousticmaterials to minimize noise of the compressor on the surrounding environment.

The compressor is driven by the rear side of output shaft of diesel engine through a heavily loaded

spring type coupling mounted on flywheel. Air filtered by inlet filter enters the inlet chamber of

compressor through inlet control valve, and then compressed in screw groove before being discharged

from air end. Then the compressed air enters fluid separator for oil/gas separation. Separated

compressed air with little oil goes through min pressure valve, air service piping and service globe

valve for customer to use. Separated fluid sets to the bottom of sump tank and is cooled by fluid

cooler and returned to the chamber of compressor unit under pressure difference.

The front side of output shaft of diesel engine drives a blow type cooling fan through belt. The cooling

fan is used to cool compressor fluid and engine coolant, removing heat generated during operation.

3.3 Compressor unit & Diesel Engine Assembly

See Fig. 3-3. Compressor unit & diesel engine assembly consists of the air end, diesel engine,connection component, elastomer coupling, cooling fan, shock absorber, bracket, etc. The system isthe core of the entire machine.


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Coupling and Connector

Diesel Engine

Fan

Engine Support

Shock Absorber

Compressor

Compressor Support

Fig. 3-3 Compressor unit & diesel engine assembly

3.3.1 Compressor Unit

The compressor is very important in the compressor unit designed by US Sullair, featuring fluid

injection and lubrication. This unit provides continuous pulse-free compressed air to meet your needs.

Compared to other compressors, the Sullair air end is unique in mechanical reliability and durability

design. With its working parts meeting the “inspection free” process requirement, the air end is free of

maintenance and internal inspection during normal operation.

Inside the casing of the compressor unit, there is a pair of parallel fine-machined rotors (male rotor

and female rotor) with spiral grooves. Inlet and outlet are diagonally placed on rotor case. Screw

groove of female rotor meshes with and is driven by the screw tooth of male rotor. In a working cycle

of inhaling, enclosing, compressing and exhaling, the revolving rotors enclose inhaled air in the closed

screw groove space between rotors and case, and the bulk of screw groove space varies as the rotors

are revolving.

Rotors revolve to suck air. In the meantime, large amount of fluid is injected into the closed screw

groove space between rotors and case through a specially designed injector and mix with air directly.

Fluid serves for three main purposes:1) As coolant, the injected fluid controls the rise of air temperature by absorbing large amount of

heat normally associated with compression.2) Seals the leakage gap between the rotors and the stator and also that between the rotors to reduce

internal leak.3) Acts as a lubricating film between the rotors, allowing the male rotor to directly drive the female

rotor. It also absorbs part of mechanical noise.

3.3.2 Diesel Engine

Diesel engine is another crucial part of the portable rotary screw compressor. The diesel drivenportable rotary screw compressors use Dongfeng CUMMINS 6C diesel engine. 6C is not onlypowerful, fuel-economic and durable, but also easy to service and requires little maintenance. SeeOperating and Maintenance Manual of Dongfeng CUMMINS B engine.

3.4 Compressor Inlet System

See Fig. 3-4. The compressor inlet system provides clean air to the compressor. It consists of onecompressor air filter, one Inlet control valve and pressure difference indicator for filter element, etc.


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Anchor hoop

Air intake hose

Pressure difference indicator

Air filter assembly

Anchor hoop

Support

Fig. 3-4 Compressor Inlet System

Air filter of compressor inlet system adopts cross-flow mode, capable of dealing with very dirty air.

Operator should frequently clean the dust gathered in the dust pocket in the rear cover of air filter. If

the pressure drop alarm of filter turns red, then the flow resistance in air filter is too high. Please

service or replace the main filter element in time. A safety element is equipped in the filter to give

temporary protection in case of main filter element failure. Safety filter element does not need

maintenance normally and should be replaced together with the main element.

Caution: (1) The mesh of safety filter element is larger than that of main element. It only provides temporaryprotection in case of main element failure (for 4 to 6 hours). Therefore, the failed main element must bereplaced immediately. Otherwise, rotor wear or bearing damage could occur.

(2) If the pressure drop alarm indicator at the outlet of air filter turns red, please service or replace the mainfilter element promptly and then press the reset button on the end of pressure drop indicator to clear thealarm.

Piping of compressor inlet system is made of high quality rubber hoses, capable of resisting cold orhot environment and is highly durable. To ensure air tightness and reliability, stainless steel “T”screw-type hoops are used for connection.

▲Warning

Never use iron wire to strap the rubber hose. Never use rubber hose with crack. If a loose T hoop or hosedamage is found, stop the machine immediately and take measures to ensure air tightness of the piping.

Never attempt to run the machine when air filter element is not present or is damaged, otherwise thecompressor unit may be seriously damaged.

3.5 Diesel engine inlet system

See Fig. 3-5. The engine inlet system provides clean air to the diesel engine. It consists of one air filter,intake pipeline and pressure difference indicator for filter element, etc.


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Air filter support

Anchor hoopAir filter assembly

Pressure difference indicator

Reducing Joint

Intake Stainless Steel Tubing

Air intake hose

Fig. 3-5 Diesel Engine Inlet System

Air filter of engine inlet system is the same with compressor adopts cross-flow mode, capable of

dealing with very dirty air. Operator should frequently clean the dust gathered in the dust pocket in the

rear cover of air filter. If the pressure drop alarm of filter turns red, then the flow resistance in air filter

is too high. Please service or replace the main filter element in time. A safety element is equipped in

the filter to give temporary protection in case of main filter element failure. Safety filter element does

not need maintenance normally and should be replaced together with the main element.

Caution: (1) The mesh of safety filter element is larger than that of main element. It only provides temporaryprotection in case of main element failure (for 4 to 6 hours). Therefore, the failed main element must bereplaced immediately. Otherwise, early wear out of diesel engine and even scuffling could occur.

(2) If the pressure drop alarm indicator at the outlet of air filter turns red, please service or replace the mainfilter element promptly and then press the reset button on the end of pressure drop indicator to clear thealarm.

Piping of engine inlet system is made of high quality rubber hoses, capable of resisting cold or hotenvironment and is highly durable. To ensure air tightness and reliability, stainless steel “T”screw-type hoops are used for connection.

▲Warning

Never use iron wire to strap the rubber hose. Never use rubber hose with crack. If a loose T hoop or hosedamage is found, stop the machine immediately and take measures to ensure air tightness of the piping.

Never attempt to run the machine when air filter element is not present or is damaged, otherwise thecompressor unit may be seriously damaged.

3.6 Compressor Discharge System

Compressor discharge system consists of fluid/air separator, min pressure valve, relief valve, serviceglobe valve, discharge piping, etc. See Fig. 3-6.


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Min pressure valve

Relief valve

Relief valve Discharge Pipe

Air Discharge Pipe

Fluid/air separator tank

Air service support

Service valve Unit discharge pipe

Drain pipe

Fig. 3-6 Compressor discharge systemIn a working compressor, air trapped in the screw grooves is compressed constantly; meanwhile thefluid continuously injected into screw grooves absorbs the heat created in compression. When the bulkof screw groove drops to certain value (designed value), screw groove space is connected to aspecifically designed outlet, and oil/air mixture is discharged. Since there are multiple screw groovesbetween the rotor pair, and rotors revolve at high speed, compressed air is discharged continuouslywithout surge.Oil/air mixture discharged from air end then enters a specifically designed fluid/air separator. Oil/airmixture flows along the inside of sump tank due to high speed. Most of the fluid is separated from airdue to centrifugal effect and forms larger fluid droplets. Fluid droplets fall to the bottom of the sump.Baffle boards and isolation boards inside the separator make air and fluid droplets spin and changedirection, to separate more and more fluid from compressed air. After first stage of separation, onlytiny amount of fluid mist is left behind. As the air travels through the element of the separator, finefluid droplets are condensed on separator element’s fiber due to collision, dispersion and interception.Droplets collected on the outer side of fiber then fall to the bottom of sump tank under gravity.Droplets collected on the inner side of fiber converge at the bottom of separator element. A return lineleads from the bottom of separator element to the low pressure chamber of compressor unit. Fluidcollecting on the bottom of the separator is returned to the low pressure chamber of compressor unitdue to pressure difference. The return line is equipped with an orifice (with filter) to ensure steadyfluid return. A check valve is also provided in return line to prevent fluid backflow from compressorunit to filter, which may otherwise contaminate discharge air with fluid content next time the machineis started.A min pressure valve is equipped between the fluid/air separator and service valve to establish aminimum tank pressure when the compressor unit is operating, to maintain proper operation oflubrication system. When the machine is not operating or unloaded, the min pressure valve acts as acheck valve to prevent compressed air from backflow. Triggering pressure of the min pressure valvehas been set before shipment.After separation, oil content in the compressed air is only a few PPMs. Compressed air is available touser through the min pressure valve. There are two service valves of different specifications on thebottom of control panel side, so as to accommodate different needs of the user.A relief valve is equipped on the separator sump tank. When air pressure inside the tank exceedspressure setting of the relief valve, the relief valve opens automatically. Triggering pressure of reliefvalve is preset at factory. Please do not change. A temperature probe and a temperature switch areequipped on the discharge tube of air end. If compressor discharge temperature is above the setting of


17

the temperature switch, which will shut down the machine automatically.The fluid filling screw cap of separator has been specially designed to discharge residual pressurewithin the tank when you disassemble the machine. The sight glass on the sump tank is used toobserve fluid level inside the separator. For a machine not in operation, fluid level should fall slightlybelow the center of sight glass.

▲Warning

DO NOT remove nuts, oil plug, and other parts when the compressor is running or pressurized. Shut down

and bleed internal pressure of the compressor prior to operation.

NEVER replace with or use the relief valve of other type.

3.7 Compressor Cooling and Lubrication System

The cooling and lubrication system of compressor consists of cooler set (fluid cooler, coolant tank andintercooler), fluid filter, thermal valve and piping. See Fig. 3-8.Compressor fluid not only serves as the coolant, absorbing heat generated in compression to controltemperature rise of compressed air, but also the sealant between rotors and case, and fluid of movingrotors.The thermal valve has two entrances and two exits. The entrances are called Port A and Port B. Fluidfrom fluid/air separator enters through Part A and fluid from cooler enters through Part B. The exits

are called Port C and Port D. Fluid from Port C goes back to air end viafluid filter and fluid from Port D enters cooler.Upon start-up, the fluid temperature is low. So the thermal valve is closed.Therefore, Port A and D are not connected. Cold fluid flows out from PortC through thermal valve without passing fluid cooler. Then it goes intofluid filter before entering the working chamber and lubrication points ofbearings.As the compressor continues to run, fluid temperature rises. At a certainpoint, the thermal valve begins to open, and Port A is connected with PortC and D. A portion of fluid is routed from Port D through the fluid cooler.Cooled fluid flows into thermal valve through Port B. Since Port B and Care always connected, cooled fluid goes to the filter via Port C beforeentering air end. The rest of fluid flows back to air end from Port C

without going through cooler. As fluid temperature continue to rise to the threshold of thermal valve,the valve full opens and Port A and C are disconnected. Therefore all fluid goes into fluid coolerthrough Port D. Cooled fluid flows into thermal valve from Port B. Then it goes into fluid filter beforeentering air end.

The fluid filter consists of filter seat, replaceable spin-on element with a built-in bypass valve, whichmaintains a proper fluid flow even when the filter element becomes plugged or when the fluidviscosity is too high. A visual pressure drop indicator is equipped on the top of fluid filter. When itturns red, the fluid filter element should be replaced.

D

C

B

A

Fig. 3-7 Thermal Valve Diagram


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Cooler AssemblyFan Guard

Water supply pipe

Oil outlet pipe

Return line system

Fluid filter

Thermal valveOil inlet pipe

Drain Pipe (Water Cooled)

Drain Pipe (Fluid Cooled)

Fig. 3-8 Cooling & lubrication systemThe cooler is equipped with the coolant recovery tank, to which all air stored up in the water supplychamber will be pushed from the top as the coolant is heated and expands during operation. If there isno air in the water supply chamber, the extra coolant will be pushed into the recovery tank. When themachine is down, the coolant contracts, due to cooling of the engine system, and is forced back to themain radiator system with air pressure through vacuum valve on the radiator cover. The coolantrecovered by the recovery tank can be recycled.

3.8 Control System

Control system (see Fig. 3-9) is capable of modulating inlet air volume and engine speedautomatically based on air demand, while maintaining a fixed service pressure. The system consistsof:Inlet control valve, pressure regulation valve, circulation blow-off valve, Start/Run solenoid valve,Start/Run/Stop switch, orifice, shut-down blow-off valve, piping and connectors.

Normally the control system needs not to be adjusted. In case adjustment is necessary, writtenapproval from Sullair shall be obtained. Please refer to Section 4.6 – Mode Setting Procedure.

To modulate the capacity of the compressor is to modulate inlet air volume by varying engine’s RPMand opening of inlet valve. The compressor has four working modes: A. Starting mode; B. Loadedoperating mode; C. Modulating mode; and D. Shutdown mode.

3.8.1 Starting mode

Before starting the machine, turn the Start/Run/Stop switch to “Start” position. Now the inlet valve isclosed under spring force to ensure minimum load upon starting. Once the machine is started, inletvalve will be opened by vacuum and system pressure will build up rapidly. During pressure rise,pressure regulating valve does not work and Start/Run solenoid valve is energized. Control air reducesthe inlet valve via Start/Run solenoid valve. Meanwhile, circle unloading valve and blow-down valveare activated. When air volume from inlet valve equals to air volume to blow-down valve, the inletvalve is in balance. In the meantime, control air goes to the speed cylinder of diesel engine to controlthe engine at idle speed (1300rpm). With the engine fully warmed up (warm-up time is 60s), Start/Runsolenoid valve is cut off and Start/Run/Stop switch will trip to “Run” position automatically. Now thecompressed air that controls the openness of inlet valve and engine speed is completely vented. Inletvalve is opened again and engine runs at full speed under spring force.

In cold region, it is difficult to start the diesel engine at low temperature. The engine is equipped withelectric heating module. Press the “Test” button below instrument panel and pressure “Preheat” oncethe yellow light is on. Preheating function normally ends in 45s. Turn off the Preheat button afterpreheating is over and restart the machine.


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3.8.2 Loaded Operating Mode

When system pressure exceeds the threshold of min pressure valve, the valve will open and themachine will start to service. Now the inlet valve is fully opened and the machine is running underload. System pressure soon reaches the rating and machine enters normal operating mode. The dieselengine keeps running at normal speed during normal operation.

3.8.3 Modulating Mode

If the demand of compressed air is lower than machine’s delivery, line pressure will increase. Whenthe pressure exceeds the threshold of regulation valve, the regulation valve will open gradually,sending high pressure control air into the piston chamber of inlet valve and speed regulation cylinderof engine to narrow the inlet proportionately. Meanwhile, system will reduce engine speed. If linepressure continues to rise, inlet port will be further reduced and so is engine speed until the engine isrunning at idle (idle speed is preset).

If demand of compressed air increases now, the pressure which inside the fluid/air separator will drop.When the pressure drops to the threshold of regulation valve, the valve will close, causing control airto fully open the inlet valve. Now the engine will run at full speed and the machine will operate at fullload.

3.8.4 Shutdown Mode

Normally the Shut-down blow-off valve is closed. Turn the Start/Run/Stop switch to “Stop” position.Now the Start/Run solenoid valve is energized. Control air gradually reduces the inlet valve.Meanwhile, circle unloading valve and blow-down valve are activated to release compressed air influid/air separator. In the meantime, control air goes to the speed cylinder of diesel engine to controlthe engine at idle speed (1300rpm). The engine runs at idle speed for 3 minutes. Once the machine iscooled down, it will stop automatically.

In case of emergency, press emergency stop button to stop the machine immediately. Note that in sucha case, the cooling & lubrication system of compressor unit and engine will stop working immediatelywhile the machine is still very hot. Therefore emergency stop can be harmful to the machine. Do notuse the emergency stop button unless there is an emergency.

Air filter clog indicator

Air filter

Orifice

Orifice

Checkvalve

Circulation blow-o ff valve

Solenoid valve

Pressure regulate valve

Orifice Check valve

Water trap

Shut-down blow-o ff valve

Min pressure valve

Pressure differenceindicator for fluid/airseparator element

Reliefvalve

Filter

Check valveSight GlassOrificeFluid/air separator

Blow-off valve

Air filter clog indicator

Fluid filter

Thermalvalve

Fluid CoolerCooling fan

Electronic drain valve

Air end

Coupling

Diesel Engine

Speed Regulation Cylinder

Legend Fluid Piping

Control Air Piping

Measurement Air Piping

Compressed Air Piping

Air filter

Inlet controlvalve

Air filter clogindicator

Fig. 3-9 System schematics


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3.8.5 Energy-saving Module

The module is a patented product from Sullair which helps reduce fuel consumption and overall cost

with improved efficiency

3.9 Auto Protection System

Auto protection system is crucial to the machine. It is used to make sure the machine could not be

started, or would stop automatically or otherwise give alarm message in case of fault conditions, thus

protecting the compressor unit and diesel engine. The system consists of compressor discharge

temperature protection, engine fuel level protection, engine coolant temperature protection, engine oil

pressure protection and starting sump tank pressure protection, etc.

When the machine is running, any of the above protection functions may stop the machine or make it

unable to start. Each protection function is detailed below.

Compressor discharge temperature protection: A temperature switch is mounted on the dischargepiping of air end. When compressor discharge temperature is above the setting temperature(129 /265°F for RH model,115 /239°F for XH and H model)℃ ℃ , the discharge temperatureswitch will open to stop the machine automatically. Meanwhile, corresponding alarm indicatorwill appear on instrument panel.

Hot protection in the fluid/air separator tank: discharge pipe temperature in the air end normally ishigher than that in fluid/air separator tank, and discharge temperature of the air end is protective;however, to prevent abnormal conditions, such as fire in the separator tank, a temperature switchshould be placed near the mixed gas inlet of the fluid/air separator which acts when thetemperature is higher than the preset temperature (for RH model: 129 /265°F, for XH and H:℃115 /239°F℃ ) and causes the unit power off automatically, Meanwhile, corresponding alarmindicator will appear on instrument panel.

Diesel fuel level protection: when the level is below the setting of the level sensor, SULLAIRmulti-function display will show accordingly.

Engine coolant temperature protection: Coolant temperature switch of the engine is mounted onthe main coolant pipe of the engine. When coolant temperature of engine reaches 107 (225°F),℃the engine will stop automatically, At the same time SULLAIR multi-function display will showaccordingly.

Engine oil pressure protection: Pressure of engine oil is crucial to the operation of engine. Normalengine pressure range is 240kPa to 480kPa. It is normal that the pressure is lower at idle speed. Ifoil pressure is lower than 103 kPa(15psi), the engine will stop automatically, At the same timeSULLAIR multi-function display will show accordingly.

Starting sump tank pressure protection: If the fluid/air separator sump tank pressure is above 15psi,system is unable to be started and alarm indication will be shown on instrument panel.

3.10 Engine Fuel System

Fuel system is an important system of diesel engine. It significantly influences the power, costeffectiveness, reliability and durability of the engine. Fuel system provides clean fuel free of dust,water and air, to meet the requirements of engine on power, torque, RPM, fuel consumption, noise,emission, start-up and idle speed. The fuel system consists of fuel tank, filling strainer, fuel prefilter,suction filter, fuel level sensor and fuel piping. See Fig. 3-10.

The filling cap is equipped with a filling strainer. It is convenient for filling operation and can preventimpurities from entering the system.

Suction filter is mounted on tank. It is used to further remove impurities inside fuel tank.

The prefilter is installed after suction filter and is equipped with a water separator. It not only removeswater inside fuel, but also effectively reduces the load on fuel filters of the engine.


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Fuel level sensorFuel prefilter

Fuel Suction TubeFuel inletfilterSuction filter

Fuel tank

Return pipe

Fig. 3-10 Fuel System

Maintain the fuel system according to requirements １, you will find out that it is easy to keep the

electric fuel injection system at its top performance and lowest fault rate.

Fuel tank capacity is 275L, sufficient for the operation of one shift with 8 hours. A blow-off valve

under the bottom of fuel tank is used to remove water and impurities accumulated at the bottom of

tank regularly.

See Section 1.6 – Diesel Fuel for details of fuel.

See the Operating and Maintenance Manual of Dongfeng CUMMINS C Industrial Engine for

details of fuel system of the engine.

3.11 Engine Lubrication System

Engine lubrication system provides pressurized fluid to the moving parts of engine to create fluid

friction (contact-free friction), and to cool those parts unable or difficult to be cooled the by cooling

system. The system also cleans the surface of engine parts.

See Section 1.4 – Engine Oil for details of engine oil.

See the Operating and Maintenance Manual of Dongfeng CUMMINS C Industrial Engine for

details of lubrication system of the engine.

3.12 Engine Cooling System

Cooling system of the engine consists of radiator, coolant pump, thermostat, water jacket and rubberpipe. See Fig. 3-7. Total and partial circulations of cooling system are realized through thermostat tomaintain favorable temperature for engine, thus achieving better power, cost-effectiveness andreliability.A temperature switch is equipped on the main coolant pipe of the engine. When coolant temperatureof engine reaches 107 , the engine will stop automatically. If engine temperature persists above 99 ,℃ ℃

１ 1) Use fuel manufactured by a reputable company. Fuel must be settled for at least 24 hours before using to separatewater and impurities.

2) Clean water in the water separator and fuel tank everyday before start to work.3) Top up fuel tank with diesel after work everyday to expel air and prevent condensate.4) Clean and service fuel system and fuel filters as specified regularly.


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the engine oil will deteriorate at an early time and the non-metal flexible parts in engine and coolingsystem will harden sooner. Therefore operating time above 99 should be avoided as much as℃possible. Operation at such a condition shall not exceed 50h during a year.Radiator is an important component of engine cooling system. It is an enclosed, direct flow, forcedcirculation tube-and-fin radiator with pressure cap. The opening threshold of pressure cap is 50kPa,which guarantees that water will not boil below 108 at an altitude of 1500m. Pressure cap not only℃enhances cooling performance of the radiator, but also reduces or even eliminates bubble and air-lockin the coolant circulation, especially the air-lock effect around coolant pump inlet (where the pressureis the lowest). Pressure cap keeps the inlet of pump at positive pressure, reducing erosion on pumpimpeller and case, ensuring stable coolant flow and removing heat from the engine with sufficientcoolant.Please use long-life antifreeze & antirust coolant for the diesel engine. See Section 1.5 – EngineCoolant. Antifreeze & antirust coolant does not erode metal or rubber materials, and can ensure thatno scale would form in water jackets of the cooling system to protect engine in extremely cold regions.Coolant should be changed every 2 years or 3000 hours. A properly sealed system needs not to addcoolant frequently. However, user should check and refill antirust regularly to maintain theconcentration. Please fill the coolant slowly in order to release air remnant and vapor created at hightemperature.Caution: DO NOT MIX antifreeze & antirust of different brands.

3.13 Engine Discharge System

Engine discharge system operates to reduce exhaust noise, prevent exhaust from leaking and keepexhaust way clear. The system consists of tail pipe, silencer, rainproof cap, etc.

Tail pipe

Silencer

Rainproof cap

Silencer cover

Fig. 3-11 Engine Discharge System

Turbocharger connects to intake manifold on one end and exhaust manifold on the other. All air/fumesucked in/exhausted by diesel engine goes through the turbocharger. When the engine is running, fumefrom exhaust manifold enters turbocharger and pushes impeller; on the other end, air from air filterenters the inlet of turbocharger and is compressed by turbocharger impeller before flowing into theintake manifold of engine.When engine load increases, more fuel will be injected into cylinder and thus more fume generated,causing turbocharger impeller revolving faster to suck more air. Since extra air is provided byturbocharger, more fuel will combust, thus higher output power of the engine.


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Top speed of turbocharger is controlled by turbocharger control tube, maximum engine racing speedsetting and field altitude.To eliminate potential scalding or fire caused by hot exhaust piping, the tail pipe is covered with heatinsulation sleeve to insulate heat and reduce noise.A section of corrugated metal tube is inserted into tail pipe to accommodate heat expansion anddeformation caused by vibration. The rain cap above the outlet of silencer prevents rain/snow fromentering into the silencer. Do not remove the rain cap or replace with an inappropriate one.

3.14 Instrument Control System

See Fig. 3-12 Instruments and controls on the panel include SULLAIR multi-function display,discharge pressure gauge, discharge thermometer, Start/Run/Stop switch, Preheat/Test/Non-preheatSwitch and alarm indicators. To ensure normal operation of the machine, operators shall be familiarwith the function and use of each display and control in order to make correct judgment according toreadings.

Discharge temperature Discharge pressure

Dischargeoverheat

High startingsump tankpressure

Preheat Start

Test Run

Non-Preheat Stop

SULLAIR Multi-function Display

Fig. 3-12 Instrument & control system

Discharge pressure gauge – It displays the pressure of compressed air supplied by the machine.

Discharge thermometer – It is used to measure the discharge temperature of compressor unit. Normal

reading for RH model should be 176~265 (80~℉ 129 )℃ and 176~239 (80~115 )℉ ℃ for H and XH

model.

Start/Run/Stop switch – It is used to engage the electrical system of the machine and the starter of

diesel engine. It is a 3-position switch, i.e. “Start”, “Run” and “Stop” in sequence. Turn the switch to

“Start” to start the machine. In such a case the engine will run at idle speed with no load for 60s. Once

it is fully warmed up, the switch will trip to “Run” automatically. Now the engine will run at full

speed and the compressor will work at rated pressure with load. Turn the switch to “Stop” and the will

engine run at idle speed for 3 minutes. Once the machine is cooled down, it will stop automatically.

Preheat/Detection/Non-preheat Switch: when the diesel engine temperature is too low to start, the

switch is placed at “Detection” position, if the battery power is not sufficient, “Preheat” yellow

indicator lights; the unit is ready for the air inlet preheat setting with heating intervals at 45s. Switch

off when the heating is done and restart the unit.

Alarm indicators – Two indicators, Discharge overheat and High can pressure. Corresponding

indicators will be on when there is a fault condition within the machine.


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Enter into four parameters displayLanguage

History Fault Codes

Engine ConfigurationSetting single parameter display

3.14.1 SULLAIR multi-function display

SULLAIR display can show:

Parameters:

Engine rotation

speed

Hours of operation

of the engine

Hours of operation

of the unit

System voltage

Coolant temperature

Engine oil pressure

Fuel level

SULLAIR multi-function display uses matured technology of capacitive touch key without any tear

and wear. The key effects can be shown by screen flashes, with the functions as below:

3.14.1.1 Basic application

a. Press the Menu key to enter the menu.

b. Scroll to select with Left/Right key.

c. In the case of multiple pages, when the cursor is pointed at top or bottom the screen willauto-page.

Menu key: to enter/exit the menu

Left key: to select left/up

Right key: to select right/down

Enter key: confirm or conceal/read dynamic Fault information

Enter into four parameters display

LanguageHistory Fault CodesEngine ConfigurationSetting single parameter display

General Fault Indicator(Amber)

Shutdown Indicator(red)

Screen

Menu key

Left key (up) Right key (down)

Panel box

Enter key


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Setting single parameter display

Setting four parameters display

Measurement

Backlight Adjustment

Contrast Adjustment

d. When the cursor is pointed at the selected option and press the Enter Key the relevant contentunder the option will appear.

e. The “MORE” as shown at bottom of the screen indicates there are more pages to show byLeft/Right key.

More

3.14.1.2 Operation Guidance

a. When the Sullair multi-function display is powered on, the screen will show as they are if theengine ECU transmission waits for start-up signal. When there is no such info it is possible tostart the engine.

Preheat, Standby

b. Once the engine is started, the rotation speed can be shown on the screen. Press Left/Right keyto browse other parameters.

RPM Water temperature

3.14.1.3 Screen Display Setup

Each screen may display one engine parameter only (the “single parameter display”) or fourparameters (the “four parameters display”).

a. Single Parameter Display

There are three options:


26

“Default Settings”– this option includes a set of preset engine parameters: Hours of engine operation,engine rotation speed, system voltage, battery voltage, engine coolant temperature and engine oilpressure.

“Customized Settings”– this option allows a user to set up the type, number and sequence ofparameters for display.“Auto Scan”– if this browse function is selected, the display will automatically display the selectedparameters one by one repeatedly.

b. Display Setup of Single Parameter Display

1. Press the Menu key, and move the Left/Right key to the “Setting Single Parameter Display”, thenpress the Enter Key.

2. If “Default Settings” is to be selected, move the cursor on the option and press the Enter key whenthe screen displays the message “Restore to Default Settings at Factory”.

3. If “Customized Settings” is to be selected, move the cursor on the option and press the Enter keywhen the screen displays the engine parameters available.

4. Press the Left/Right key to the desired parameter and then the Enter key. The number right to theselected parameter represents the serial number of the parameter.

5. To cancel display of a selected parameter, move the cursor on the option and press the Enter keywhen the number right to the selected parameter disappears indicating the display canceled.

6. Move the cursor to select other parameters as Customized settings. To return to the CustomizedSetting any time by pressing the Menu key.

7. If “Auto Scan” function is selected, each parameter will be displayed once on a screen repeatedly.

When the above display settings are done, press the Menu key once to return to the main menu, ortwice to Single Parameter Display page.

c. Four-Parameter Display Settings

Four-Parameter Display screen consists of four blocks, each of which represents a parameter. Thefour parameters displayed at factory are: coolant temperature, engine rotation speed, engine oilpressure, and battery voltage. The operator may also customize the parameters for display.

1. Press the Menu key, move the Left/Right key to select the “Setting four-parameter display”, thenpress the Enter key.

2. If “Default Settings” is to be selected, move the cursor on the option and press the Enter keywhen the screen displays the message “Restore to Default Settings at Factory”.

3. If “Customized Settings” is to be selected, move the cursor on the option and press the Enter keywhen the four-parameter screen displays.

4. Move Left/Right key to the block for edit.5. Press the Enter key and the parameters optional will display. The parameter where the cursor is

located is the parameter to be selected. The number right to the selected parameter represents thelocation of the block on the screen.

1 = upper left, 2 = bottom left, 3 = upper right, 4 = bottom right

Water temperature RPM

Engine oiltemperature

Engine oilpressure

Engine rotation speed

Hours of operation of the engine

Fuel level

Engine Coolant temperature

Engine oil temperature

Engine oil pressure

3

1

2

4

6. Press the Left/Right key to the desired parameter and then the Enter key to confirm.7. Press the Menu key to return to the Customized Settings page.


27

8. The newly selected parameter has replaced the old one in the block for edit.9. Repeat the steps above for customized settings of the remaining blocks.

3.14.1.4 Main Menu Options

In this section the functions all the options under the main menu of the Sullair Multi-function Display

will be introduced. Press the Menu key any time to display these options on the screen. Select with

the Right/Left key and press the Enter key to enter the option as selected.

“Language”

In this option, you can choose Chinese and English. The selected language is suffixed with an asterisk

mark.

“History Fault Codes” *

In this option, you can check the historical fault information of the engine and transmission system.

“Engine Configuration” *

In this option, you can check the configuration data of the engine and transmission system.

* This function is not supported by the all types of engines.

“Measurement”

You can choose appropriate measurement with this option. British: PSI, oF. Metric: KPA, BAR, and

KPa, Bar and oC.

“Backlight Adjustment”

Use this option to adjust lightness of the backlight on the screen.

“Contrast Adjustment”

Use this option to adjust contrast of the screen.

“Tools”

This option provides troubleshooting and setting functions. (For details read the section “Tools”)

3.14.1.5 Fault and Alarm

Sullair Multi-function display provides two methods to display fault of the engine and alarms: thevisual alarm (See the section “Panel Functions”) and the screen display the fault for alarming.

Visual Alarm

Amber —general fault


28

Red –shutdown

Fault alarm is displayed on screen

Instrument Fault

General Fault

Shutdown

Instrument Fault

Simulation signals on the instruments will be connected to the display. In the event of fault on thesimulation instruction, the single parameter or four-parameter display page will be replaced with thefault screen message “no response from the instrument”.

General Fault

When the display receives fault signal form the engine, the single parameter or four-parameterdisplay page will be replaced with the dynamic fault screen page.

Shutdown

When the display receives the shutdown signal form the engine, the single parameter or

four-parameter display page will be replaced with the dynamic fault screen page.

Hints: Fault alarm disappears only when the causes of the fault have been settled.

Fault Confirmation Information

1. Press the Enter key to confirm and hide the dynamic fault message page. The screen display willreturn to the single parameter or four-parameter display page. However, the relevant fault symbol willremain on the page.

2. Press the Enter key to confirm and hide the dynamic fault message page. The screen display will

return to the dynamic fault message page. Press the Enter key again to return to the single parameter

or four-parameter display page.

3.14.1.6 Tools

Choose the “Tools” in the main menu and the options below will appear:

1. “Option List Data”- This option is used to check the instruction related information when the PVA

or PVM simulation instruction is connected with the display.

2. “Clearing all the Option Lists”- Delete the simulation instruction information stored from the

display memory.

3. “Software Version“- Check the displays software version.

4. “Modbus Settings”- See the section “ Modbus Settings” as below.

5. “Fault Version Conversion”- Check/change J1939 Fault Code Conversion.


29

Hints: There are four versions of the J1939 Fault Code Conversion. The display will search the J1939v. 4 by default, and in case of failure the code can be set up to interpret the three other versions of theJ1939 codes. For most of the engines, the ECU (current fault) uses the J1939 v. 4, therefore, thisoption is rarely used.

Once a fault received cannot be interpreted, the user may try other version J1939. If it is impossible tointerpret with the changed version (SPN), this means the ECU is using the J1939 v. 4. If it isimpossible to interpret with the changed fault code, try other J1939 version available and continue tocheck the fault code (SPN).

6. “Simulation Signal Input”– Two options are available:

“Backlight Adjuster” may be used to receive signal transmitted by an external backlight adjuster.

“Fuel Level” may be used to receive signal transmitted by a fuel level sensor.

7. “Choose Engine ECU”– monitor all the ECU or a specific engine

3.14.1.7 Modbus Setting

1. Enter the “Tools” menu, choose the“Modbus Setting”.

2. Choose between the two communication modes and press the Enter key to confirm.

“Slave Station Activation”– SCADA or remote Modbus Master Station

“Master Station Activation”– Driving simulation instrument

3. Choose “Serial communication port settings” (valid on in the Slave Station Activation mode),

press the Enter key to complete the following settings.

4. Scroll the cursor to set up each of the options: “Baud Rate”, “Parity”, “Data Bit”, and “Stop Bit”.

3.14.1.8 Troubleshooting

“Preheat, Standby” Message on the ScreenIf the connected engine ECU (choose the engine) transmits the signal “Preheat, Standby”, the displaywill show accordingly. When this message is not shown, the operator may start the engine. Hints: theengine vendors suggest not start an engine when this message is shown. Once the prestart processends, the screen will not display this message any longer.“CAN Bus Fault” Message on the ScreenCAN bus has not received CAN bus information for at least 30 seconds.“ECU No Response” Message on the ScreenThe engine ECU does not respond to the history fault code (DM2) sent by the display. This meansthat the engine ECU may not support broadcasting the history fault code (DM2) on the J1939 CANbus.“No History Fault Code” Message on the ScreenThe engine ECU does not respond to the history fault code (DM2) sent by the display. There is nohistory fault code.“No History Option List Data” Message on the ScreenThere is no information about the connected Option List.“No Data” Message in the Parameter AreaThe display has not received any information of the parameter for at least 5 seconds.


30

“Not Supported” Message in the Parameter Area

The engine ECU sends the message to the display to indicate this parameter is not supported.

“Data Error” Message in the Parameter Area

The engine ECU sends the data is error message to the display or to select fule level in the Simulation

Signal Input of the Tool menu, but the display does not connect to Murphy sensor.

The screen display color is too light or dark to read.

It may be caused by inappropriate contrast settings. Press down the Menu key for more than 5seconds and the contrast will resume to the default setting at the factory.

Caution:

(1) The unit may be restarted only when the pressure in the fluid/air separator is below 15psi (1.0bar).

(2) Oil pressure low indicator will stay on until the pressure goes back to 20~50psi (1.4~3.5bar).

(3) When the machine is not running, turn the Start/Run/Stop switch to “Stop” position to run the machine atidle speed for 3~5 minutes.

(4) Remove all fault conditions before restarting the machine.

3.15 Electrical System

See Fig. 3-12. The electrical system is responsible for machine start/stop, parameter display and

automatic protection. The system consists of battery, engine starter, alternator, start/stop relay, electric

cabinet, sensors and switches.

3.16 Frame System

The machine is mounted on a two-wheel moving frame for convenient mobility. Drawbar of the

machine cannot be folded. A leg with adjustable height is used to support the machine. The leg can be

adjusted within a range of ±15°. Height of the drawbar can be adjusted as well (within a range of

480mm) to accommodate all types of tow vehicle.

The lifting chain of the machine is used for protection during lifting operation. Use the chain for

lifting. The grounding chain in the back of the machine is used to ground the machine during lifting.

Do not remove it.

3.17 Enclosure Assembly

The enclosure of the machine is elegant and conducive to ventilation. All components need to be

serviced can be accessed through air spring supported flip-up service doors. Enclosure is properly

sealed to prevent rain. Heat-resisting, flame-retardant and acoustic material is arranged inside the

enclosure, significantly reducing noise of the machine. Reflective label and warning decal provide

instruction to operators on how to operate and maintain the machine properly and safely.


31

+

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Fig. 3-12 Wiring Diagram

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 4 Operation

32

Section 4 OPERATION

4.1 General

While Sullair has built into the 550RH-750H diesel portable fluid injection screw compressors a

comprehensive array of controls and displays/indicators to assure you that it is operating properly,

you will want to recognize and interpret the readings or conditions displayed/indicated to

determine the condition or malfunction of the machine. Before starting the machine, familiarize

yourself with the controls and displays/indicators – their location, purpose and use.

4.2 Purpose of Controls and Indicators

Component Location Purpose and/or use

Start/Run/Stop switch

Instrument &control panel

Turn the switch to “Start” to start the machine. In such a case the enginewill run at idle speed with no load for 60s. Once it is fully warmed up, theswitch will trip to “Run” automatically. Now the engine will run at fullspeed and the compressor will work at rated pressure with load.

Preheat/Test/Non-preheatSwitch

When the engine cannot be started due to low temperature condition, placethe switch at the “Test” position. If the battery power is sufficient, “preheat”button lights (yellow) and the unit can be set for inlet preheat at interval of

45s. Switch off this button when heating is complete and restart the unit.

Discharge pressure gauge Service pressure of the machine.

Discharge thermometer Discharge temperature of compressor unit.

SULLAIR Multi-functionDisplay

Display the running parameters of the engine

Alarm indicatorCorresponding indicators will be on when there is a fault condition withinthe machine.

Compressor air filterplugging indicator

Air filterWhen the indicator is in red zone, it means the air filter element is seriouslyplugged and requires immediate maintenance or replacement.Engine air filter plugging

indicator

Inlet control valve Inlet port of air end Adjust inlet volume based on the demand for compressed air.

Sight glassFluid/air separatorsump tank

It is used to check the fluid level and quality inside the separator.

Thermal valveFluid exit offluid/air separator

It is used to adjust the temperature of compressor fluid. It is closed whenfluid temperature is low to bypass the fluid. In such a case the cold fluidwill not flow through fluid cooler.

Discharge temperatureswitch

Discharge pipe Stop the machine automatically when temperature exceeds the setting value.

Engine oil pressure switchDiesel Engine

Stop the machine automatically when oil pressure exceeds threshold.

Engine coolant switchStop the machine automatically when coolant temperature exceedsthreshold.

Diesel fuel level sensor Fuel tank Message will be given if fuel level is above threshold.

Temperature switch of thefluid/air separator tank

Fluid/air separatortank

Stop the machine automatically when temperature exceeds the setting value.

Min pressure valveFluid/air separatorcap

It keeps the air pressure in separator.

Relief valveFluid/air separatorsump tank

It ensures that the pressure vessel would work at safe operating pressure.When the pressure inside the separator exceeds safety pressure setting, therelief valve will open to vent air.

Pressure regulator

Control pipeline

When line pressure reaches setting, it sends control air to the inlet valve ofcompressor and speed regulation cylinder proportionately to adjust inlet

volume and rotating speed

Start/Run solenoid valve

Send control air to the inlet valve and speed regulation cylinder to adjust

inlet volume and rotating speed when the machine is being started and

stopped.Filter Filter out water and foreign content in the control airBlow-off Valve Release the compressed air in separator when the machine is being stopped.

Circulation blow-off valveIt is used to ensure working cycle of the compressor when preheatand adjustment is initiated.


33

4.3 Initial Start-up Procedure

1) Park the machine on a level ground upper-wind of the construction/operation site. Check

coolant level in radiator ２. Add coolant as stated if the level is low.

2) Check fuel tank to see if diesel needs to be filled ３.

3) Drain the water in the water separator of fuel system.

4) Check engine to see if engine oil needs to be added ４.

Caution: See Section 1 of this Manual and the Operating and Maintenance Manual of Dongfeng CUMMINS

C Industrial Engine for details of engine coolant, fuel and engine oil.

5) Check compressor fluid level５. Normally the fluid level should fall slightly under the

center of upper sight glass.

6) Close all service valves.

7) Put Start/Run /Stop switch to “Start”.

8) Check the condition of each instrument.

9) Press the button of “Start”, once the machine is started, let it warm up at 1400rpm for 1

minute, and the machine will enter running mode automatically. Now the engine is running

at rated speed and the compressor reaches rated discharge pressure quickly.

10) Close all service doors to contain machine noise and ensure proper ventilation.

11) Check the readings of instruments on instrument panel. See Section 4.5 – Troubleshooting.

12) After initial start-up, stop the compressor according to procedure. Check radiator to see if

additional coolant is required and if additional fluid is required in fluid/air separator. Check

each point of connection to see if there is any looseness. Check the tension of fan belt.

13) Make sure that the stay bolt for transport on the fluid/air separator base and the stay bolt

(marked in red) for transport on the diesel engine and air end support are loosened prior to

power-on.

▲Warning

Never load the machine when it is cold.

Never let the engine run at idle speed for more than 10 minutes.

Avoid continuous operation when coolant temperature is below 60 or above 100 .℃ ℃

4.4 Subsequent Start-up Procedure

1) Park the machine on a level ground upper-wind of the construction/operation site. Check

coolant level in radiator. Add coolant as stated if the level is low.

2) Check fuel, coolant and engine oil. Add if necessary.

3) Check fluid level in fluid/air separator. Add if necessary.

4) Drain the water in the water separator of fuel system. Drain the water separated from fuel

tank. Drain the condensate in fluid/air separator sump.

5) Proceed with step 3) to 12) of Initial Start-up Procedure.

Caution: Drain the condensate from fluid/air separator sump regularly before starting the machine for the first

time every day.

２ Coolant is 50:50 glycol solution and has been filled at factory.３ Fuel tank capacity is 275L.４ Engine oil capacity is 18L and has been filled at factory.５ Compressor fluid capacity is 26L (6.8gallon) and has been filled at factory.


34

4.5 Shutdown Procedure

1) Close all service valves. Press “Stop” button and the engine will run at idle speed for 3

minutes before shutting down.

2) In case of emergency, press emergency stop button to stop the machine immediately. Note

that in such a case, the cooling & lubrication system of compressor unit and engine will stop

to work immediately while the machine is still very hot. Therefore emergency stop can be

harmful to the machine. Do not use the emergency stop button unless there is an emergency.

▲Warning

Never shut down the machine directly during normal operation.

Caution: Each time after work, top up the fuel tank to avoid forming of solid coagulant or condensate in the tank.

4.6 Mode Setting Procedure

Mode Setting Procedure including the setting of no-load speed and rated speed of engine, and

rated pressure and low pressure of the machine. See Section 1 – Specifications for rated pressure

of the compressor.

4.6.1 Setting of Rated Mode

1) Close all service valves.

2) Start the machine according to subsequent start-up procedure.

3) Slowly open the service valve (venting behind) to speed up the engine. Then adjust the

opening of service valve to maintain system pressure (sump tank pressure) at rated operating

pressure (see Section 1 – Specifications).

4) Slowly close the service valve. When system pressure reaches “rated operating pressure + (1

~ 1.4bar)”, the pressure will stop to rise any more. Now the engine runs at idle speed and the

machine stops to supply air. If the rated pressure is not achieved, adjust pressure regulation

valve accordingly.

5) Open/close service valve repeatedly and check the system operating pressure setting. If the

setting is incorrect, find out causes and readjust until the pressure setting is right. Then lock

with adjusting screw.

▲Warning

Service valve should be opened slowly. Opening/closing service valve frequently or opening the servicevalve abruptly may introduce oil in compressed air or abnormal opening of relief valve.

4.7 Jump Start Procedure

▲Warning

The battery may contain hydrogen. Since hydrogen is highly inflammable and explosive, no sparks,flames and other sources of ignition shall be present near the compressor.

Electrolyte in battery is highly corrosive and toxic. Never contact it with eyes, skin or fabrics.Otherwise, it may cause injury or loss of property. In case of electrolyte spill, flush with large amount ofwater immediately.

1) Before jump start, read Section 2 – Safety of this Manual carefully. Jump start is anemergency procedure in case that the battery capacity is low.

2) Wear an acid-proof apron and a face mask before operation.3) Remove the vent hole cap of battery (if any). Be cautious not to allow the dust or impurities to

fall into the battery. Check the level of electrolyte and add if necessary. Then use clean wetcloth to cover the vent hole. “Maintenance free” battery does not need electrolyte level check.


35

Caution: If the electrolyte is frozen or has ice in it, never start the compressor. Otherwise, the battery mayexplode ６.

4) Park the power source vehicle beside the machine. Note that there should be no metal contactbetween the vehicle and compressor.

5) Activate the parking brake of power source vehicle and block wheels using stone blocks orother objects.

6) Set the power source vehicle to Neutral or Parking gear. Turn off irrelevant electricalequipment on the vehicle and start engine.

7) Connect one end of the first jumper wire with the positive pole of the source vehicle. If thesource vehicle has two 12V batteries in series, connect the wire onto the positive pole of thenon-grounded battery.

8) Connect the other end of the jumper wire with the positive pole of the battery of compressorstarter. If the source vehicle has two 12V batteries in series, connect the wire onto the positivepole of the non-grounded battery.

9) Connect one end of the second jumper wire with the negative pole of the source vehicle. Ifthe source vehicle has two 12V batteries in series, connect the wire onto the negative pole ofthe grounded battery.

10) Connect the other end of the second jumper wire onto the diesel engine.11) Start the machine according to normal starting procedure. Be careful not to ignite

continuously for a long period of time.12) Let the engine warm up to steady condition at idle speed. Remove the negative terminal from

the machine, and then remove the other end from the negative pole of the source vehicle.Remove another wire from the positive pole of the machine battery, and finally remove thepositive terminal from the source vehicle.

Caution: ① The jumper wire should be clean, and the rated current of the wire should be greater than the starting

current.

② Avoid accidental contact of the wire lead and wire clip with other metal parts to prevent electric arc,

which may cause fire.

③ Do not connect 24V power supply to a battery of 12V, and do not use a 12V battery to start the

compressor requiring 24V voltage.

④ Only use the source vehicle with a battery system similar to that of the machine for power supply,

and the supply voltage should be the same. Do not use power generator, electric welder or other DC

power as power source, which may cause accident.

⑤ Make sure the wire lead is firmly attached and is away from fuel line, crankcase vent hole and

battery.

4.8 Storage

If the machine is not operated for a few weeks, fluid will run off from lubrication surface ofengine and compressor. Lack of fluid will cause rust on friction pair parts and create direct metalcontact between piston, piston and cylinder sleeve, between the shaft and bearing and betweenthe crankshaft and connecting rod bearing pad upon next startup. Such direct metal contact,especially when rusty, will greatly shorten the service life of machine. Therefore, it is required todo the following after operation each time:① Carry out maintenance as per maintenance regulations in this Manual, and cover the

rain-protection canvas onto the machine.② The machine storage place should be clean and dry, free of corrosive gas.③ Start the machine once a week (at least once a month), and carry out routine regular

inspection. If the machine is not to be used for a long period of time, protect and keep themachine properly. For the requirements of safekeeping, please contact Sullair Asia ServiceDepartment and CUMMINS Service Department.

６ The machine is installed with low-temperature start battery at factory.

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

36

Section 5 MAINTENANCE

5.1 General

Appropriate maintenance is crucial to the operation and lifespan of the machine. Therefore, themaintenance procedures of rotary screw compressor must be followed. Service program givenbelow will keep the machine at top performance. Besides this section, see the Operating andMaintenance Manual of Dongfeng CUMMINS C Industrial Engine for maintenance of dieselengine. Before any maintenance work, please read Section 2 – Safety of this Manual.

▲Warning

Maintenance not only affects proper operation of the compressor but also the safety of the operators.Please drain water in the fuel water separator and fuel tank every day before starting the machine toensure proper operation of diesel engine.Do not remove nuts, oil plugs, and other parts when the compressor is running or pressurized.Shut down and bleed internal pressure of the compressor prior to operation.

5.2 Maintenance of Rotary Screw Compressor

Rotary Screw Compressor Maintenance Schedule describes the daily service of the compressor.Please service the machine according to the Operating Hour or Maintenance Interval stated in theSchedule, whichever comes first.Check fluid level before starting. If fluid is low, please refill. If the machine needs to be refilledfrequently, you need to check the machine. See Troubleshooting.Once the machine is started, check instrument readings. After the machine is warmed up, check allinstruments/gauges and check for oil/air leakage. Check for abnormal mechanical sound. If yes,please stop and release pressure before taking further procedures.

Rotary Screw Compressor Maintenance Schedule:

Operatinghours

Maintenanceinterval

Maintenanceposition

Maintenance description

10 Daily

Air filterClean the dust collection pocket. Service thefilter element if there is an alarm.

Fluid/air separator Bleed water entrapped before start up.

Fuel/waterseparator

Bleed water entrapped before start up.

Fuel tankRefill fuel every day after operation. Bleedwater entrapped before start up.

50 Weekly

Relief valve Check if it is plugged/damaged.

Fluid filterReplace filter element after the first 50operation hours.

Return lineIn 50 hours after initial start-up, clean returnline orifice and strainer.

200 1 month

Fluid cooler Clean surface.

Fan belt Check tension.

Battery Check electrolyte level.

300 2 monthsAir filter Service main filter element.

Fluid Change fluid if not AWF® fluid.

500 4 months

Fluid filter Change element if AWF® fluid.

Fuel line Check, clean if dirty and plugging.

Hose Check, change if necessary.


37

(continued)Operating

hoursMaintenance

intervalMaintenance

positionMaintenance description

500 4 months Fluid Change fluid if AWF® fluid for RH model,

1200 8 monthsFluid return line Clean orifice and filter.

Bearing ofmoving system

Add grease.

2000 12 monthsAir filter

Replace main filter element and safetyelement.

Rubber hoseReplace the rubber hose in fluid line, controlline and fuel line.

2500 12 months FluidChange fluid if AWF® fluid for XH and Hmodel,.

As required

Fluid/air separatorelement

Pressure difference indicator points red.

Battery Clean terminals, apply oil.

5.2.1 Relief valve maintenancePlugged relief valve will result in failure to open, or close after opening. In the first case, the reliefvalve will not provide protection against the pressure system, thus the compressor. In the lattercase, fluid blowing out of the sump tank may lead to property loss. Stop the compressor weeklyand check the relief valve condition.

5.2.2 Fluid filter maintenanceAfter initial 50 hours operation, change fluid filter element, then after every 500 hours or fourmonths of operation, change the element. For element change procedure see Section 5.4: PARTSREPLACEMENT AND ADJUSTMENT PROCEDURES. It is necessary to stop the machinebefore changing the element. Carefully wipe away dirty or oily foreign substances and avoidforeign substance entering the lubrication system.

5.2.3 Fluid maintenance

If AWF® fluid is used, It is necessary to replace lubricant oil for the model RH for every 500 hoursor four months, and for the model XH and H for every 2500 hours or 1 year, whichever is earlier.Note: Change interval of different types of fluid varies. Refer to detailed information in Section 1:

SPECIFICATIONS.

If the compressor is running in bad environment, change interval will be shortened.

Some fluids are incompatible, if mixed, will lead to formation of indiscernible sediment, which may cause

fluid filter plugged and other severe problems. Therefore, always avoid mixing different types of fluid and

use different type of fluid only after all fluid is drained.

This screw compressor made by Sullair uses Sullair® Fluid AWF®, which is availed at this company and

local branches.

Should fluid level in the sump tank is below the middle position of the sight glass after the compressor is shut

down, add fluid. However, this addition should be made only after the compressor is shut down and is drained.

Note: Formation of indiscernible sediment on the fluid filter element indicates that the compressor fluid is bad forproper operation, change immediately.

5.2.4 Return line maintenance

The purpose of the return line is to return fluid entrapped in the fluid/air separator element to thecompressor low-pressure chamber, on which orifices keep proper return flow. If the return line isplugged severely, especially in orifice and strainer, discharged air will contain excessive fluid.Check return line regularly, clean the orifice and strainer.


38

5.2.5 Fluid cooler maintenanceWhen oil, grease, dust and dirt collect on the cooler surface, the heat exchange effect will bereduced, ultimately leading to very high discharge temperature. For every one month or 200 hours,use dust collector, detergent or low-pressure compressed air to clean the cooler surface.

5.2.6 Air filter maintenance

The air filter should be checked daily.

Clean the dust collector daily. Do it more frequently in dusty environment.

When air filter alarm indicator is on, service the filter element. Air filter element should be

replaced every 2000 operating hours or a year, whichever comes first. See Section 5.4 – Parts

Replacement and Adjustment Procedures on how to change filter element.

5.2.7 Fluid/air separator maintenance

Generally, if the air filter and fluid filter are maintained properly, it is not required to change the

fluid/air separator element regularly.

If pressure difference indicator of fluid/air separator points red, or when fluid contained in

discharged air surges, check the fluid/air separator element, or change it as required in Section 5.4:

PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES.

When condensation water mixes with fluid, the fluid will become emulsified and deteriorated.

Prior to routine start, open drain ball valve at the bottom of the sump tank to drain water that was

collected in previous day. If fluid emulsification is severe, simply change fluid.

5.2.8 Battery maintenance

Keep battery leads, connectors, and cord grips clean, and wipe with oilcloth to prevent corrosion.

Maintain proper electrolyte level in the battery.

5.2.9 Wheel/tyre pressure

The compulsory tyre pressure is 690-760kPa, see Section 1: SPECIFICATIONS.

Grease roller bearings of the axle each year. To grease, remove end covers.

5.2.10 Hose maintenance

For every 500 hours or four months of operation, check inlet hose, hoses in lubrication piping and

control line, and change if necessary. For every 2000 hours or one year of operation, whichever

occurs first, change the rubber fitting in the fluid rubber line, control line and fuel line.

5.3 Maintenance of Diesel Engine

Diesel Engine Maintenance Schedule:

Operating

hours

Maintenance

intervalMaintenance item Maintenance description

10 Daily

Oil sump Check oil lever, refill if necessary.

Radiator Check coolant lever, refill if necessary.

Air filterClean dust collector. Service filter element if

there is an alarm.

Fuel tank Discharge water and sediments.

Prefilter Drain water.

Diesel engine Check diesel engine for abnormities.

50 Weekly

Fuel suction filter Check or clean.

BeltCheck status and tension after the first 20 to

40 hours.


39

(continued)

Operating

hours

Maintenance

intervalMaintenance item Maintenance description

300 2 months

Oil sumpIf not using API CH-4 with TBN minimum

value of 11, replace oil and fluid filter.

Engine valve clearance Measure/adjust by professionals.

Alternator Check.

Battery Check electrolyte level.

Belt tension Check. Adjust if necessary.

Cylinder head

grounding studCheck/clean/fasten.

Crankcase vent hole Clean.

Fuel/water separator Replace.

Primary fuel filter Replace.

Secondary fuel filter Replace.

Cooling system Check/add SCA antirust.

Radiator Clean surface.

Air filter Check for damage and clean.

Inlet system Check for leak and clean.

600 4 monthsEngine valve clearance Measure/adjust by professionals.

Engine speed Check and adjust.

1200 8 monthsFan hub Check.

Belt Check tension. Replace if necessary.

2000 One year Air filterReplace main filter element and safety

element.

3000 Two year Cooling system Change coolant.

As requiredCooling system Drain and wash if coolant is dirty.

Fuel system Refill and vent the fuel system as required.

Diesel Engine Maintenance Schedule describes the daily service work of the diesel engine.Please service the engine according to the Operating Hour or Maintenance Interval stated in thetable, whichever comes first. Engine may need to be serviced more frequently in harshenvironment. See the Operating and Maintenance Manual of Dongfeng CUMMINS CIndustrial Engine for other maintenance requirements and operation description of the dieselengine.

5.3.1 Fuel tankFuel tank should be refilled with diesel suitable for local ambient temperature daily or every 8hours. In order to prevent fuel from freezing, it is recommended to refill the tank everyday afterwork, and drain the condensate in the tank next day before starting the machine.

5.3.2 Engine oil/fluid filterCheck oil level using dipstick oil ruler everyday. Oil level should be in the range between Maxand Min mark. Discharge oil if oil level exceeds the Max mark and add oil if lower than the Min.If API CH-4 oil with TBN minimum value of 11 is used, change the oil and fluid filter every 300operating hours or 2 months, whichever comes first. See Section 5.4 – Parts Replacement andAdjustment Procedures on how to change.If oil is diluted, a thorough check must be carried out to find out the cause. Otherwise dieselengine may be seriously damaged.


40

5.3.3 Coolant radiator/intercooler/cooling systemCheck coolant level everyday. Add if necessary.If coolant needs to be added everyday, please check cooling system for leakage.

▲Warning

Coolant is hot and pressurized when the machine is running.

Hot coolant and vapor may cause injury.

Check coolant level only when the diesel engine is not running and the radiator cap is not feeling

hot.

Screw off radiator cap slowly to release pressure.

Antifreeze/antirust contains alkaline, which may cause injury if contacted with skin or eyes.

Never use water as antifreeze/antirust coolant.

The performance of cooler will be impaired if cooler surface is covered by oil, grease, dust or

contaminants. This could lead to coolant ebullition and machine unable to operate, or intake air

overheat even if it is cooled. Please clean the cooler surface with vacuum, detergent or

low-pressure compressed air twice a month.

Check SCA content (see the table below) in coolant every 300 operating hours or 2 months, in

order to protect engine cooling system from being damaged by coolant contamination, weld point

yellowing and general erosion. Add if SCA content in the antifreeze & antirust coolant is low.

SCA content check table

Spec. Color Freezing point ℃ Specific gravity PH

-50 Blue -50 1.070～1.060 7.5～9

-40 Blue -40 1.060～1.055 7.5～9

-35 Blue -35 1.055～1.050 7.5～9

-30 Blue -30 1.050～1.040 7.5～9

-20 Red -20 1.030～1.035 7.5～9

-10 Red -10 1.020～1.025 7.5～9

Caution: Before adding antirust to cooling system, you may need to discharge some coolant from the drain

valve at the bottom of radiator.

Check radiator cap gasket. Replace if damaged.

Coolant should be replaced every 3000 operating hours or two years, whichever comes first. See

Section 5.4 – Parts Replacement and Adjustment Procedures.

5.3.4 Inlet system

Air filter should be checked every day.

Clean dust collector and collector cap everyday. Do it more frequently in dusty environment.

When air filter alarm indicator turns red, service the filter element. Check air filter for damage and

leak in inlet system every 300 operating hours or two months, whichever comes first. Air filter

element should be replaced every 2000 operating hours or a year, whichever comes first. See

Section 5.4 – Parts Replacement and Adjustment Procedures on how to service or change filter

element.

5.3.5 Fuel Filter and Water Separator

Discharge the water in water separator everyday.

Replace fuel filter (including water separator) every 300 operating hours or two months,

whichever comes first.

If air exists in fuel system, it will be hard to start engine or engine will work unsteadily. In such a

case, vent the system manually.


41

▲Warning

Do not vent the air while engine is hot. It may cause fire if fuel is spilled on the hot exhaust manifold.

5.3.6 Fuel Suction Filter

Check or clean suction filter weekly to clean dirt collector and sieve mesh.

5.3.7 Belt Tension

Check belt tension after the first 20 to 40 operating hours. Check belt tension as follows every 300

working hours or two months thereafter, whichever comes first.

Check belt for damage. See if there is wear or crack. Replace worn or damaged belt.

Check belt tension. Check fan belt tension. Apply a force of 110N in the mid-point

between the belt wheels. Properly adjusted belt shall have an offset of 9 to 15mm. If the

tension is not right, adjust through alternator.

5.3.8 Valve Clearance

Check valve clearance after initial 300 operating hours or two months, or every 600 operating

hours or 4 months, whichever comes first. For a new engine, it is recommended to check valve

clearance at the first time of oil change. Only qualified person may do it.

5.4 Parts Replacement and Adjustment Procedures

5.4.1 Changing Compressor Fluid

Keep the compressor running for 5 to 10 minutes to warm up the fluid. Stop the machine and

release all internal pressure. Open the drain globe valve at the bottom of fluid/air separator to

discharge fluid. Refill fluid and replace filter element. See 4.2 – Changing Fluid Filter and

Section 1 – Specifications.

Caution: Do not contact fluid with skin. Hot oil may cause scald.

5.4.2 Changing Fluid Filter

Use belt wrench to remove used filter element and gasket.①

Clean gasket mounting surface.②

Apply a thin layer of oil on the new gasket.③

Fill the new filter with clean fluid.④

Screw the filter until gasket contacts the base. Then further screw 1/2 to⑤ 3/4 circle.

Restart the machine and check for leakage.⑥

▲Warning

In order to minimize damage to the filter element, use Sullair product only since other products may

not match the machine pressure.

5.4.3 Servicing and Changing Air Filter

Clean dust collector every day. Do it more frequently in dusty environment.

When air filter pressure drop indicator turns red, service the filter element. Check air filter for

damage and leak in inlet system every 300 operating hours or two months, whichever comes first.

Air filter element should be replaced every 2000 operating hours or a year, whichever comes first.

Safety filter element does not need maintenance normally and should be replaced together with the

main element.


42

Servicing and replacing procedure of air filter element:

① Remove rear cap and clean the dust collector and rear cap;

② Remove main filter element carefully. Check it in front of a light source for damage. ;

③ Use a clean wet rag to clean the inner side of air filter. Do not use compressed air;

④ Tap the end side of the filer element on a flat board. Use dry compressed air not

exceeding 2.1bar (30psi) to blow off the dust in the fold from inside in a direction 45°

to the longitudinal filter;

⑤ Reinstall the cleaned or new filter element;

⑥ Install dust collector and rear cap with opening of dust collector in correct direction.

Caution: Do not disassemble and replace air filter element when compressor is running.

Never clean filter element with oil, water or compressed air that contains water.

Filter element with damaged filter paper or gasket must be replaced immediately.

Apply small amount of oil on the surface of gasket before installing the filter element to prevent adhesion

between gasket and air filter canister.

Inferiors or unqualified air filter element may cause diesel engine not working at full power, oil needs to

be replaced frequently, early wear out of diesel engine and even scuffling.

5.4.4 Changing fluid/air separator Element

If oil is detected in service air while return line strainer, check valve, orifice and blow-off valve

diaphragm are working properly, the fluid/air separator element should be changed as follows:

Detach all pipelines from flat cap (return line, service pipe, etc.).①

Remove return line (stainless steel pipe) from flat cap connector.②

Remove bolts and gasket and pull out flat cap (do not remove the min pressure valve).③

④ Pull out separator element.

⑤ Clean the gasket surface between flat cap and canister. Do not let debris or dust fall into

the canister.

⑥ Install the new separator element. Do not remove the staple on gasket.

⑦ Install flat cap. Screw on the bolts with hand. Then fasten the bolts in to steps④ ⑤

alternately.

⑧ Reconnect all pipes. The stainless steel fluid return should be 1.5mm from the bottom of

separator element to ensure smooth fluid flow.

⑨ Clean return line strainer, orifice and check valve before restarting the machine.

⑩ Fasten bolts on the flat cap as described in step after running for 24 hours.⑦

5.4.5 Changing Fuel Water Separator/Fuel Filter

① Use belt wrench to remove used filter element and gasket.

② Clean gasket mounting surface.

③ Apply a thin layer of oil on the new gasket.

④ Fill the new water separator/fuel filter with clean fuel.

Screw the filter until gasket contacts the base. Then further screw 1/2 to 3/4 circle.⑤

Restart the machine and check for leakage.⑥

Caution: Fill up the filter element with fuel. If air exists in fuel system, it will be hard to start the engine or engine

will work unsteadily.


43

5.4.6 Changing Coolant

▲Warning

Coolant is hot and pressurized when the machine is running.

Hot coolant and vapor may cause injury.

Check coolant level only when the diesel engine is not running and the radiator cap is not feeling

hot.

Screw off radiator cap slowly to release pressure.

Antifreeze/antirust contains alkaline, which may cause injury if contacted with skin or eyes.

Never use water as antifreeze/antirust coolant.

① After the machine is stopped and coolant is cool, screw off radiator cap slowly to release

pressure.

② Screw off drain valve of radiator to discharge coolant of radiator and engine.

③ Close drain valve.

④ Refill coolant as described in Section 1.5.

⑤ Fasten radiator cap.

5.4.7 Changing Engine Oil

Keep the compressor running for 5 to 10 minutes to warm up the fluid. Stop the machine. Open

the drain valve at the bottom of oil sump to discharge oil. Refill oil and replace filter element. See

Section 5.4.2 – Changing Fluid filter and Section 1 – Specifications.

Caution: Do not contact fluid with skin. Hot oil may cause scald.

5.4.8 Adjusting Regulation System

If the compressor cannot reach rated operating pressure or speed, the regulation system needs to

be adjusted. See Section 4.6 - Mode Setting Procedure for details.

5.5 Troubleshooting

Machine fault could be caused by various reasons. Normally a fault is not caused by just one

component or one reason. Therefore troubleshooting can be difficult.

The troubleshooting table is based on extensive field application and laboratory data of

manufacturer. It illustrates common faults that may happen to the machine and general causes and

resolutions of the faults. It may not explicit all possible faults and resolutions.

Before repair or replace any part, please analyze all possible causes thoroughly. When a problem

is encountered, observe carefully and find out fault and its causes before service to avoid

unnecessary damage to the machine.

Always keep the following in mind:

a. Check loose electric wire;

b. Check damaged piping;

c. Check for part damage caused by overheating or short circuit (normally accompanied by

color change or burnt smell).

If the fault condition may not be resolved according to the recommended method, please contact

local representative of Sullair or Sullair Service Department.


44

TROUBLESHOOTING

Symptom Probable cause Remedy

1. Insufficient airdelivery

Air demand is excessiveCheck to see if the air demand matches compressordelivery.

Engine speed low Adjust speed or check engine fuel filter.

Air filter pluggedCheck if there is any service indication oninstruments. Replace filter element if necessary.

Compressed air leakage Check air service pipe and valve for leakage.

Pressure regulation valve failureor damaged

Adjust pressure regulation valve as described inSection 4 - Operation. Check regulation valvediaphragm and replace if necessary (spare partsprovided).

Fluid/air separator elementplugged

Replace separator element, fluid filter and fluid.

Compressor rotor wear Contact Sullair technician.

2. Low servicepressure

Air demand is excessiveCheck to see if the air demand matches compressordelivery.

Air filter pluggedCheck if the pressure drop indicator turns red.Clean/replace filter element if necessary.

Compressed air leakage Check air service pipe and valve for leakage.


Check/replace (spare parts provided).

3. Compressoroverheat

Fluid level in sump tank low Add fluid. Check for leakage.

Fluid cooler is dirty or clogged. Clean fluid filter fin.

Fan belt loose or damaged Adjust tension wheel or replace belt.

Thermal component of thermalvalve failure

Replace thermal component.

Fluid filter plugged. Replace filter element.

Return line plugged. Clean return line strainer and orifice.

Hot air circumfluence Move the machine or change direction to avoidcircumfluence.

4. Excessive fluidconsumption

Clogged return line strainer Clean strainer and orifice.

Leak in lubrication systemCheck all pipes, connections and components.Repair or replace if necessary.

Fluid/air separator elementdamaged.

Replace the element.

Low system pressure Check min pressure valve and orifice of silencer.

Fluid level too highCheck fluid level from sight glass. Drain excessfluid.

5. Relief valveopened

Pressure setting of pressureregulation valve is high

Adjust pressure setting.

Control air leakage Check control line.

Inlet valve will not close (stuck) Service or replace inlet valve.

Control system clogged Check control line.


Check/replace (spare parts provided).

Relief valve failure Replace.

6. Compressorshuts down withair demandpresent

Out of fuel Check fuel level and fuel system.

Discharge temperature switchactivated

Activation of discharge temperature switch may becaused by overheat compressor. See item 3.

Coolant overheat Check coolant level, thermostat and fan.

Low coolant level Check coolant level.

Low oil pressure Check dipstick and fluid filter

Switch failure Test the switch.

Electric circuit failure Test electric circuit.


45

(continued)

7. Excessive machinevibration

Engine speed low Adjust speed and check fuel filter.

Bolts of pulley or shock absorberloose

Fasten bolts or nuts.

Pulley or shock absorberimbalance

Replace with new pulley or shock absorber.

Fan lobe imbalance.If the vibration is eliminated by detaching thebelt, replace with a new fan.

Machine frame loose or wear Fasten bolts. Replace parts if necessary.

Engine ignition problem or speedunstable

See item 13 to 15.

8. Engine can becranked but cannotbe started – nofume in tail pipe

No fuel in tank Add fuel.

Fuel line plugged Check/purge fuel line.

Fuel pump failure Check or replace fuel pump.

Fuel filter pluggedCheck and replace fuel filter. Check if the fuelis suitable for local ambient temperature andchange thoroughly if not.

Fuel injector failure Remove, adjust and repair or replace.

9. Engine is hart to beor cannot be started– with fume in tailpipe

Low crank speed Check if battery, starter and cable terminalsare secured.

Cold starter is needed or does notwork

Determine devices needed and check ifoperation is proper.

Inferior fuel Drain fuel completely and flush fuel system.

“Cloud point” of fuel is higherthan ambient temperature

Replace fuel and fuel filters.

Air filter plugged Check air filter. Clean or replace.

Air in fuel system Vent the fuel system.

Timing problem of fuel injection Check and adjust injection timing.

Valve clearance problem Readjust valve clearance.

10. Engine will stopafter starting

Low idle speed Check idle speed adjusting screw.

Engine is loaded Start machine without load.



11. Low engine speed

Wrong speed system setting Check and adjust speed system setting.

Fuel filter plugged Check fuel filter. Replace if necessary.

Air filter plugged Check air filter. Clean or replace.

Pressure regulation valve failure Check, adjust or replace.

12. Engine vibrates atidle speed



Low fuel level Add fuel.

Fuel line and filter plugged Purge fuel line and replace filter.


13. Idle speed unstable





14. Engine ignitionproblem or speedunstable




46

(continued)

14. Engine ignitionproblem or speedunstable

Wrong valve clearanceCheck pushrod, spring and adjust valveclearance.


Timing problem of fuel injection Adjust injection timing if necessary.

15. Engine temperaturewill not rise

Thermometer failure Adjust or replace.

Thermostat failure Test or replace.

16. Rough combustion

Poor fuel quality. Discharge fuel, replace with new filter elementand refill with clean fuel.



Fuel injector failureUse ET to find out failed injector throughcylinder isolation test.

17. Engine speed willvary atfull-load/no-load

Engine speed regulator or fuelpump failure

Check if speed limit screw and speedregulation cylinder are in proper location andlength.

Speed regulation cylinder failure Check speed limit screw or reset spring.

Control line failure Check if the control line connected toregulation cylinder is clogged or is leaking.

18. Low engine power

Speed regulator not set properly Check/adjust regulation pushrods.

Poor fuel quality Drain fuel and purge fuel line.

Air filter plugged Check, clean or replace.

Air or fuel line leaking orthrottled

Fasten connectors. Replace if necessary.


Fuel line and filter plugged Purge fuel line and replace filter.

High oil level Drain excess oil to normal level.

Fuel return line clogged. Clean.

Leakage in turbocharger or intakemanifold

Check intake manifold pressure. Clean, repairor replace.

Carbon accumulation or damageon turbocharger

Check turbocharger. Clean, repair or replace.

Timing problem of fuel injectionpump

Check injection pump timing.

Valve position error Check pushrod and spring.

Timing problem of fuel injection Remove, test, clean and repair.

Fuel injector failure Remove, test, clean and repair.

19. Engine overheat

Fan belt loose or damaged Adjust tension or replace belt.

Fan pulley installation positionproblem

Adjust pulley.

Low coolant level Add coolant.

Radiator fin clogged Clean fin surface.

Low oil level Add oil to normal level.

Coolant pump failure Replace pump.

Radiator pressure cap failure Check pressure cap. Replace if necessary.

Thermostat failure or not working Check or replace thermostat.

Fuel quantity high or badinjection timing

Check/replace injection pump.

Overloaded Check pressure setting. Adjust if necessary.

20. Black smoke ordense gray smoke

Insufficient air for combustionCheck if air filter is plugged. Check if intakemanifold pressure and turbocharger areworking properly.


47

(continued)

20. Black smoke ordense gray smoke

Injector timing problem Test all injectors. Replace if necessary.



Fuel quantity high Check/adjust injection pump.

Engine temperature will not rise Check thermostat and cooling system.

21. White smoke ordense blue smoke

Too much oil Drain excess oil.

Engine ignition problem or speedunstable

See item 15.

Timing problem of fuel injection Adjust timing.

Turbocharger oil seal damageCheck intake manifold for oil. Repair ifnecessary.

Valve guide wear Check/repair cylinder head.

Piston ring wear Replace piston ring.

22. High fuelconsumption

Fuel system leakage Check fuel system. Repair or replace parts.

Injection timing problem Adjust injection timing.

23. Low engine oilpressure

Oil insufficient Add oil to normal level. Check for leakage.

Pressure gauge or sensor failure Check/replace.

Oil is diluted (with diesel orwater)

Find out causes. Change oil and fluid filterelement.

Wrong oil viscosity Check and change with right oil.

Fluid filter or fluid cooler clogged Check/clean. Change fluid filter and oil.

Oil pressure regulation valvefailure

Check, repair or replace.

Oil pump, bearing wear or otherreasons

Contact engine manufacturer to repair orreplace parts.

24. Engine early wear

Dirty oil Change dirty oil and fluid filter.

Intake piping leakage Check all intake piping components. Repair ifthere is a leakage.

Air filter or gasket damage Check air filter. Replace filter element.

Fuel in oil Find out causes. Repair/change oil and fluidfilter.

25. Coolant in oil

Fluid cooler core damaged Replace with new cooler core.

Cylinder head gasket damaged Replace with new gasket and fasten bolts asspecified.

Cylinder head cracked or defect Replace with new cylinder head.

Cylinder block cracked ordefective

Replace with new cylinder block.

Cylinder jacket gasket damaged Replace with new gasket.

26. Oil in fume

Too much oil in air port Contact engine manufacturer to check andrepair.

Valve guide wear Check/repair cylinder head.

Piston ring wear Replace with new piston ring.

Engine runs at idle speed for toolong

Do not let engine run at idle speed for toolong.

27. Abnormalmechanical noise inengine

Connecting rod bearing linerdamaged

Check connecting rod bearing liner and necksurface of crankshaft.

Timing gear damaged Replace with new parts.

Crankshaft damaged Repair or replace crankshaft.

28. Abnormal noise inair valve or airvalve driving parts

Air valve spring damaged Replace damaged spring.

Camshaft damaged Replace the camshaft and clean the enginethoroughly.


48

(continued)

28. Abnormal noise inair valve or airvalve driving parts

Air valve pushrod damaged Replace camshaft and pushrod, and clean theengine thoroughly. Check if air valve movesfreely.

Air valve damaged Replace air valve. Adjust if necessary.

29. Motor starter doesnot start

Low battery output power Check battery. Charge or replace the batteryaccordingly.

Circuit or switch failure Repair. Replace if necessary.

Starter's magnetic switch failure Replace with new switch.

Starter failure Repair or replace.

30. Alternator does notcharge

Alternator belt loose Adjust belt to proper tension.

Charging circuit, groundingcircuit or battery terminal failure

Check all cables and terminals. Fasten alltermination nuts and clean terminals. Replacefailed parts.

Rotor winding failure Replace with new winding.

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 6 Noise Control

49

Section 6 NOISE CONTROL6.1 Noise Emission

Sullair warrants to the end user and every potential user that the compressor sold by Sullair to theprimary dealer conforms to the noise emission rules and regulations of the People’s Republic ofChina and US EPA in terms of design, manufacture, installation and test.Such warranty applies to the entire machine, and is not restricted to any special part or partialsystem only. If there is any violation to noise emission regulations in the machine sold to theprimary dealer, Sullair will be responsible for the solution, whether it is due to the design,manufacture, installation or specific system or part.

6.2 Prohibited Operation

Never disassemble or damage any parts in the silencing system (except for maintenance)before selling or delivering to the dealer or when the machine is in use.

Never operate the machine with a part in the silencing system removed.Never:

A. Disassemble or damage:a. Diesel engine silencing system and its parts;b. Compressor inlet system and its parts;c. Enclosure and any part.

B. Remove:a. Silencer;b. Shock absorberc. Air spring;d. Door and partition;e. Fan guard;f. Weather strip;g. Acoustic material;h. Engine tail pipe heat insulation sleeve.

C. Operate the machine when the door is open (except for adjustment or partsreplacement).

6.3 Service Record

Please operate and maintain the machine properly to avoid damaging the silencing system.Check at least once a year the silencer and engine discharge system, air filter and air inlet system,engine vibration reduction system, enclosure, etc. Make sure all parts are installed and tightened,in good operating condition. Check the acoustic materials, and make sure there is no missing ordeformed parts and all the parts are installed in good condition. In case of damage, do not start themachine. Order and replace parts according the parts list.For each service, keep record for the service item and service content. Please refer to the followingtable:

Service itemPersonnelLocationData

Service itemPersonnelLocationData

550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section7 Parts Ordering

50

Section 7 PARTS ORDERINGProcedure for Ordering Parts

Parts should be ordered from the nearest branch of Sullair or your Sullair Representative. If forany reason parts cannot be obtained in this manner, contact Sullair Parts Department directly at theaddress listed at the back cover of this Manual.When ordering parts, you should always indicate the model and serial number of the compressor.Since Sullair constantly improves its products, the content in the manual may differ from theactual assembly after a period of time. Model and serial number can be obtained from the serialnumber plate located on the compressor or Bill of Lading.When ordering parts, please read carefully the illustration parts list. See Parts List, p/n:88291004-642.

600/655 Diesel Driven Portable Rotary Screw Compressor, Operating and Maintenance Manual Section 7 Parts Ordering

５１

Global Sales & Service

SULLAIR CORPORATION

3700 East Michigan Boulevard

Michigan City, Indiana 46360 U.S.A.

Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only)

Fax: 001-219-874-1273

SULLAIR ASIA Website: http://www.sullair-asia.com Hotline: 800-830-3977

Sullair Singapore: 74 Joo Koon Circle, Jurong Singapore 629093

Telephone:65-68611211 Fax:65-68612967

Sullair Taipei: No. 1, 3rd Floor, 248 Zhongshan Road, Linkou Village, Taipei County

Tel: 02-26013500 Fax: 02-26013032

Shenzhen Factory: Zuo Paotai Road, Chiwan, Shekou, Shenzhen, P. R. China

518068

Tel: 0755-26851686 Fax: 0755-26835157

Suzhou Factory: 266 Changyang Street, Singapore Industrial Park, Suzhou, 215000

Tel: 0512-87162388 Fax: 0512-87162389,87162387

Shanghai Branch: Room 2903, Raffles City Plaza, 266 Xizang Road Central,

Shanghai City 200001

Tel: 021-53852036,53852038 Fax: 021-53852035

Beijing Branch: Room 601, Yulin Building, No.5 Xiangjia2 Xiangjunnanli,

Zhaoyang District , Beijing City 100027

Tel: 010-64629770,64629768 Fax: 010-64629773

Chengdu Branch: Room 1102,T2 Raffles city Plaza, No.3 the Fourth ,People south

Road, Wuhou, Chengdou City, 610041, PRC

Tel: 028-86527506, 86527507 Fax: 028-86527505

Shenyang Branch: Room 906 Tower II, City Plaza Shenyang NO.206 Nanjing North

Street Heping District, Shenyang, PRC

Tel: 024-22818450, 22818550 Fax: 024-23342452

Xi’an Branch: Room I, Floor 13, New time Plaza, 55 Lianhu North Street, Xi’an

City 710001

Tel: 029-87206201, 87206202 Fax: 029-87206204

Wuhan Branch: Room 1805,Wanda Center, No.96, Linjiang avenue, Wuchang

District Wuhan City, 430060, PRC

Tel: 027-87322745 Fax: 027-88167769

Xinjiang Branch: Unit J, 9th Floor, National Development Bank Tower, 339

Zhongshan Road, Urumqi, 830002

Tel: 0991-2308451, 2308452 Fax: 0991-2308450

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