Sullair 900XH User manual

OPEN FRAME
AIR COMPRESSOR
900XH - 1350XH
and Aftercooled Models
350 PSIG
CATERPILLAR
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number
02250166-434
©Sullair Corporation
The information in this document is
correct at the time of printing for
Portable Compressor Serial Number
200601080007
and all subsequent Serial Numbers.

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction in the proper
operation, maintenance and service of Sullair equipment. Individual seminars on
Portable compressors are presented at regular intervals throughout the year at a 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
4 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
7 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
11 2.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
14 2.6 CAPACITY CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
15 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
15 2.8 INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION
18 2.9 ENGINE CONTROL MODULE, FUNCTIONAL
DESCRIPTION
19 2.10 ELECTRICAL SYSTEM, FUNCTIONAL DESCRIPTION
20 2.11 AFTERCOOLER AIR SYSTEM, SYSTEM, FUNCTIONAL
DESCRIPTION
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Continued...

TABLE OF CONTENTS
Section 3
SPECIFICATIONS 25 3.1 SPECIFICATIONS
26 3.2 LUBRICATION GUIDE - COMPRESSOR
26 3.3 APPLICATION GUIDE
26 3.4 LUBRICATION GUIDE - ENGINE
Section 4
OPERATION 29 4.1 GENERAL
29 4.2 PURPOSE OF CONTROLS
30 4.3 INITIAL START-UP PROCEDURE
30 4.4 SUBSEQUENT START-UP PROCEDURE
31 4.5 SHUTDOWN PROCEDURE
Section 5
MAINTENANCE 33 5.1 GENERAL
33 5.2 DAILY OPERATION
33 5.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
33 5.4 MAINTENANCE EVERY 100 HOURS
33 5.5 MAINTENANCE EVERY 250 HOURS
33 5.6 MAINTENANCE EVERY 300 HOURS
33 5.7 MAINTENANCE EVERY 500 HOURS
33 5.8 MAINTENANCE EVERY 1000 HOURS
34 5.9 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
34 COMPRESSOR FLUID CHANGE PROCEDURE
34 SERVICING THE MAIN FLUID FILTER
34 AIR FILTER MAINTENANCE
36 CONTROL SYSTEM ADJUSTMENT
37 SEPARATOR ELEMENT REPLACEMENT
37 5.10 TROUBLESHOOTING
38 5.11 TROUBLESHOOTING GUIDE
Section 6
NOISE CONTROL 41 6.1 NOISE EMISSIONS WARRANTY
41 6.2 TAMPERING WITH NOISE CONTROL SYSTEM
PROHIBITED
41 35 6.3 NOISE EMISSIONS MAINTENANCE AND
MAINTENANCE RECORD LOG
Continued...

TABLE OF CONTENTS
Section 7
ILLUSTRATIONS
AND PARTS LIST 45 7.1 PROCEDURE FOR ORDERING PARTS
46 7.2 RECOMMENDED SPARE PARTS LIST
48 7.3 ENGINE AND COMPRESSOR MOUNTING
52 7.4 AIR INLET SYSTEM - ALL MODELS
56 7.5 EXHAUST SYSTEM - ALL MODELS
58 7.6A ENGINE RADIATOR AND FLUID COOLING SYSTEM
62 7.6B ENGINE RADIATOR AND FLUID COOLING SYSTEM -
AFTERCOOLED
66 7.7 ENGINE RADIATOR ASSEMBLY - ALL MODELS
68 7.8 AFTERCOOLER MOUNTING - ALL MODELS
70 7.9 CONTROL SYSTEM HOSE ROUTING - ALL MODELS
72 7.10 SPEED CONTROL CYLINDER AND PARTS -
ALL MODELS
74 7.11 AIR CONTROL MANIFOLD ASSEMBLY - ALL MODELS
76 7.12A INLET VALVE AND PARTS (6.5”) - 900XH
78 7.12B INLET VALVE AND PARTS (8”) - 1150XH AND 1350XH
80 7.13A INLET VALVE PARTS - 6.5” - 900XH
82 7.13B INLET VALVE PARTS - 8” - 1150XH AND 1350XH
84 7.14A DISCHARGE SYSTEM - 900XH AND 1150XH
86 7.14B DISCHARGE SYSTEM - 900XH AND 1150XH
AFTERCOOLED
88 7.14C DISCHARGE SYSTEM - 1350XH AFTERCOOLED
94 7.15A RECEIVER AND PARTS - 900XH & 1150XH
STANDARD AND AFTERCOOLED
100 7.15B RECEIVER AND PARTS - 1350XH STANDARD
AND AFTERCOOLED
104 7.16 WATER SEPARATOR TRAP - AFTERCOOLED ONLY
108 7.17 SUB-ASSEMBLY - HGIH PRESSURE FILTER /
CHECK VALVE / ORIFICE
108 7.18 DISCHARGE / CHECK VALVE ASSEMBLY
110 7.19 MINIMUM PRESSURE / CHECK VALVE
112 7.20 FUEL SYSTEM AND PARTS - ALL MODELS
114 7.21 ELECTRICAL PARTS - ALL MODELS
116 7.22 INSTRUMENT PANEL AND PARTS - ALL MODELS
120 7.23 FRAME AND PARTS
122 7.24 DECAL GROUP
130 7.25 DECAL LOCATIONS