Sullair 125 User manual

PORTABLE AIR
COMPRESSOR
125, 130, 160H, 185 CFM
and 49 HP Models
CATERPILLAR, JOHN DEERE, PERKINS
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number
02250159-733
©Sullair Corporation
The information in this document
is correct at the time of printing
for Portable Compressor Serial
Number :
004-151422
and all subsequent Serial
Numbers.

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the
proper operation, maintenance and service of Sullair equipment. Individual seminars on
Portable compressors are presented at regular intervals throughout the year at a dedi-
cated training facility at the Sullair corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts,
troubleshooting of the most common problems, and actual equipment operation. The
seminars are recommended for rental house and Contractor Maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1-888-SULLAIR or 219-879-5451 (ext. 5363)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1 PAGE
SAFETY 1 1.1 GENERAL
1 1.2 TOWING
3 1.3 PRESSURE RELEASE
4 1.4 FIRE AND EXPLOSION
5 1.5 MOVING PARTS
6 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
6 1.7 TOXIC AND IRRITATING SUBSTANCES
6 1.8 ELECTRICAL SHOCK
7 1.9 LIFTING
7 1.10 ENTRAPMENT
7 1.11 JUMP STARTING
Section 2
DESCRIPTION
9 2.1 INTRODUCTION
9 2.2 DESCRIPTION OF COMPONENTS
10 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
10 2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
10 2.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
12 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
16 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
16 2.8 INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION
18 2.9 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
18 2.10 SHUTDOWN SYSTEM, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 21 3.1A SPECIFICATIONS - PERKINS AND CATERPILLAR
22 3.1B SPECIFICATIONS - JOHN DEERE 125, 130
(2-WHEEL AND LRG)
23 3.1C SPECIFICATIONS - JOHN DEERE 49HP, 160H, 185
(2-WHEEL AND LRG)
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Continued...

TABLE OF CONTENTS
Section 3 PAGE
SPECIFICATIONS 24 3.2 LUBRICATION GUIDE
(CONTINUED) 24 3.3 APPLICATION GUIDE
24 3.4 LUBRICATION GUIDE - ENGINE
Section 4
OPERATION 25 4.1 GENERAL
25 4.2 PURPOSE OF CONTROLS
26 4.3 START-UP PROCEDURE
26 4.4 SUBSEQUENT START-UP PROCEDURE
26 4.5 SHUTDOWN PROCEDURE
Section 5
MAINTENANCE 27 5.1 GENERAL
27 5.2 DAILY OPERATION
27 5.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
27 5.4 MAINTENANCE EVERY 50 HOURS
27 5.5 MAINTENANCE EVERY 100 HOURS
27 5.6 MAINTENANCE EVERY 200 HOURS
27 5.7 MAINTENANCE EVERY 250 HOURS
28 5.8 MAINTENANCE EVERY 500 HOURS
28 5.9 MAINTENANCE ANNUALLY OR EVERY 1500 HOURS
28 5.10 MAINTENANCE EVERY YEAR OR 12,000 MILES
28 5.11 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
28 COMPRESSOR FLUID CHANGE PROCEDURE
28 AIR FILTER MAINTENANCE
29 SEPARATOR ELEMENT REPLACEMENT
29 PROCEDURE FOR SETTING SPEED AND PRESSURE
CONTROLS ON PORTABLE COMPRESSORS WITH
POPPET VALVE
31 OPERATING ADJUSTMENTS
31 BEARING LUBRICATION
32 5.12 TROUBLESHOOTING INTRODUCTION
32 5.13 TROUBLESHOOTING GUIDE
Section 6
NOISE CONTROL 35 6.1 NOISE EMISSIONS WARRANTY
35 6.2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
35 6.3 NOISE EMISSIONS MAINTENANCE AND
MAINTENANCE RECORD LOG
Continued...

TABLE OF CONTENTS
Section 7 PAGE
ILLUSTRATIONS
AND PARTS LIST 39 7.1 PROCEDURE FOR ORDERING PARTS
40 7.2 RECOMMENDED SPARE PARTS LIST
42 7.3A ENGINE, COMPRESSOR AND PARTS - PERKINS
AND CAT MODELS 125, 130 & 185
46 7.3B ENGINE, COMPRESSOR AND PARTS - JOHN
DEERE MODELS 125, 130, 185 & 49HP
50 7,.3C ENGINE, COMPRESSOR AND PARTS - JOHN
DEERE MODEL 160H
54 7.4A AIR INLET AND EXHAUST - PERKINS AND CATERPILLAR
MODELS 125, 130 & 185
56 7.4B AIR INLET AND EXHAUST - JOHN DEERE MODELS 125,
130, 185, 49HP & 160H
58 7.5 RADIATOR AND COMPRESSOR FLUID COOLING SYSTEM -
ALL MODELS
62 7.6 FRAME, RUNNING GEAR AND PARTS - ALL MODELS
66 7.7A DISCHARGE SYSTEM AND PARTS - ALL MODELS
EXCEPT JOHN DEERE 160H
70 7.7B DISCHARGE SYSTEM AND PARTS - JOHN DEERE
MODEL 160H
74 7.8A REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -
ALL MODELS EXCEPT JOHN DEERE 160H
74 7.8B REGULATOR VALVE/BLOWDOWN VALVE ASSEMBLY -
JOHN DEERE MODEL 160H
76 7.9 ELECTRIC PARTS - ALL MODELS
78 7.10 FUEL TANK AND PARTS - ALL MODELS
80 7.11 CANOPY, ACOUSTICAL PANELS AND PARTS -
ALL MODELS
82 7.12 INSTRUMENT PANEL, PANEL DOOR AND MOUNTING
PARTS - ALL MODELS
84 7.13A INSTRUMENT PANEL AND PARTS - JOHN DEERE /
CATERPILLAR / PERKINS MODELS 125, 130, 185,
49HP (STANDARD GAUGE)
86 7.13B INSTRUMENT PANEL AND PARTS - JOHN DEERE
MODEL 160H (STANDARD GAUGE)
88 7.13C INSTRUMENT PANEL AND PARTS - CATERPILLAR
AND PERKINS (AUSTRALIAN) MODELS 130-185
90 7.13D INSTRUMENT PANEL AND PARTS - JOHN DEERE /
CATERPILLAR / PERKINS MODELS 125, 130, 185 & 49HP
(FULL GAUGE)
92 7.13E INSTRUMENT PANEL AND PARTS - JOHN DEERE
MODEL 160H (FULL GAUGE)
Continued...

Section 7 PAGE
ILLUSTRATIONS
AND PARTS LIST
(CONTINUED) 94 7.14 SINGLE HOSE REEL OPTION - ALL MODELS
96 7.15 DUAL HOSE REEL OPTION- ALL MODELS
100 7.16A ONE PINT OILER OPTION- ALL MODELS
102 7.16B ONE QUART OILER / MOISTURE SEPARATOR OPTION -
ALL MODELS
104 7.17 DECALS
116 7.18 DECAL LOCATIONS - ALL MODELS
120 7.19 CANADIAN TAIL / CLEARANCE LIGHTS - ALL MODELS
122 7.20 DRAWBAR INSTALLATION - STANDARD
TABLE OF CONTENTS

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation designs and manufactures all of
its products so they can be operated safely.
However, the responsibility for safe operation rests
with those who use and maintain these products.
The following safety precautions are offered as a
guide which, if conscientiously followed, will mini-
mize the possibility of accidents throughout the
useful life of this equipment. Read the CIMA Safety
Manual prior to compressor operation and towing, if
applicable in your area.
The air compressor should be operated only by
those who have been trained and delegated to do
so, and who have read and understood this
Operator’s Manual. Failure to follow the instruc-
tions, procedures and safety precautions in this
manual can result in accidents and injuries.
NEVER start the air compressor unless it is safe to
do so. DO NOT attempt to operate the air com-
pressor with a known unsafe condition. Tag the air
compressor and render it inoperative by discon-
necting the battery so others who may not know of
the unsafe condition will not attempt to operate it
until the condition is corrected.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements
and/or all pertinent Federal, State and Local codes
or requirements.
DO NOT modify the compressor except with written
factory approval.
Each day walk around the air compressor and
inspect for leaks, loose or missing parts, damaged
parts or parts out of adjustment. Perform all recom-
mended daily maintenance.
Inspect for torn, frayed, blistered or otherwise dete-
riorated and degraded hoses. Replace as required.
1.2 TOWING (I)
A. PREPARING TO TOW
1. Prior to hitching the air compressor to the tow
vehicle, inspect all attachment parts and equip-
ment, checking for (i) signs of excessive wear or
corrosion, (ii) parts that are cracked, bent, dented
or otherwise deformed or degraded, and (iii) loose
nuts, bolts or other fasteners. Should any such con-
dition be present, DO NOT TOW until the problem
is corrected.
2. Back the tow vehicle to the compressor and posi-
tion it in preparation for coupling the compressor.
3. If the compressor is provided with a drawbar
latched in the vertical upright position, carefully
unlatch drawbar and lower it to engage the coupling
device. If not, raise drawbar to engage coupling
device or otherwise couple the compressor to the
towing vehicle.
Use the screw jack provided or a chain fall if you
cannot lift or lower it without avoiding injury to your-
self or others. Keep hands and fingers clear of the
coupling device and all other pinch points. Keep
feet clear of drawbar to avoid injury in case it should
slip from your hands.
4. Make sure the coupling device is fully engaged,
closed and locked.
5. If chains are provided, pass each chain through
its point of attachment on the towing vehicle; then
hook each chain to itself by passing the grab hook
over (not through) a link. Cross chains under front
of drawbar before passing them through points of
attachment on towing vehicle to support front of
drawbar in case it should accidentally become
uncoupled.
6. Make sure that the coupling device and adjacent
structures on the towing vehicle (and also, if uti-
lized, chain adjustment, brake and/or electrical
interconnections) DO NOT interfere with or restrict
motion of any part of the compressor, including its
Estimated hose life based on a 5-day 8-hour
work week is 3 years. These conditions exist on
an 8-hour shift only. Any other operation of the
equipment other than 8-hour shifts would short-
en the hose life based on hours of operation.
NOTE
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
(I) While not towed in the usual sense of the word, many of these instructions are directly applicable to skid-mount-
ed portable air compressors as well.
WARNING
DO NOT tow the compressor should its weight
exceed the rated limit of the tow vehicle, as the
vehicle may not brake safely with excess weight.
continued
NOTE
N
See rated limit in tow vehicle Operator’s Manual,
and review its instructions and other require-
ments for safe towing.
NOTE (CONT.)

Section 1
SAFETY
2
coupling device, with respect to the towing vehicle
when maneuvering over any anticipated terrain.
7. If provided, make sure chain length, brake and
electrical interconnections provide sufficient slack
to prevent strain when cornering and maneuvering,
yet are supported so they cannot drag or rub on
road, terrain or towing vehicle surfaces which might
cause wear that could render them inoperative.
8. On two-wheeled models, fully retract front screw
jack and any rear stabilizer legs. If a caster wheel
is provided on the screw jack it is part of the screw
jack and can not be removed. Follow the same
procedure for stowing away the wheeled jack as
you would for the standard screw jack. Pull the pin
connecting the jack to the drawbar and raise the
screw jack to its full up position. Rotate the screw
jack to its stowed position, parallel to the drawbar,
and reinsert the pin. Make sure the jack is secured
in place prior to towing.
9. Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire size
or type. Also, make sure wheel bolts, lugs or nuts
are tightened to the specified torques.
10. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating properly
and that their lenses are clean and functional. Also,
make sure all reflectors and reflecting surfaces,
including the slow moving vehicle emblem on com-
pressors provided with same, are clean and func-
tional.
11. Make sure all service air hoses (not air brake
hoses) are disconnected or are fully stowed and
secured on hose reels, if provided.
12. Make sure all access doors and tool box covers
are closed and latched. If the compressor is large
enough to hold a man, make sure all personnel are
out before closing and latching access doors.
13. Make sure parking brakes in towing vehicle are
set, or that its wheel are chocked or blocked, or that
it is otherwise restrained from moving. Then,
release the compressor parking brakes, if provided.
14. Make sure the compressor wheels are not
chocked or blocked, and that all tie-downs, if any,
are free.
15. Test running brake operation, including break-
away switch operation if provided, before attempt-
ing to tow the compressor at its rated speed or less
when conditions prevail.
16. DO NOT carry loose or inappropriate tools,
equipment or supplies on or in the compressor.
17. DO NOT load this equipment with accessories
or tools such that it is unbalanced from side to side
or front to back. Such unbalance will reduce the
towability of this equipment and may increase the
possibility of tipping, rolling over, jackknifing, etc.
Loss of control of the towing vehicle may result.
B. TOWING
1. Observe all Federal, State, and Local laws while
towing this equipment (including those specifying
minimum speed).
2. DO NOT exceed the towing speeds listed below
under ideal conditions. Reduce your speed accord-
ing to posted speed limits, weather, traffic, road or
terrain conditions.
a. Two axle four-wheel steerable models:
15MPH (24KMPH).
b. All other models: 55 MPH (88KMPH).
3. Remember that the portable air compressor may
approach or exceed the weight of the towing vehi-
cle. Maintain increased stopping distances accord-
ingly. DO NOT make sudden lane changes, U-
turns, or other maneuvers. Such maneuvers can
cause the compressor to tip, roll over, jackknife or
slide and cause loss of control of the towing vehi-
cle. Tipping, rolling over, etc. can occur suddenly
without warning. U-turns especially should be
made slowly and carefully.
4. Avoid grades in excess of 15° (27%).
Retract the front screw jack only after attaching
the compressor to the tow vehicle. Raise the
screw jack to its full up position and pull the pin
connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the
drawbar, and reinsert the pin. Make sure the jack
is secured in place prior to towing.
If a caster wheel is provided on the screw jack it
is part of the screw jack and can not be removed.
Follow the same procedure for stowing away the
wheeled jack as you would for the standard
screw jack. Pull the pin connecting the jack to
the drawbar and raise the screw jack to its full up
position. Rotate the screw jack to its stowed
position, parallel to the drawbar, and reinsert the
pin. Make sure the jack is secured in place prior
to towing.
WARNING
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
WARNING

Section 1
SAFETY
3
5. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain.
6. 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/or adjacent structure whether
towing forward or backing up, regardless of the ter-
rain being traversed.
7. DO NOT permit personnel to ride in or on the
compressor.
8. Make sure the area behind, in front of, and under
the compressor is clear of all personnel and
obstructions prior to towing in any direction.
9. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compres-
sor and the towing vehicle.
C. PARKING OR LOCATING COMPRESSOR
1. Park or locate compressor on a level surface, if
possible. If not, park or locate compressor across
grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on
grades exceeding 15° (27%).
2. Make sure compressor is parked or located on a
firm surface than can support its weight.
3. Park or locate compressor so the wind, if any,
tends to carry the exhaust fumes and radiator heat
away from the compressor air inlet openings, and
also where the compressor will not be exposed to
excessive dust from the work site.
4. On four-wheel models, park compressor with
front wheels in straight ahead position.
5. Set parking brakes and disconnect breakaway
switch cable and all other interconnecting electrical
and/or brake connections, if provided.
6. Block or chock both sides of all wheels.
7. If provided, unhook chains and remove them
from the points of chain attachment on the towing
vehicle, then hook chains to bail on drawbar or wrap
chains around the drawbar and hook them to them-
selves to keep chains off the ground which might
accelerate rusting.
8. Lower front screw jack and/or any front and rear
stabilizer legs. Make sure the surface they contact
has sufficient load bearing capability to support the
weight of the compressor.
9. If a caster wheel is provided on the screw jack it
is part of the screw jack and can not be removed.
Follow the same procedure for stowing away the
wheeled jack as you would for the standard screw
jack. Raise the screw jack to its full up position and
pull the pin connecting the jack to the drawbar.
Rotate the screw jack to its stowed position, paral-
lel to the drawbar, and reinsert the pin. Make sure
the jack is secured in place prior to towing.
10. Disconnect coupling device, keeping hands and
fingers clear of all pinch points. If the compressor is
provided with a drawbar, DO NOT attempt to lift the
drawbar or if hinged, to raise it to the upright posi-
tion, by hand, if the weight is more than you can
safely handle. Use a screwjack or chain fall if you
cannot lift or raise the drawbar without avoiding
injury to yourself or others.
11. When possible, stow hinged drawbar in the ver-
tical upright position. Make certain it is securely
latched in the vertical upright position. Keep feet
clear of drawbar at all times to avoid crushing acci-
dents in case it should slip from your hands or oth-
erwise fall to the ground.
12. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barricades
and/or flares (if at night) if compressor is parked on
or adjacent to public roads. Park so as not to inter-
fere with traffic.
1.3 PRESSURE RELEASE
A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
Retract the front screw jack only after attaching
the compressor to the tow vehicle.
continued
Raise the screw jack to its full up position and
pull the pin connecting the jack to the drawbar.
Rotate the screw jack to its stowed position, par-
allel to the drawbar, and reinsert the pin. Make
sure the jack is secured in place prior to towing.
If a caster wheel is provided on the screw jack it
is part of the screw jack and can not be removed.
Follow the same procedure for stowing away the
wheeled jack as you would for the standard
screw jack. Pull the pin connecting the jack to
the drawbar and raise the screw jack to its full up
position. Rotate the screw jack to its stowed
position, parallel to the drawbar, and reinsert the
pin. Make sure the jack is secured in place prior
to towing.
WARNING
WARNING (cont).
WARNING

Section 1
SAFETY
4
otherwise disabled.
B. Install an appropriate flow-limiting valve between
the compressor service air outlet and the shutoff
(throttle) valve, when an air hose exceeding 1/2”
(13mm) inside diameter is to be connected to shut-
off (throttle) valve, to reduce pressure in case of
hose failure, per OSHA Standard 29 CFR 1926.302
(b) (7) or any applicable Federal, State and Local
codes, standards and regulations.
C. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
exceeding 1/2” (13mm) inside diameter that is to be
connected to the manifold to reduce pressure in
case of hose failure.
D. Provide an appropriate flow-limiting valve for
each additional 75 feet (23 meters) of hose in runs
of air hose exceeding 1/2” (13mm) inside diameter
to reduce pressure in case of hose failure.
E. Flow-limiting valves are listed by pipe size and
rated CFM. Select appropriate valve accordingly.
F. DO NOT use tools that are rated below the max-
imum rating of this compressor. Select tools, air
hoses, pipes, valves, filters and other fittings
accordingly. DO NOT exceed manufacturer’s rated
safe operating pressures for these items.
G. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
H. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to zero
internal pressure before removing the cap.
I. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers, and
before attempting to refill optional air line anti-icer
systems with antifreeze compound.
J. Keep personnel out of line with and away from
the discharge opening of hoses, tools or other
points of compressed air discharge.
K. DO NOT use air at pressures higher than 30
psig (2.1 bar) for cleaning purposes, and then only
with effective chip guarding and personal protective
equipment per OSHA Standard 29 CFR 1910.242
(b) or any applicable Federal, State and Local
codes, standards and regulations.
L. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
M. This equipment is supplied with an ASME
designed pressure vessel protected by an ASME
rated relief valve. Lift the handle once a week to
make sure the valve is functional. DO NOT lift the
handle while machine is under pressure.
N. If the machine is installed in an enclosed area it
is necessary to vent the relief valve to the outside
of the structure or to an area of non-exposure.
O. DO NOT remove radiator filler cap until the
coolant temperature is below its boiling point. Then
loosen cap slowly to its stop to relieve any excess
pressure and make sure coolant is not boiling
before removing cap completely. Remove radiator
filler cap only when cool enough to touch with a
bare hand.
P. The ethyl ether in the replaceable cylinders used
in diesel ether starting aid systems (optional) is
under pressure. DO NOT puncture or incinerate
those cylinders. DO NOT attempt to remove the
center valve core or side pressure relief valve from
these cylinders regardless of whether they are full
or empty.
Q. If a manual blowdown valve is provided on the
receiver, open the valve to insure all internal pres-
sure has been vented prior to servicing any pres-
surized component of the compressor air/fluid sys-
tem.
1.4 FIRE AND EXPLOSION
A. Refuel at a service station or from a fuel tank
designed for its intended purpose. If this is not pos-
sible, ground the compressor to the dispenser prior
to refueling.
B. Clean up spills of fuel, fluid, battery electrolyte or
coolant immediately if such spills occur.
C. Shut off air compressor and allow it to cool.
Then keep sparks, flames and other sources of
ignition away and DO NOT permit smoking in the
vicinity when adding fuel, or when checking or
adding electrolyte to batteries, or when checking or
adding fluid, or when checking diesel engine ether
starting aid systems or replacing cylinders, or when
refilling air line anti-icer systems antifreeze com-
pound.
D. DO NOT permit liquids, including air line anti-
icer system antifreeze compound or fluid film to
accumulate on bottom covers or on, under or
around acoustical material, or on any external or
internal surfaces of the air compressor. Wipe down
using an aqueous industrial cleaner or steam clean
as required. If necessary remove acoustical mate-
rial, clean all surfaces and then replace acoustical

Section 1
SAFETY
5
material. Any acoustical material with a protective
covering that has been torn or punctured should be
replaced immediately to prevent accumulation of
liquids or fluid film within the material. DO NOT use
flammable solvents for cleaning purposes.
E. Disconnect the grounded (negative) battery con-
nection prior to attempting any repairs or cleaning
inside the enclosure. Tag the battery connections
so others will not unexpectedly reconnect it.
F. Keep electrical wiring, including the battery ter-
minals and other terminals, in good condition.
Replace any wiring that has cracked, cut abraded
or otherwise degraded insulation or terminals that
are worn, discolored or corroded. Keep all termi-
nals clean and tight.
G. Turn off battery charger before making or break-
ing connections to the battery.
H. Keep grounded conductive objects such as tools
away from exposed live electrical parts such as ter-
minals to avoid arcing which might serve as a
source of ignition.
I. Replace damaged fuel tanks or lines immediately
rather than attempt to weld or otherwise repair
them. DO NOT store or attempt to operate the
compressor with any known leaks in the fuel sys-
tem. Tag the compressor and render it inoperative
until repair can be made.
J. Remove any acoustical material or other materi-
al that may be damaged by heat or that may sup-
port combustion prior to attempting weld repairs.
Remove diesel engine ether starting aid cylinders
and air line anti-icer system components containing
antifreeze compound, prior to attempting weld
repairs in any place other than the fuel system. DO
NOT weld on or near the fuel system.
K. Keep a suitable fully charged class BC or ABC
fire extinguisher or extinguishers nearby when serv-
icing and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure
to ventilate thoroughly prior to attempting to start
the engine.
N. DO NOT operate compressor under low over-
hanging leaves or permit such leaves to contact hot
exhaust system surfaces when operating the com-
pressor in forested areas.
O. Ethyl ether used in diesel engine ether starting
aid systems is extremely flammable. Change cylin-
ders, or maintain or troubleshoot these systems
only in well-ventilated areas away from heat, open
flame or sparks. DO NOT install, store or otherwise
expose ether cylinders to temperatures above
160°F (71°C). Remove ether cylinder from the com-
pressor when operating in ambient temperatures
above 60°F (16°C).
P. DO NOT attempt to use ether as a starting aid in
gasoline engines or diesel engines with glow plugs
as serious personnel injury or property damage
may result.
Q. DO NOT spray ether into compressor air filter or
into an air filter that serves both the engine and the
compressor as serious damage to the compressor
or personal injury may result.
R. Antifreeze compound used in air line anti-icer
systems contains methanol which is flammable.
Use systems and refill with compound only in well-
ventilated areas away from heat, open flames or
sparks. DO NOT expose any part of these systems
or the antifreeze compound to temperatures above
150°F (66°C). Vapors from the antifreeze com-
pound are heavier than air. DO NOT store com-
pound or discharge treated air in confined or unven-
tilated areas. DO NOT store containers or
antifreeze compound in direct sunlight.
S. Store flammable fluids and materials away from
your work area. Know where fire extinguishers are
and how to use them, and for what type of fire they
are intended. Check readiness of fire suppression
systems and detectors if so equipped.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body
and also clothing away from belts, pulleys and other
moving parts.
B. DO NOT attempt to operate the compressor with
the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
when exposed to hot or moving parts inside the
enclosure.
D. Keep access doors closed except when making
repairs or adjustments, performing service or when
starting or stopping the compressor.
E. Make sure all personnel are out of and clear of
the compressor prior to attempting to start or oper-
ate it.
F. Shut off engine before adding fuel, fluid, coolant
lubricants, air line antifreeze compound or battery
electrolyte, or before replacing ether starting aid
cylinders.

Section 1
SAFETY
6
G. Disconnect the grounded negative battery con-
nection to prevent accidental engine operation prior
to attempting repairs or adjustments. Tag the bat-
tery connection so others will not unexpectedly
reconnect it.
H. When adjusting the controls, it may require oper-
ation of the equipment during adjustment. DO NOT
come in contact with any moving parts while adjust-
ing the control regulator and setting the engine
RPM. Make all other adjustments with the engine
shut off. When necessary, make adjustment, other
than setting control regulator and engine RPM, with
the engine shut off. If necessary, start the engine
and check adjustment. If adjustment is incorrect,
shut engine off, readjust, then restart the engine to
recheck adjustment.
I. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, antifreeze or
other liquids to minimize possibility of slips and
falls.
1.6 HOT SURFACES, SHARP EDGES AND SHARP
CORNERS
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of
air discharge and away from hot exhaust gases.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other
Federal, State or Local codes or regulations.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utiliza-
tion equipment and DO NOT discharge air from
these systems into unventilated or other confined
areas.
C. Operate the compressor only in open or well-
ventilated areas.
D. If the compressor is operated indoors, discharge
engine exhaust fumes outdoors.
E. Locate the compressor so that exhaust fumes
are not apt to be carried towards personnel, air
intakes servicing personnel areas or towards the air
intake of any portable or stationary compressor.
F. Fuels, fluids, coolants, lubricants and battery
electrolyte used in the compressor are typical of the
industry. Care should be taken to avoid accidental
ingestions and/or skin contact. In the event of
ingestion seek medical treatment promptly. DO
NOT induce vomiting if fuel is ingested. Wash with
soap and water in the event of skin contact.
G. Wear an acid-resistant apron and a face shield
or goggles when servicing the battery. If electrolyte
is spilled on skin or clothing, immediately flush with
large quantities of water.
H. Ethyl ether used in diesel engine ether starting
aid systems is toxic, harmful or fatal if swallowed.
Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, DO NOT induce
vomiting, but call a physician immediately.
I. Wear goggles or a full face shield when testing
ether starting aid systems or when adding
antifreeze compound to air line anti-icer systems.
Keep openings of valve or atomizer tube of ether
starting aid system pointed away from yourself and
other personnel.
J. If ethyl ether or air line anti-icer system
antifreeze compound enters the eyes or if fumes
irritate the eyes, they should be washed with large
quantities of clean water for 15 minutes. A physi-
cian, preferably any eye specialist, should be con-
tacted immediately.
K. DO NOT store ether cylinders or air line anti-icer
system antifreeze compound in operator’s cabs or
in other similar confined areas.
L. The antifreeze compound used in air line anti-
icer systems contains methanol and is toxic, harm-
ful or fatal if swallowed. Avoid contact with the skin
or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administering a table-
spoon of salt in each glass of clean warm water
until vomit is clear, then administer two tablespoons
of baking soda in a glass of clean water. Have
patient lay down and cover eyes to exclude light.
Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. Keep the towing vehicle or equipment carrier,
Death or serious injury may occur from inhaling
compressed air without using proper safety
equipment. See OSHA standards, and/or any
Federal, State or Local codes or regulations on
safety equipment.
DANGER

Section 1
SAFETY
7
compressor hoses, tools and all personnel at least
10 feet (3 meters) from power lines and buried
cables.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain dry
footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when
making adjustments or repairs to exposed live parts
of the electrical system.
C. Attempt repairs only in clean, dry and well- light-
ed and ventilated areas.
D. Stay clear of the compressor during electrical
storms! It can attract lightning.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air lifted by hel-
icopter must not be supported by the lifting bail, but
by slings instead. In any event, lift only in full com-
pliance with OSHA Standards 29 CFR 1910 subpart
N or any other Local, State, Military and Federal
regulations that may apply.
B. Inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts or
nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condition
and has a rated capacity of at least the net weight
of the compressor plus an additional 10%
allowance for weight of snow, ice, mud or stored
tools and equipment. If your are unsure of the
weight, then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and latched
on the bail.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been lift-
ed clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance whenev-
er compressor is suspended.
J. Set compressor down only on a level surface
capable of supporting at least its net weight plus an
additional 10% allowance for the weight of snow,
ice, mud or stored tools and equipment.
K. If the compressor is provided with parking
brakes, make sure they are set, and in any event,
block or chock both sides of all running wheels
before disengaging the lifting hook.
1.10 ENTRAPMENT
A. Make sure all personnel are out compressor
before closing and latching enclosure doors.
B. If the compressor is large enough to hold a man
and if it is necessary to enter it to perform service
adjustments, inform other personnel before doing
so, or else secure the access door in the open posi-
tion to avoid the possibility of others closing and
possibly latching the door with personnel inside.
1.11 JUMP STARTING
A. Observe all safety precautions mentioned else-
where in this manual.
B. Batteries may contain hydrogen gas which is
flammable and explosive. Keep flames, sparks and
other sources of ignition away.
C. Batteries contain acid which is corrosive and poi-
sonous. DO NOT allow battery acid to contact
eyes, skin, fabrics or painted surfaces as serious
personal injury or property damage could result.
Flush any contacted areas thoroughly with water
immediately. Always wear an acid-resistant apron
and face shield when attempting to jump start the
compressor.
D. Remove all vent caps (if so equipped) from the
battery or batteries in the compressor. DO NOT per-
mit dirt or foreign matter to enter the open cells.
E. Check fluid level. If low, bring fluid to proper level
before attempting to jump start (not applicable to
maintenance-free batteries).
F. DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60°F (16°C)
before attempting to jump start or it may explode.
G. Cover open cells of all compressor batteries with
clean dampened cloths before attempting to jump
start.
H. Attempt to jump start only with a vehicle having
a negative ground electrical system with the same
voltage, and is also equipped with a battery or bat-
teries of comparable size or larger than supplied in
the compressor. DO NOT attempt to jump start
using motor generator sets, welders or other
sources of DC power as serious damage may
result.
I. Bring the starting vehicle alongside the compres-
sor, but DO NOT permit metal to metal contact
between the compressor and the starting vehicle.

Section 1
SAFETY
8
J. Set the parking brakes of both the compressor (if
provided) and the starting vehicle or otherwise
block both sides of all wheels.
K. Place the starting vehicle in neutral or park, turn
off all non-essential accessory electrical loads and
start its engine.
L. Use only jumper cables that are clean, in good
condition and are heavy enough to handle the start-
ing current.
M. Avoid accidental contact between jumper cable
terminal clips or clamps and any metallic portion of
either the compressor or the starting vehicle to min-
imize the possibility of uncontrolled arcing which
might serve as a source of ignition.
N. Positive battery terminals are usually identified
by a plus (+) sign on the terminal and the letters
POS adjacent to the terminal. Negative battery ter-
minals are usually identified by the letters NEG
adjacent to the terminal or a negative (-) sign.
O. Connect one end of a jumper cable to the posi-
tive (POS) (+) battery terminal in the starting vehi-
cle. When jump starting 24V compressors and if the
starting vehicle is provided with two (2) 12V batter-
ies connected in series, connect the jumper cable
to the positive (POS) (+) terminal of the unground-
ed battery.
P. Connect the other end of the same jumper cable
to the positive (POS) (+) terminal of the starter
motor battery in the compressor, or when jump
starting 24V compressor, to the positive (POS) (+)
terminal of the ungrounded battery in the compres-
sor.
Q. Connect one end of the other jumper cable to
the grounded negative (NEG) (-) terminal of the bat-
tery in the starting vehicle. When jump starting 24V
compressors and if the starting vehicle is provided
with two (2) 12V batteries connected in series, con-
nect the jumper cable to the negative (NEG) (-) ter-
minal of the grounded battery.
R. Check your connections. DO NOT attempt to
start a 24V compressor with one 12V battery in the
starting vehicle. DO NOT apply 24V to one 12V
battery in the compressor.
S. Connect the other end of this same jumper cable
to a clean portion of the compressor engine block
away from fuel lines, the crank case breather open-
ing and the battery.
T. Start the compressor in accordance with normal
procedure. Avoid prolonged cranking.
U. Allow the compressor to warm up. When the
compressor is warm and operating smoothly at nor-
mal idle RPM, disconnect the jumper cable from the
engine block in the compressor, then disconnect
the other end of this same cable from the grounded
negative (NEG) (-) terminal of the battery in the
starting vehicle. Then disconnect the other jumper
cable from the positive (POS) (+) terminal of the
battery in the compressor, or if provided with two (2)
12V batteries connected in series, from the
ungrounded battery in the compressor, and finally,
disconnect the other end of this same jumper cable
from the positive (POS) (+) terminal of the battery in
the starting vehicle or from the positive (POS) (+)
terminal of the ungrounded battery in the starting
vehicle, if it is provided with two (2) 12V batteries
connected in series.
V. Remove and carefully dispose of the dampened
cloths, as they may now be contaminated with acid,
then replace all vent caps.

Section 2
DESCRIPTION
9
2.1 INTRODUCTION
The Sullair 125, 130, 160H, 185 CFM and 49 HP
Portable Air Compressors offer superior perform-
ance and reliability along with a minimal amount of
maintenance requirements.
The compressor is equipped with a Sullair rotary
screw compressor unit. Compared to other com-
pressors, the Sullair is unique in mechanical relia-
bility and compressor durability. No inspection is
required of the working parts within the compressor
unit.
As you continue reading this manual and come to
learn how the compressor operates and is cared
for, you will see how surprisingly easy it is to keep a
Sullair compressor in top operating condition.
Read Section 5 (Maintenance) and learn how to
keep your compressor in top operating condition.
Should any problem or question arise which cannot
be answered in this text, contact your nearest
Sullair representative or the Sullair Corporation
Service Department.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure 2-1. The components and assem-
blies of the Sullair Portable Air compressor are
clearly shown. The package includes a heavy duty
rotary screw air compressor, a diesel engine,
fuel tank, compressor inlet system, compressor
cooling and lubrication system, compressor
discharge system, capacity control system,
instrument panel and electrical system.
A low profile canopy offers improved handling and
mobility. The clamshell canopy provides easy
access to all serviceable components.
This model meets EPA regulations for 76dbA at 7
meters (23 feet).
The Sullair air compressors are capable of deliver-
ing capacities as follows:
Model 125 125 CFM @ 100 psig (6.9 bar)
Model 130 130 CFM @ 100 psig (6.9 bar)
Model 49 HP 160 CFM @ 100 psig (6.9 bar)
Model 185 185 CFM @ 100 psig (6.9 bar)
Model 160H 160 CFM @ 150 psig (10.3 bar)
The control system can easily be adjusted for pres-
Figure 2-1 Sullair Rotary Screw Portable Air Compressor

Section 2
DESCRIPTION
10
sures from 85 to 125 psig (5.9 to 8.6 bar) for stan-
dard machines, and from 85 to 150 psig (5.9 to 10.3
bar) for “H” machines. The compressor unit is driv-
en by an industrial diesel engine designed to pro-
vide enough horsepower for more than adequate
reserve at rated conditions. Refer to the Engine
Operator’s Manual for a more detailed description
of the engine.
The engine cooling system is comprised of a
radiator, high capacity fan and thermostat. The
high capacity fan pushes air through the radiator,
keeping the engine at the proper operating temper-
ature.
The same fan also cools the fluid in the compressor
cooling and lubrication system. The engine radiator
and the compressor fluid cooler sit side by side
which allows the fan air to push through both simul-
taneously. As air passes through the fluid cooler,
the heat of compression is removed from the fluid.
The compressor is supplied with a large capacity
fuel tank which will keep the compressor running
through one (1) eight hour shift under normal oper-
ating conditions.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair compressors feature the Sullair compres-
sor unit, a single-stage, positive displacement,
flood lubricated-type compressor. This unit pro-
vides continuous (pulse-free) compression to meet
your needs. With a Sullair compressor, no mainte-
nance or inspection of the internal parts of the com-
pressor unit is required.
Fluid is injected into the compressor unit where it
mixes directly with the air as the rotors turn, com-
pressing the air. The fluid flow has three main func-
tions:
1. As coolant, it controls the rise of air tem-
perature normally associated with the heat
of compression.
2. Seals the leakage paths between the rotors
and the stator and also between the rotors
themselves.
3. Acts as a lubricating film between the rotors
allowing one rotor to directly drive the other.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
At this time, the air flows to your service line and the
fluid is cooled in preparation for reinjection.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
Refer to Figure 2-2. The compressor cooling and
lubrication system is designed to provide ade-
quate lubrication as well as maintain the proper
operating temperature of the compressor. In addi-
tion to the fluid cooler and interconnecting pip-
ing, the system consists also of three other compo-
nents: a fluid filter, thermal valve, and a fan
which perform the following functions:
•The fluid filter filters the fluid.
•The thermal valve functions as a tempera-
ture regulator directing fluid either to the
cooler or to the compressor unit, bypassing
the cooler as will be explained later.
•The fan pushes air through the cooler
removing the heat of compression from the
fluid.
The functions of the lubrication system are
explained in more detail below. Fluid is used in the
system as a coolant and as a lubricant. It is housed
in the receiver/sump which, will from this time for-
ward, be referred to as the SUMP.
Upon start-up, fluid flows from the sump to the fluid
thermal valve. Fluid circulation is achieved by forc-
ing the fluid from the high pressure region of the
sump to a lower pressure area in the compressor
unit. A minimum pressure device (see Section 2.5
Compressor Discharge System) is provided to
assure adequate fluid flow under all conditions.
When entering the thermal valve upon start-up, the
fluid temperature is cool and thus it is not necessary
to route it through the cooler. Hence the fluid flows
through the fluid filter and on to the compressor unit
bypassing the cooler. As the compressor continues
to operate, the temperature of the fluid rises and the
thermostatic control opens, allowing a portion of
the fluid to the cooler. When the temperature reach-
es 160°F (71°C), the thermostat is fully open allow-
ing all fluid entering the thermal valve to be direct-
ed to the cooler.
The cooler is a radiator-type that works in conjunc-
tion with the engine fan. The fan pushes air through
the cooler removing the heat of compression from
the fluid. From the cooler, the fluid is then routed
back through the fluid filter. All fluid flowing to the
compressor unit passes through this filter. The fluid
leaving the filter flows to the compressor unit where
it lubricates, seals and cools the compression
chamber as well as lubricates the bearings and
gears.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION
Refer to Figures 2-3, 2-4A, 2-4B or 2-4C. The

Section 2
DESCRIPTION
11
Sullair compressor unit discharges compressed
air/fluid mixture into the sump. The sump has three
functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the air/fluid separator.
The compressed air/fluid mixture enters the sump
and is directed against the side of the sump. By
change of direction and reduction of velocity, large
droplets of fluid separate and fall to the bottom of
the sump. The fractional percentage of fluid remain-
ing in the compressed air collects on the surface of
the final separator element as the compressed air
flows through the separator. As more and more fluid
collects on the element surface, the fluid descends
to the bottom of the separator. A return line (or scav-
enge tube) leads from the bottom of the separator
element to the inlet region of the compressor unit.
Fluid collecting on the bottom of the separator ele-
ment is returned to the compressor by the pressure
difference between the area surrounding the sepa-
rator element and the compressor inlet. An orifice
(protected by a strainer) is included in this return
line to assure proper flow.
The sump is ASME code rated at 200 psig (13.8
bar) working pressure. A minimum pressure device
located downstream from the separator, assures a
minimum receiver pressure of 85 psig (5.9 bar) dur-
ing all conditions. This pressure is necessary for
proper air/fluid separation and proper fluid circula-
tion.
A pressure relief valve (located on the wet side of
the separator) is set to open if the sump pressure
exceeds 200 psig (13.8 bar). A temperature switch
will shut down the compressor if the discharge tem-
perature reaches the specified limit given in Section
3, Specifications.
Fluid is added to the sump via a capped fluid filler.
Figure 2-2 Compressor Cooling and Lubrication System
DO NOT remove caps, plugs, and/or other com-
ponents when compressor is running or pres-
surized.
WARNING

Section 2
DESCRIPTION
12
Stop compressor and relieve all internal pressure
before doing so.
2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figures 2-3, 2-4A, 2-4B or 2-4C. The pur-
pose of the control system is to regulate the amount
of air intake in accordance with the amount of com-
pressed air being used. The control system con-
sists of a pressure regulating valve(s), air inlet
valve, system blowdown valve, and tubing con-
necting the various components to the compressor
and engine governor. The functional descriptions of
the control system are given in four distinct phases
of operation. It applies to any control system with
the exception of those with stated pressures which
are dependent on pressure requirements. The pres-
sures stated will be in accordance with a compres-
sor having an operating pressure range of 100 to
110 psig (6.9 to 7.6 bar).
START - 0 TO 40 PSIG (0 to 2.8 BAR)
COLD WEATHER
To minimize problems in cold weather, starting aids,
engine coolant heaters and dry-side receiver relief
valves should be used. Refer to the engine opera-
tors manual for additional information.
COLD START
When the compressor is started, the sump pressure
will quickly rise from 0 to 40 psig (0 to 2.8 bar).
During this period the pressure regulator valve is
inactive. At this pressure range the idle warm-up
control maintains a closed inlet valve for engine idle
operation. After engine start-up, turn the handle of
the selector valve warm-up control (located on the
instrument panel) from the “start” to the “run” posi-
tion within the first 30 seconds of operation. The
instrument panel annunciator light will go off after
30 seconds. The inlet valve is fully open due to inlet
air pressure, and the compressor operates at full
capacity operation. As the compressor operates at
full capacity, the engine runs at full speed.
NORMAL OPERATION - 85 TO 100 PSIG (5.9 TO
6.9 BAR) OR 85 TO 150 PSIG (5.9 TO 10.3 BAR)
FOR “H” MACHINES
When the warm-up control selector valve handle is
moved to the “run” position, the sump pressure
rises above 85 psig (5.9 bar). At this time, the inlet
valve remains fully open for maximum air output.
The engine will continue to run at full speed during
this phase of operation.
Figure 2-3 Compressor Discharge System

Section 2
DESCRIPTION
13
Figure 2-4A Control System with Piping and Instrumentation - 125 and 130 Models (Caterpillar and Perkins)

Section 2
DESCRIPTION
14
Figure 2-4B Control System with Piping and Instrumentation - 125, 130, 49HP and 185 Models (Caterpillar and
Perkins)