Sullair 1600H User manual

Portable Air Compressor
1600H
Tier 4 Final
Condensate Management System
Caterpillar/Perkins
PART NUMBER:
02250251-632 R01
The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
201612120000
and all subsequent serial numbers.
ADDENDUM
Publication date: 03/27/2020
Copyright © 2020 Sullair, LLC. All rights reserved.
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
Subject to EAR, ECCN EAR99 and related export control restrictions.
SAFETY WARNING
Users are required to read the
entire User Manual before han-
dling or using the product.

Service Training Courses
Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and
servicing of Sullair products. Individual courses on Portable compressors are offered at regular intervals
throughout the year at Sullair’s training facility located in Michigan City, Indiana and on-site at Sullair distributor
locations.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and distributor service personnel.
For more information contact:
Sullair Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5623)
[email protected]
www.SullairTraining.com
- Or Write -
Sullair
1 Sullair Way
Michigan City, IN 46360
Attn: Training Department
Subject to EAR, ECCN EAR99 and related export control restrictions.

Table of Contents
1600H T4F CAT/Perkins Addendum Table of Contents
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 3
Section 1: Description..............................................................................................5
1.1 Introduction & functional description................................................................................................5
1.2 Piping and instrumentation - Condensate management system.....................................................6
Section 2: Operation ................................................................................................9
2.1 Overview..........................................................................................................................................9
2.2 Shutdown procedure .......................................................................................................................9
Section 3: Maintenance..........................................................................................11
3.1 Overview........................................................................................................................................11
3.2 Troubleshooting.............................................................................................................................11
Section 4: Drawings ...............................................................................................13
4.1 Exhaust system.............................................................................................................................14
4.2 Exhaust pipe, 5 inches..................................................................................................................22
4.3 Exhaust pipe tail, 5 inches.............................................................................................................24
4.4 Discharge system - aftercooled/filtered with CMS.........................................................................28
4.5 Drains - aftercooled/filtered with CMS...........................................................................................34

Table of Contents 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
4 Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 1
1600H T4F CAT/Perkins Addendum 1: Description
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 5
Description
1.1 Introduction & functional
description
This compressor is equipped with Sullair’s Condensate
Management System (CMS). This system utilizes the
waste heat from the engine exhaust to evaporate con-
densate produced when operating in after-cooled mode.
Using CMS eliminates the need to collect and dispose of
condensate.
When operating in after-cooled mode, condensate is pro-
duced by the aftercooler and separated from the air
stream in the moisture separator.Asmall amount of addi-
tional condensate is removed by the after filters. These
condensate streams are routed to the exhaust and driven
by system pressure. Once at the exhaust, an atomizing
nozzle is used to inject the condensate into the exhaust
stream where it is evaporated.
Figure 1-1: Discharge System with Condensate Management System
1. Aftercooler
2. After-filters
3. Moisture separator
4. Strainer
5. Blow-down valve
6. Exhaust pipe
7. Nozzle

1: Description 1600H T4F CAT/Perkins Addendum
02250251-632 R01
6 Subject to EAR, ECCN EAR99 and related export control restrictions.
1.2 Piping and instrumentation - Condensate management system
02250250-793 R01

1600H T4F CAT/Perkins Addendum 1: Description
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 7
1.2 Piping and instrumentation - Condensate management system
Components
Key Description
1FILTER,AIR
2 GAUGE,AIR FILTER RESTRICTION
3 VALVE,INLET
4 COMPRESSOR
5 VALVE,RELIEF
6 SWITCH,TEMPERATURE
7 SENSOR,TEMPERATURE
8 SENSOR,PRESSURE
9 VALVE,DISCHARGE CHECK
10 TANK,AIR OIL SEPARATOR
11 SIGHTGLASS,OIL LEVEL
12 VALVE,MINIMUM PRESSURE
13 VALVE,BALL
14 COOLER,AIR
15 SEPARATOR,MOISTURE
16 ORIFICE
17 VALVE,SOLENOID 3WNO
18 STRAINER
19 SIGHTGLASS,ORIFICE BLOCK
20 VALVE,THERMAL BYPASS
21 COOLER,OIL
22 FILTER,OIL
23 VALVE,OIL STOP
24 VALVE,BACKPRESSURE
25 VALVE,BLOWDOWN NC
26 VALVE,CHECK
27 ELEMENT,AIR/OIL SEPARATOR
28 FILTER,AFTERCOOLED AIR
29 VALVE,OIL FILTER RELIEF
30 VALVE,OIL COOLER RELIEF
31 VALVE,BLOWDOWN NO
32 SILENCER, BLOWDOWN
33 NOZZLE,SPRAY
Component Description
P1 DRY SIDE PRESSURE
P2 CONTROL PRESSURE
P3 WET SIDE PRESSURE
P4 AFTERCOOLER FILTER DISCHARGE PRESSURE
T1 COMPRESSOR DISCHARGE TEMPERATURE (CDT)
T2 RECEIVER TANK TEMPERATURE (RTT)
T3 AFTERCOOLER DISCHARGE TEMPERATURE
Key Description

1: Description 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
8 Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 2
1600H T4F CAT/Perkins Addendum 2: Operation
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 9
Operation
2.1 Overview
Follow machine operation guidelines from 1600H T4F
CAT User Manual 02250225-985. The Condensate Man-
agement System is automatic and does not require addi-
tional inputs from the operator. It is important to slowly
close the service valve prior to a shutdown. This allows
the system to be purged of condensate during the cool
down period.
2.2 Shutdown procedure
WARNING
The E-Stop (emergency stop switch) should be
used only in the event of an emergency. Refrain
from using the E-Stop to shut the machine down
during normal operations or equipment damage
can occur. All usage of the E-Stop is logged in per-
manent memory for use by service technicians
when troubleshooting a machine. Non-emergency
use of E-Stop is considered equipment abuse and
could void the manufacturer’s warranty.

2: Operation 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
10 Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 3
1600H T4F CAT/Perkins Addendum 3: Maintenance
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 11
Maintenance
3.1 Overview
The Condensate Management System is equipped with a
strainer to prevent clogging of the atomizing nozzle. This
strainer should be cleaned every 250 hours. Refer to Fig-
ure 1-1 on page 5 for location of strainer.
3.2 Troubleshooting
Table 3-1: Troubleshooting
Symptom Probable cause Remedy
Excessive amounts of
water exiting service valve.
Plugged condensate line strainer
preventing flow of condensate to
exhaust stream. Clean strainer.
Plugged orifice in atomizing nozzle. Clean orifice or replace nozzle. Care
must be taken to not damage or move
the pin during cleaning.

3: Maintenance 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
12 Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 4
1600H T4F CAT/Perkins Addendum 4: Drawings
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 13
Drawings
Consult your machine’s primary parts list manual for any drawing not listed in this section.

4: Drawings 1600H T4F CAT/Perkins Addendum
02250251-632 R01
14 Subject to EAR, ECCN EAR99 and related export control restrictions.
4.1 Exhaust system
02250243-420 R01 (sh1)

1600H T4F CAT/Perkins Addendum 4: Drawings
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 15
4.1 Exhaust system
02250243-420 R01 (sh2)

4: Drawings 1600H T4F CAT/Perkins Addendum
4.1 Exhaust system
02250251-632 R01
16 Subject to EAR, ECCN EAR99 and related export control restrictions.
02250243-420 R01 (sh3)

1600H T4F CAT/Perkins Addendum 4: Drawings
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 17
4.1 Exhaust system
02250243-420 R01 (sh4)

4: Drawings 1600H T4F CAT/Perkins Addendum
4.1 Exhaust system
02250251-632 R01
18 Subject to EAR, ECCN EAR99 and related export control restrictions.
Key Part number Qty Description Notes
1 02250190-467 1 ELBOW,SILICONE 1.75" ID
2 02250190-484 2 CLAMP,BAND 5" FLAT CAT SHIPPED LOOSE
3 02250191-399 2 JOINT,EXPANSION 5" BELLOWS CAT SHIPPED LOOSE
4 02250191-406 4 CLAMP,BAND BALL JOINT 5" CAT SHIPPED LOOSE
5 02250193-412 2 WRAP,BLANKET CEM BELLOWS SHIPPED LOOSE
6 02250204-369 1 BAND,MOUNTING 5"
7 02250204-467 1 ENGINE EXHAUST SYSTEM,CAT C15 T4F
8 02250210-393 1 CAP,RAIN 5" STAINLESS
9 02250213-574 1 CLAMP,WRM DRV SAE 10
10 02250219-657 1 WRAP,EXH 1600 CEM
11 02250219-882 1 HOSE,ASSY DEF LINE SHIPPED LOOSE
12 02250220-099 1 MUFFLER,5" INLET ID
13 02250220-323 1 PIPE,EXHAUST TO CEM
14 02250220-466 1 GROMMET,RUB 1.375X1.875X.1875
15 02250220-467 1 GROMMET,RUB 1.375 X 1.75 X .5
16 02250220-547 1 PIPE,EXHAUST TO CEM
17 02250220-616 1 HOSE,DEF TRANSFER 3/8" ID
18 02250221-086 4 WRAP,PUSH LOK TIE
19 02250221-228 1 TANK,DEF 12.7GAL W/PETU SHIPPED LOOSE
20 02250221-515 1 STRAP,ASSY DEF TANK SHIPPED LOOSE
21 02250223-608 1 PIPE,EXHAUST TO CEM
22 02250223-618 1 SUPPORT,BRACKET CEM MOUNT
23 02250223-637 1 WRAP,EXHST PIPE 1600J
24 02250223-662 1 HOSE,MP 13/32" ID X 120.5" OAL
25 02250224-050 1 HOSE,MP 13/32" ID X 140.5" OAL
26 02250224-067 1 HOSE,STR SILICONE 1.75" ID
27 02250224-102 1 HOSE,MP 5/16" ID X 134.5" OAL
28 02250224-111 1 SUPPORT,BRACKET DEF LINE 1600J
29 02250224-144 1 HOSE,MP 13/32" ID X 93.5" OAL
30 02250224-145 1 HOSE,MP 13/32" ID X 90" OAL
31 02250226-037 1 SUPPORT,BRACKET CEM MOUNT
32 02250227-001 1 PIPE,CEM TO CAC 1600

1600H T4F CAT/Perkins Addendum 4: Drawings
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 19
4.1 Exhaust system
33 02250227-002 1 SUPPORT,BRACKET CAC PIPE
34 02250227-162 1 WRAP,EXHST PIPE 1600J
35 02250227-362 1 VALVE,BALL DEF DRAIN 3/4-16
36 02250232-723 1 BAND,EXH MUFFLER 9" OD
37 02250248-230 1 SENSOR,NOX 15L T4F TAIL SHIPPED LOOSE
38 02250248-231 1 SENSOR,NOX 15L T4F TURBO SHIPPED LOOSE
39 02250250-685 1 SUPPORT,BRACKET MUFFLER
40 02250250-766 1 PIPE,EXHST 5.0"
41 02250250-767 1 PIPE,EXHST TAIL 5.0"
42 02250250-769 1 NOZZLE,1/4" NPT
43 040083 4 CLAMP, HOSE 1 13/16 - 2 3/4ADJ
44 043197 1 CLAMP, HOSE 1/2"
45 241260 3 CLAMP,SEAL 5"
46 250025-635 13 CLAMP, TUBE RUBR CTD 7/8" DIA
47 408300-003 5 CLAMP, HOSE O.D. .750
48 408300-004 18 CLAMP, HOSE O.D. .875
49 408300-005 1 CLAMP, HOSE O.D. 1.062
50 825305-283 1 NUT, HEX FLGD PLTD 5/16-18
51 829216-035 8 CAPSCREW,HEX 10.9 M16 X 35MM
52 829704-075 4 SCREW, HX SER WASH 1/4 X 3/4"
53 829705-075 28 SCREW, HX SER WASH 5/16 X 3/4"
54 829705-100 2 SCREW, HX SER WASH 5/16 X 1"
55 829706-100 2 SCREW, HX SER WASH 3/8 X 1"
56 829707-075 2 SCREW, HEX SER WASH 7/16X3/4"
57 829707-100 5 SCREW, HEX SER WASH 7/16 X 1"
58 837806-094 2 WASHER,SPRLOCK REG PLTD 3/8
59 837810-156 8 WASHER, SPRLOCK REG PLTD 5/8"
60 838008-125 4 WASHER, SPRLOCK REG PLTD 1/2"
61 838205-071 2 WASHER,PL-B REG PLTD 5/16
62 838206-071 2 WASHER,PL-B REG PLTD 3/8
63 838207-071 4 WASHER, PL-B REG PLTD 7/16"
64 838208-112 4 WASHER, PL-B REG PLTD 1/2"
Key Part number Qty Description Notes

4: Drawings 1600H T4F CAT/Perkins Addendum
4.1 Exhaust system
02250251-632 R01
20 Subject to EAR, ECCN EAR99 and related export control restrictions.
65 838210-112 8 WASHER, PL-B REG PLTD 5/8"
66 843201-023 2 WRAP, TIE NYLON TY23MX
67 843201-027 3 WRAP, TIE NYLON TY27MX
68 843201-272 1 WRAP, TIE NYLON TY272MX
69 866506-337 2 NUT, HEX 3/8-16 PLT
70 868304-125 1 U-BOLT 1/4 X 1 1/4" PIPE PLT
71 868308-500 2 U-BOLT, 1/2 X 5" PIPE PLTD
72 874510-045 4 SCREW,SOCKET ISO M10X45MM PC 12.9
73 884406-044 1 CONNECTOR,STR THD/ORFS 7/16 X 3/8
74 884406-056 1 CONNECTOR,STR THD/ORFS 9/16 X 3/8
75 884408-025 2 CONNECTOR,STR THD/ORFS 7/16 X 1/2
76 884408-056 4 CONNECTOR,STR THD/ORFS 9/16 X 1/2
77 888708-056 1 ELBOW,ST THD/ORFS 9/16 X 1/2
Drawing notes
A1 TO FUEL TANK (CURB SIDE)
A2 TO ENGINE WATER PUMP
A3 TO ENGINE DIFFUSER
A4 TO COOLING FAN SHROUD
A5 TO FRAME
A6 TO ENGINE FUEL FILTER
A7 TO CHARGE AIR COOLER
A8 TO LIFT BAIL SUPPORT
A9 TO COOLER SUPT BRKT
A10 TO FUEL HOSE
A11 WRAP TO FUEL BREATHER HOSE
A12 WRAP TO DEF HOSE
A13 USE EXISTING BOLT FROM DEF TANK
A14 BOLTS TO BE LOCKED WITH MEDIUM STRENGTH SCREW LOCK ADHESIVE PER SULLAIR ENG. SPEC 005898; COLOR CODE BLUE
A15 ORIENT AS SHOWN
Key Part number Qty Description Notes