Sullair 300HH Installation and maintenance instructions

OPERATOR’S MANUAL AND PARTS LIST
Po r t a b l e ai r Co m P r e s s o r
300HH, 375, 375H a n d 425 ex P o r t
Caterpillar Standard and Aftercooled and Filtered
Part Number:
02250169-733
©
Sullair corPoratioN
The information in this document
is correct at the time of printing for
portable compressor serial number
200705010000
and all subsequent serial numbers.
keeP for
future
refereNce

375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
Section 2
DESCRIPTION
INTRODUCTION2.1
The Sullair 300HH, 375, 375H, and 425 CFM Standard
and Aftercooled Portable Air Compressors offer superior
performance, reliability and require a minimal amount of
maintenance. Compared to other compressors, Sullair’s
are unique in terms of reliability and durability. Compressor
internal components require no routine maintenance
inspections.
DESCRIPTION OF COMPONENTS2.2
Figure 2-1 shows the main components and
subassemblies of the Sullair 300HH, 375, 375H, and 425
Standard and Aftercooled Portable Air Compressors.
These packages include a heavy duty rotary screw air
compressor, a diesel engine, fuel tank, compressor
inlet system, compressor cooling and lubrication
system, compressor discharge system, capacity
control system, instrument panel and electrical
system. A low prole canopy offers improved handling and
mobility. Large side service doors provide easy access to
all serviceable components. This model meets EPA sound
level regulations of 76dbA at 7 meters (23 feet). Sullair air
compressors have the following delivery capacities:
Model 300HH, 300CFM@ 200 psig (13.8 bar)
Model 375, 375CFM @ 100 psig (6.9 bar)
Model 375H, 375CFM @ 150 psig (10.3 bar)
Model 425, 425CFM @ 100 psig (6.9 bar)

375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
SECTION 2
Radiator/Fluid Cooler Assembly1.
Radiator/Fluid Cooler Assembly With Air To Air Aftercooler2.
Lifting Bail3.
Engine Air Filter4.
Compressor Air Filter5.
Fuel Tank6.
Battery Shutoff Switch7.
Service Valves8.
Serial Number Plate Location9.
Receiver/Sump Tank10.
Minimum Pressure/Check Valve11.
Engine Exhaust Mufer12.
Moisture Separator13.
Optional Discharge Air Filters14.
Figure 2-1: Sullair Rotary Screw Portable Air Compressor – Caterpillar Standard and Aftercooled Models
The control system can easily be adjusted for pressures
from 80 to 125 psig (5.6 to 8.6 bar) for standard machines,
from 80 to 150 psig (5.6 to 10.3 bar) for “H” machines and
from 80 psig to 200 psig (5.6 to 13.8 bar) for “HH”
machines. The compressor unit is driven by an industrial
diesel engine designed to provide enough horsepower to
provide an adequate reserve under rated conditions.
Refer to the Engine Operator’s Manual for a more
detailed description of the engine. The engine cooling
system is comprised of a radiator, charge air cooler, high
capacity fan, and thermostat. The high capacity fan pushes
air through the radiator to maintain the engine’s specied
operating temperature. The same fan also cools the uid in
the compressor cooling and lubrication system.
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375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
DESCRIPTION
The engine radiator, charge air cooler, and the compressor
uid cooler are next to each other allowing the fan air to
push through all three simultaneously. As air passes
through the uid cooler, the heat of compression is
removed from the uid. The compressor’s high capacity
fuel tank contains enough fuel for one eight hour shift
under normal operating conditions.
SULLAIR COMPRESSOR UNIT,2.3
FUNCTIONAL DESCRIPTION
Sullair compressors are single-stage, positive
displacement, ood lubricated-type compressors that
provide continuous (pulse-free) compression to meet
various demand loads. Sullair compressors require no
routine maintenance or inspection of their internal parts or
systems. The compressor works by injecting uid into the
compressor unit where it mixes directly with the air as the
rotors turn: the rotor’s rotation compresses the air. The
uid ow has three main functions:
It acts as a coolant, to control the rise of air1.
temperature which is generated by compression (heat
of compression).
Seals the leakage paths between the rotors and the2.
stator and also between the rotors themselves.
Lubricates the rotors allowing one rotor to directly3.
drive the other.
After the air uid mixture is discharged from the
compressor unit, the uid is separated from the air. At this
time, the air ows to the service line and the uid is cooled
in preparation for re-injection.
COMPRESSOR COOLING2.4
AND LUBRICATION SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-2. The compressor cooling and
lubrication system is designed to provide adequate
lubrication as well as maintain the proper operating
temperature of the compressor. In addition to the uid
cooler and interconnecting piping, the system consists also
of three other components: a uid lter, thermal valve, and
a fan which perform the following functions:
The uid lter removes and collects any contaminants •
in the uid.
The thermal valve functions as a temperature•
regulator directing uid either to the cooler or to the
compressor unit.
The fan pushes air through the cooler dissipating the•
heat resulting from compression of the uid.
The functions of the lubrication system are explained in
more detail below. Fluid is used in the system as a coolant
and as a lubricant: the sump serves as the uid reservoir.
At start-up, uid ows from the sump to the uid thermal
valve. Fluid circulation is achieved by forcing the uid from
the high pressure region of the sump to a lower pressure
area in the compressor unit. A minimum pressure device
(See Compressor Discharge System, Functional
Description on page 14) is provided to assure adequate
uid ow under all conditions. When entering the thermal
valve upon start-up, the uid temperature is cool and thus
it is not necessary to route it through the cooler. The uid
ows through the uid lter and on to the compressor unit
bypassing the cooler. As the compressor continues to
operate, the temperature of the uid rises and the
thermostatic control opens, allowing a portion of the uid
into the cooler.
When the temperature reaches 155°F (68°C), the
thermostat is fully open allowing all uid entering the
thermal valve to ow to the cooler.
The cooler is a radiator type that works in concert with the
engine fan. The fan pushes air through the cooler
removing the heat from the uid. From the cooler, the uid
is then routed back through the uid lter. All uid owing
to the compressor unit passes through this lter. The uid
leaving the lter ows to the compressor unit where it
lubricates, seals and cools the compression chamber; and
lubricates the bearings and gears.
Fluid Cooler1.
Engine2.
Compressor3.
Thermal Valve4.
Fluid Filter5.
Receiver Tank6.
Figure 2-2: Compressor Cooling and Lubrication
System
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375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
SECTION 2
2.5 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3. The Sullair compressor unit
discharges a compressed air/uid mixture into the sump.
The sump has three functions:
It acts as a primary uid separator.1.
Serves as the compressor uid reservoir.2.
Houses the air/uid separator.3.
The compressed air/uid mixture enters the sump and is
directed against the side of the sump. Because of a
change of direction and reduction of velocity, large droplets
of uid separate and fall to the bottom of the sump. The
small amount of uid remaining in the compressed air
collects on the surface of the separator element as the
compressed air ows through the separator. As more uid
collects on the element surface, it then ows to the bottom
of the separator. A return line (or scavenge tube) leads
from the bottom of the separator element to the inlet region
of the compressor unit. Fluid collecting on the bottom of
the separator element is returned to the compressor by the
pressure difference between the area surrounding the
separator element and the compressor inlet. An orice
(protected by a strainer) is included in this return line to
assure proper and unobstructed ow. The sump is ASME
code rated at 250 psig (17.1 bar) working pressure. A
minimum pressure device located downstream from the
separator, ensures a minimum receiver pressure of 80
psig (5.5 bar) during all conditions. Keeping this pressure
level stable is necessary for proper air/uid separation and
proper uid circulation. A pressure relief valve (located on
the wet side of the separator) is set to open if the sump
pressure exceeds 250 psig (17.1 bar).
Fluid is added to the sump through a capped uid ller.
CAPACITY CONTROL SYSTEM,2.6
FUNCTIONAL DESCRIPTION
Refer to Figure 2-4, Figure 2-5 or Figure 2-6. The purpose
of the control system is to regulate the amount of air intake
and match it to the demand (required output) on the
compressor. The control system consists of a pressure
regulating valve(s), air inlet valve, system blowdown valve,
engine speed control, and tubing connecting the various
components of the compressor and engine. The functional
descriptions of the control system are described by relating
them to four distinct phases of operation. They apply to
any control system with the exception of those with
specied pressures which are dependent on pressure
requirements. The given values apply to a compressor
with an operating pressure range of 100 to 110 psig (6.9 to
7.6 bar).
Start – 0 To 40 psig (0 To 2.8 Bar) Cold Start
When the compressor is started, the sump pressure
quickly rises from 0 to 40 psig (0 to 2.8 bar). During this
period the pressure regulator valve is inactive. At this
pressure range the idle warm-up control keeps the inlet
valve closed for engine idle operation. Within 30 seconds
of starting the compressor (the instrument panel
annunciator light goes off after 30 seconds) turn the
handle of the warm-up selector valve (located on the
instrument panel) from the START to the RUN position.
The inlet valve is fully open due to inlet pressure, and the
compressor operates at full capacity. When the
compressor operates at full capacity, the engine runs at full
speed.
WARNING
DO NOT remove caps, plugs
and/or other components when
the compressor is running or
pressurized. Stop the compressor
and relieve all internal pressure
before removing these items.

375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
DESCRIPTION
Engine1.
Strainer2.
Minimum Pressure/Check Valve3.
Service Air Outlet4.
Receiver Tank (Sump)5.
Separator Element6.
Minimum Pressure Valve7.
Non-Aftercooled/Aftercooled Service Air Valve8.
Service Air Outlet9.
Receiver Tank (Sump)10.
Optional Discharge Air Filters11.
Moisture Separator12.
Aftercooler13.
Air14.
Fluid/Air15.
Figure 2-3: Compressor Discharge System – Standard and Aftercooled Models
S
T
ANDARD MODE
L
AFTERCOOLED MODE
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375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List
SECTION 2
Air Pressure Gauge1.
Instrument Panel2.
Idle Warm-Up Valve3.
Inlet Valve4.
Air Filter5.
Regulator/Blowdown Valve Manifold6.
Minimum Pressure Check Valve7.
Pressure Relief Valve8.
Fuid Fill/Fluid Level Sight Glass9.
Optional Discharge Air Filters10.
Optional Moisture Separator11.
Optional Aftercooler12.
Aftercooled Machines ONLY13.
Fluid Filter14.
Thermal Valve15.
Compressor Unit16.
Fluid Cooler17.
Air18.
Fluid/Air19.
Fluid20.
Strainer21.
Engine Speed Control Cylinder22.
Figure 2-4: Control System with Piping and Instrumentation - 375 and 425 Models
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