300hh (CAT)

OPERATOR’S MANUAL AND PARTS LIST
Portable Air Compressor

300HH, 375, 375H and 425 Export
Caterpillar Standard and Aftercooled and Filtered
Part Number:
02250169-733
keep for
future
reference
©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.
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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 dedicated training facility at Sullair’s 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,
Contractor Maintenance and Service Personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Customer Care 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
1 - SAFETY............................................................................................................ 1
GENERAL........................................................................................................ 1
Towing.............................................................................................................. 1
Preparing To Tow....................................................................................... 1
Towing ...................................................................................................... 3
Parking Or Locating Compressor.............................................................. 3
Pressure Release............................................................................................ 4
Fire And Explosion........................................................................................... 5
Moving Parts.................................................................................................... 6
Hot Surfaces, Sharp Edges And Sharp Corners.............................................. 6
Toxic And Irritating Substances........................................................................ 6
Electrical Shock............................................................................................... 7
Lifting............................................................................................................... 7
Entrapment...................................................................................................... 8
Jump Starting................................................................................................... 8
California Proposition 65 . ................................................................................. 9
Implementation of Lockout/Tagout................................................................... 9
explosive atmosphere.................................................................................... 10
2 - DESCRIPTION................................................................................................ 11
Introduction ................................................................................................... 11
Description Of Components........................................................................... 11
Sullair Compressor Unit, Functional Description........................................... 13
Compressor Cooling And Lubrication System, Functional Description.......... 13
Compressor Discharge System, Functional Description................................ 14
Capacity ContRol SysTem, Functional Description........................................ 14
Start – 0 To 40 psig (0 To 2.8 Bar) Cold Start.......................................... 14
Normal Operation – 80 to 100 psig (5.6 to 6.9 bar) or 80 to 150 psig
(5.6 to 10.3 bar) for H machines or 80 to 200 psig (5.6 to 13.8 bar) for
HH machines........................................................................................... 20
Modulation – 100 to 110 psig (6.9 to 7.5 bar) or 150 to 165 psig (10.3
to 11.4 bar) for H machines or 200 to 220 psig (13.8 to 15.2 bar) for
HH machines........................................................................................... 20
Shutdown ............................................................................................... 20
Air Inlet System, Functional Description ....................................................... 20
Instrument Panel Group, Functional Description........................................... 20
Wiring Diagram.............................................................................................. 22
Electrical System, Functional Description...................................................... 23
Compressor Shutdown & Warning System, Functional Description.............. 23
375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List iii

SECTION 7
Aftercooled And Filtered Air System, Functional Description......................... 24

3 - Specifications.......................................................................................... 25
Specifications – 300HH and 375 Caterpillar.................................................. 25
Specifications – 375H and 425 Caterpillar..................................................... 26
Lubrication Guide – Compressor................................................................... 28
Application Guide........................................................................................... 28
Lubrication Guide – Engine............................................................................ 28
4 - GENERAL....................................................................................................... 29
General.......................................................................................................... 29
Purpose Of Controls...................................................................................... 29
Control or Indicator Purpose.................................................................... 29
Initial Startup/Shutdown Procedure............................................................... 30
Startup..................................................................................................... 30
Shutdown................................................................................................. 30
Restart Procedure.......................................................................................... 30
5 - MAINTENANCE.............................................................................................. 31
General.......................................................................................................... 31
Daily Maintenance......................................................................................... 31
Maintenance After Initial 50 Hours Of Operation........................................... 32
Maintenance Every 50 Hours......................................................................... 32
Maintenance Every 100 Hours....................................................................... 32
Maintenance Every 250 Hours....................................................................... 32
Maintenance Every 1500 Hours..................................................................... 32
Part Replacement And Adjustment Procedures............................................. 33
Compressor Fluid Change Procedure..................................................... 33
Compressor Fluid Filter Element Replacement....................................... 33
Air Filter Maintenance ............................................................................ 33
Air Filter Replacement............................................................................. 33
Element Inspection.................................................................................. 34
Separator Element Replacement............................................................ 34
Procedure For Setting Speed And Pressure Controls On Portable
Compressors Equipped With Poppet Valves . ........................................ 34
Bearing Lubrication.................................................................................. 36
First and Second Stage Discharge Air Filter Maintenance – Aftercooled &
Filtered Models........................................................................................ 37
Trouble Shooting............................................................................................ 38
6 - NOISE CONTROL.......................................................................................... 43
Noise Emissions Warranty............................................................................. 43
Tampering with the Noise Control System is Prohibited................................ 43
Noise Emission Maintenance and Maintenance Record Log.................. 44
Noise Emissions Maintenance and Maintenance Record Log....................... 44
Procedure For Ordering Parts........................................................................ 47
7 - ILLUSTRATIONS AND PARTS LIST............................................................. 47
Recommended Spare Parts List.................................................................... 49
Engine, Compressor And Parts...................................................................... 50
Radiator & Compressor Fluid Cooling System.............................................. 54
Air Inlet System & Exhaust System............................................................... 58
Control Parts & Discharge Parts - 375 and 425............................................. 60
Control Parts & Discharge Parts - 300HH and 375H..................................... 64
Regulator/Blowdown Valve - 375 And 425..................................................... 68
Regulator/Blowdown Valve - 300HH and 375H............................................. 70
Control Parts Orifice - 300HH and 375H........................................................ 72
Service Valves............................................................................................... 74
Optional AfterCooler/Filter And Parts............................................................. 76
iv 375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List

Table of Contents
Electrical Parts............................................................................................... 80
Instrument Panel & Parts............................................................................... 82
Fuel Tank & Connections............................................................................... 86
Frame, Axle & Parts And Axle Assembly........................................................ 88
Axle Assembly................................................................................................ 92
Canopy, Acoustical Panels & Parts................................................................ 94
Decals............................................................................................................ 96
Decal Locations........................................................................................... 108
375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List v

SECTION 7
THIS PAGE INTENTIONALLY LEFT BLANK
vi 375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List

Section 1
SAFETY
Each day, walk around the air compressor and inspect for
NOTE leaks, loose or missing parts, damaged parts or parts out
of adjustment. Perform all recommended daily
maintenance.
Inspect for torn, frayed, blistered or otherwise deteriorated
and degraded hoses. Replace as required.
CAUTION
OPERATOR IS REQUIRED TO READ Estimated hose life based on a 5-day
ENTIRE INSTRUCTION MANUAL. 8-hour work week is 3 years. These
conditions exist on an 8-hour shift
1.1 General only. Any other operation of the
equipment other than 8-hour shifts
Sullair Corporation designs and manufactures all of its would shorten the hose life based on
products so they can be operated safely. However, the hours of operation.
responsibility for safe operation rests with those who use
and maintain these products. The following safety
precautions are offered as a guide which, if 1.2 Towing
conscientiously followed, will minimize the possibility of
accidents throughout the useful life of this equipment. NOTE
Read the CIMA Safety Manual prior to compressor
operation and towing, if applicable in your area. While not towed in the usual sense of
The air compressor should be operated only by those who the word, many of these instructions
have been trained and delegated to do so, and who have are directly applicable to skid-
read and understood this Operator’s Manual. Failure to mounted portable air compressors as
follow the instructions, procedures and safety precautions well.
in this manual can result in accidents and injuries.
NEVER start the air compressor unless it is safe to do so. Preparing To Tow
DO NOT attempt to operate the air compressor with a
known unsafe condition. Tag the air compressor and WARNING
render it inoperative by disconnecting the battery so others
who may not know of the unsafe condition will not attempt DO NOT tow the compressor should
to operate it until the condition is corrected.
its weight exceed the rated limit of the
Use and operate the air compressor only in full compliance tow vehicle, as the vehicle may not
with all pertinent OSHA requirements and/or all pertinent brake safely with excess weight. See
Federal, State and Local codes or requirements. rated limit in tow vehicle Operator’s
DO NOT modify the compressor except with written Manual, and review its instructions
factory approval. and other requirements for safe
towing.

SECTION 1
A. Prior to hitching the air compressor to the tow vehicle, G. If provided, make sure chain length, brake and
inspect all attachment parts and equipment, checking electrical interconnections provide sufficient slack to
for (i) signs of excessive wear or corrosion, (ii) parts prevent strain when cornering and maneuvering, yet
that are cracked, bent, dented or otherwise deformed are supported so they cannot drag or rub on road,
or degraded, and (iii) loose nuts, bolts or other terrain or towing vehicle surfaces which might cause
fasteners. Should any such condition be present, DO wear that could render them inoperative.
NOT TOW until the problem is corrected.
B. Back the tow vehicle to the compressor and position WARNING
it in preparation for coupling the compressor.
This equipment may be tongue heavy.
C. If the compressor is provided with a drawbar latched
in the vertical upright position, carefully unlatch DO NOT attempt to raise or lower the
drawbar and lower it to engage the coupling device. If drawbar by hand if the weight is more
not, raise drawbar to engage coupling device or than you can safely handle.
otherwise couple the compressor to the towing
vehicle.
CAUTION
WARNING Retract the front screw jack only
after attaching the compressor to the
This equipment may be tongue heavy. tow vehicle. Raise the screw jack to
DO NOT attempt to raise or lower the its full up position and pull the pin
drawbar by hand if the weight is more connecting the jack to the drawbar.
than you can safely handle. Rotate the screw jack to its stowed
position, parallel to the drawbar, and
Use the screw jack provided or a reinsert the pin. Make sure the jack is
chain fall if you cannot lift or lower secured in place prior to towing.
it without avoiding injury to yourself
or others. Keep hands and fingers If a caster wheel is provided on the
clear of the coupling device and all screw jack it is part of the screw jack
other pinch points. Keep feet clear and can not be removed. Follow the
of drawbar to avoid injury in case it same procedure for stowing away
should slip from your hands. the wheeled jack as you would for
the standard screw jack. Pull the pin
connecting the jack to the drawbar
D. Make sure the coupling device is fully engaged, and raise the screw jack to its full
closed and locked. up position. Rotate the screw jack
E. If chains are provided, pass each chain through its to its stowed position, parallel to the
point of attachment on the towing vehicle; then hook drawbar, and reinsert the pin. Make
each chain to itself by passing the grab hook over sure the jack is secured in place prior
(not through) a link. Cross chains under front of to towing.
drawbar before passing them through points of
attachment on towing vehicle to support front of H. On two-wheeled models, fully retract front screw jack
drawbar in case it should accidentally become and any rear stabilizer legs. If a caster wheel is
uncoupled. provided on the screw jack it is part of the screw jack,
F. Make sure that the coupling device and adjacent and can not be removed. Follow the same procedure
structures on the towing vehicle (and also, if utilized, for stowing away the wheeled jack as you would for
chain adjustment, brake and/or electrical the standard screw jack. Pull the pin connecting the
interconnections) DO NOT interfere with or restrict jack to the drawbar and raise the screw jack to its full
motion of any part of the compressor, including its upright position. Rotate the screw jack to its stowed
coupling device, with respect to the towing vehicle position, parallel to the drawbar, and reinsert the pin.
when maneuvering over any anticipated terrain. Make sure the jack is secured in place prior to towing.
I. 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.

SAFETY
J. If provided, make sure all dual stop, tail directional F. Maneuver in a manner that will not exceed the
and clearance lights are operating properly and that freedom of motion of the compressor’s drawbar and/
their lenses are clean and functional. Also, make sure or coupling device, in or on the towing vehicle’s
all reflectors and reflecting surfaces, including the coupling device and/or adjacent structure whether
slow moving vehicle emblem on compressors towing forward or backing up, regardless of the
provided with same, are clean and functional. terrain being traversed.
K. Make sure all service air hoses (not air brake hoses) G. DO NOT permit personnel to ride in or on the
are disconnected or are fully stowed and secured on compressor.
hose reels, if provided.
H. Make sure the area behind, in front of, and under the
L. Make sure all access doors and tool box covers are compressor is clear of all personnel and obstructions
closed and latched. If the compressor is large enough prior to towing in any direction.
to hold a man, make sure all personnel are out before
closing and latching access doors. I. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compressor
M. Make sure parking brakes in towing vehicle are set, and the towing vehicle.
or that its wheels are chocked or blocked, or that it is
otherwise restrained from moving. Then, release the Parking Or Locating Compressor
compressor parking brakes, if provided. A. Park or locate compressor on a level surface, if
N. Make sure the compressor wheels are not chocked possible. If not, park or locate compressor across
or blocked, and that all tie-downs, if any, are free. grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on
O. Test running brake operation, including breakaway grades exceeding 15̊ (27%).
switch operation if provided, before attempting to tow
the compressor at its rated speed or less when B. Make sure compressor is parked or located on a firm
conditions prevail. surface that can support its weight.
P. DO NOT carry loose or inappropriate tools, C. Park or locate compressor so the wind, if any, tends
equipment or supplies on or in the compressor. to carry the exhaust fumes and radiator heat away
from the compressor air inlet openings, and also
Q. DO NOT load this equipment with accessories or where the compressor will not be exposed to
tools such that it is unbalanced from side to side or excessive dust from the work site.
front to back. Such unbalance will reduce the
towability of this equipment and may increase the D. On steerable models, park compressor with front
possibility of tipping, rolling over, jackknifing, etc. wheels in straight-ahead position.
Loss of control of the towing vehicle may result. E. Set parking brakes and disconnect breakaway switch
Towing cable and all other interconnecting electrical and/or
brake connections, if provided.
A. O
bserve all Federal, State, and Local laws while
towing this equipment (including those specifying F. Block or chock both sides of all wheels.
minimum speed). G. If provided, unhook chains and remove them from the
B. DO NOT exceed the towing speeds listed below points of chain attachment on the towing vehicle,
under ideal conditions. Reduce your speed according then hook chains to bail on drawbar or wrap chains
to posted speed limits, weather, traffic, road or terrain around the drawbar and hook them to themselves to
conditions: keep chains off the ground which might accelerate
rusting.
1. Two axle four-wheel or three axle six-wheel
steerable models: 15 MPH (24 km/h).
2. All other models: 55 MPH (88 km/h).
C. Remember that the portable air compressor may
approach or exceed the weight of the towing vehicle.
Maintain increased stopping distances accordingly.
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 vehicle. Tipping,
rolling over, etc. can occur suddenly without warning.
U-turns especially should be made slowly and
carefully.
D. Avoid grades in excess of 15̊ (27%).
E. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain.

SECTION 1
H. Lower front screw jack and/or any front and rear K. When possible, stow hinged drawbar in the vertical
stabilizer legs. Make sure the surface they contact upright position. Make certain it is securely latched in
has sufficient load bearing capability to support the the vertical upright position. Keep feet clear of
weight of the compressor. drawbar at all times to avoid crushing accidents in
case it should slip from your hands or otherwise fall
WARNING to the ground.
L. Move the towing vehicle well clear of the parked
This equipment may be tongue heavy. compressor and erect hazard indicators, barricades
DO NOT attempt to raise or lower the and/or flares (if at night) if compressor is parked on or
drawbar by hand if the weight is more adjacent to public roads. Park so as not to interfere
than you can safely handle. with traffic.
NOTE
CAUTION
While not towed in the usual sense of
Retract the front screw jack only the word, many of these instructions
after attaching the compressor to the are directly applicable to skid-
tow vehicle. Raise the screw jack to mounted portable air compressors as
its full up position and pull the pin well.
connecting the jack to the drawbar.
Rotate the screw jack to its stowed
position, parallel to the drawbar, and 1.3 Pressure Release
reinsert the pin. Make sure the jack is A. Open the pressure relief valve at least weekly to
secured in place prior to towing. make sure it is not blocked, closed, obstructed or
On two-wheeled models, fully otherwise disabled.
retract front screw jack and any rear B. Install an appropriate flow-limiting valve between the
stabilizer legs. If a caster wheel is compressor service air outlet and the shutoff (throttle)
provided on the screw jack it is part valve, when an air hose exceeding 1/2" (13 mm)
of the screw jack and can not be inside diameter is to be connected to the shutoff
removed. Follow the same procedure (throttle) valve, to reduce pressure in case of hose
failure, per OSHA Standard 29 CFR 1926.302 (b) (7)
for stowing away the wheeled jack or any applicable Federal, State and Local codes,
as you would for the standard screw standards and regulations.
jack. Pull the pin connecting the jack
to the drawbar and raise the screw C. When the hose is to be used to supply a manifold,
install an additional appropriate flow-limiting valve
jack to its full up position. Rotate the between the manifold and each air hose exceeding
screw jack to its stowed position, 1/2" (13 mm) inside diameter that is to be connected
parallel to the drawbar, and reinsert to the manifold to reduce pressure in case of hose
the pin. Make sure the jack is secured failure.
in place prior to towing. D. Provide an appropriate flow-limiting valve for each
additional 75 feet (23 m) of hose in runs of air hose
I. If a caster wheel is provided on the screw jack, it is exceeding 1/2" (13 mm) inside diameter to reduce
part of the screw jack and cannot be removed. Follow pressure in case of hose failure.
the same procedure for stowing away the wheeled
jack as you would for the standard screw jack. Raise E. Flow-limiting valves are listed by pipe size and rated
the screw jack to its full upright position and pull the CFM. Select appropriate valve accordingly.
pin connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the F. DO NOT use tools that are rated below the maximum
drawbar and reinsert the pin. Make sure the jack is rating of this compressor. Select tools, air hoses,
secured in place prior to towing. pipes, valves, filters and other fittings accordingly. DO
NOT exceed manufacturer’s rated safe operating
J. Disconnect coupling device, keeping hands and pressures for these items.
fingers clear of all pinch points. If the compressor is
provided with a drawbar, DO NOT attempt to lift the G. Secure all hose connections by wire, chain or other
drawbar or if hinged, to raise it to the upright position suitable retaining device to prevent tools or hose
by hand, if the weight is more than you can safely ends from being accidentally disconnected and
handle. Use a screwjack or chain fall if you cannot lift expelled.
or raise the drawbar without avoiding injury to H. Open fluid filler cap only when compressor is not
yourself or others. running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to zero
internal pressure before removing the cap.

SAFETY
I. Vent all internal pressure prior to opening any line, D. DO NOT permit liquids, including air line anti-icer
fitting, hose, valve, drain plug, connection or other system antifreeze compound or fluid film, to
component, such as filters and line oilers, and before accumulate on bottom covers or on, under or around
attempting to refill optional air line anti-icer systems acoustical material, or on any external or internal
with antifreeze compound. surfaces of the air compressor. Wipe down using an
aqueous industrial cleaner or steam clean as
J. Keep personnel out of line with and away from the required. If necessary, remove acoustical material,
discharge opening of hoses, tools or other points of clean all surfaces and then replace acoustical
compressed air discharge. material. Any acoustical material with a protective
K. DO NOT use air at pressures higher than 30 psig (2.1 covering that has been torn or punctured should be
bar) for cleaning purposes, and then only with replaced immediately to prevent accumulation of
effective chip guarding and personal protective liquids or fluid film within the material. DO NOT use
equipment per OSHA Standard 29 CFR 1910.242 (b) flammable solvents for cleaning purposes.
or any applicable Federal, State and Local codes, E. Disconnect the grounded (negative) battery
standards and regulations. connection prior to attempting any repairs or cleaning
L. DO NOT engage in horseplay with air hoses as death inside the enclosure. Tag the battery connections so
or serious injury may result. others will not unexpectedly reconnect it.
M. This equipment is supplied with an ASME designed F. Keep electrical wiring, including the battery terminals
pressure vessel protected by an ASME rated relief and other terminals, in good condition. Replace any
valve. Lift the handle once a week to make sure the wiring that has cracked, cut abraded or otherwise
valve is functional. DO NOT lift the handle while degraded insulation or terminals that are worn,
machine is under pressure. discolored or corroded. Keep all terminals clean and
tight.
N. If the machine is installed in an enclosed area it is
necessary to vent the relief valve to the outside of the G. Turn off battery charger before making or breaking
structure or to an area of non-exposure. connections to the battery.
O. DO NOT remove radiator filler cap until the coolant H. Keep grounded conductive objects such as tools
temperature is below its boiling point. Then loosen away from exposed live electrical parts such as
cap slowly to its stop to relieve any excess pressure terminals to avoid arcing which might serve as a
and make sure coolant is not boiling before removing source of ignition.
cap completely. Remove radiator filler cap only when I. Replace damaged fuel tanks or lines immediately
cool enough to touch with a bare hand. rather than attempt to weld or otherwise repair them.
P. The ethyl ether in the replaceable cylinders used in DO NOT store or attempt to operate the compressor
diesel ether starting aid systems (optional) is under with any known leaks in the fuel system. Tag the
pressure. DO NOT puncture or incinerate those compressor and render it inoperative until repair can
cylinders. DO NOT attempt to remove the center be made.
valve core or side pressure relief valve from these J. Remove any acoustical material or other material that
cylinders regardless of whether they are full or empty. may be damaged by heat or that may support
Q. If a manual blowdown valve is provided on the combustion prior to attempting weld repairs. Remove
receiver, open the valve to ensure all internal diesel engine ether starting aid cylinders and air line
pressure has been vented prior to servicing any anti-icer system components containing antifreeze
pressurized component of the compressor air/fluid compound, prior to attempting weld repairs in any
system. place other than the fuel system. DO NOT weld on or
near the fuel system.
1.4 Fire And Explosion K. Keep a suitable, fully charged class BC or ABC fire
extinguisher or extinguishers nearby when servicing
A. Refuel at a service station or from a fuel tank and operating the compressor.
designed for its intended purpose. If this is not
possible, ground the compressor to the dispenser L. Keep oily rags, trash, leaves, litter or other
prior to refueling. combustibles out of and away from the compressor.
B. Clean up spills of fuel, fluid, battery electrolyte or M. Open all access doors and allow the enclosure to
coolant immediately if such spills occur. ventilate thoroughly prior to attempting to start the
engine.
C. Shut off air compressor and allow it to cool. Then
keep sparks, flames and other sources of ignition N. DO NOT operate compressor under low overhanging
away and DO NOT permit smoking in the vicinity leaves or permit such leaves to contact hot exhaust
when adding fuel, or when checking or adding system surfaces when operating the compressor in
electrolyte to batteries, or when checking or adding forested areas.
fluid, or when checking diesel engine ether starting
aid systems or replacing cylinders, or when refilling
air line anti-icer systems antifreeze compound.

SECTION 1
O. Ethyl ether used in diesel engine ether starting aid H. When adjusting the controls, it may require operation
systems is extremely flammable. Change cylinders, of the equipment during adjustment. DO NOT come
or maintain or troubleshoot these systems only in in contact with any moving parts while adjusting the
well-ventilated areas away from heat, open flame or control regulator and setting the engine RPM. Make
sparks. DO NOT install, store or otherwise expose all other adjustments with the engine shut off. When
ether cylinders to temperatures above 160 ̊F (71 ̊C). necessary, make adjustment, other than setting
Remove ether cylinder from the compressor when control regulator and engine RPM, with the engine
operating in ambient temperatures above 60 ̊F (16 ̊C). shut off. If necessary, start the engine and check
adjustment. If adjustment is incorrect, shut engine off,
P. DO NOT attempt to use ether as a starting aid in readjust, then restart the engine to recheck
gasoline engines or diesel engines with glow plugs as adjustment.
serious personnel injury or property damage may
result. I. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, antifreeze or
Q. DO NOT spray ether into compressor air filter or into other liquids to minimize possibility of slips and falls.
an air filter that serves both the engine and the
compressor as serious damage to the compressor or
personal injury may result. 1.6 Hot Surfaces, Sharp Edges
R. Antifreeze compound used in air line anti-icer And Sharp Corners
systems contains methanol which is flammable. Use A. Avoid bodily contact with hot fluid, hot coolant, hot
systems and refill with compound only in well- surfaces and sharp edges and corners.
ventilated areas away from heat, open flames or
sparks. DO NOT expose any part of these systems or B. Keep all parts of the body away from all points of air
the antifreeze compound to temperatures above discharge and away from hot exhaust gases.
150 ̊F (66 ̊C). Vapors from the antifreeze compound
are heavier than air. DO NOT store compound or C. Wear personal protective equipment including gloves
discharge treated air in confined or unventilated and head covering when working in, on or around the
areas. DO NOT store containers of antifreeze compressor.
compound in direct sunlight. D. Keep a first aid kit handy. Seek medical assistance
S. Store flammable fluids and materials away from your promptly in case of injury. DO NOT ignore small cuts
work area. Know where fire extinguishers are and and burns as they may lead to infection.
how to use them, and for what type of fire they are
intended. Check readiness of fire suppression 1.7 Toxic And Irritating
systems and detectors if so equipped. Substances
1.5 Moving Parts A. DO NOT use air from this compressor for respiration
(breathing) except in full compliance with OSHA
A. Keep hands, arms and other parts of the body and Standards 29 CFR 1920 and any other Federal, State
also clothing away from belts, pulleys and other or Local codes or regulations.
moving parts.
B. DO NOT attempt to operate the compressor with the DANGER
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. INHALATION HAZARD!
E. Make sure all personnel are out of and clear of the Death or serious injury can result
compressor prior to attempting to start or operate it. from inhaling compressed air without
F. Shut off engine before adding fuel, fluid, coolant using proper safety equipment.
lubricants, air line antifreeze compound or battery See OSHA standards and/or any
electrolyte, or before replacing ether starting aid applicable Federal, State, and Local
cylinders. codes, standards and regulations on
G. Disconnect the grounded negative battery connection safety equipment.
to prevent accidental engine operation prior to B. DO NOT use air line anti-icer systems in air lines
attempting repairs or adjustments. Tag the battery supplying respirators or other breathing air utilization
connection so others will not unexpectedly reconnect equipment and DO NOT discharge air from these
it. systems into unventilated or other confined areas.

SAFETY
C. Operate the compressor only in open or well- B. Keep all parts of the body and any hand-held tools or
ventilated areas. other conductive objects away from exposed live
parts of electrical system. Maintain dry footing, stand
D. If the compressor is operated indoors, discharge on insulating surfaces and DO NOT contact any other
engine exhaust fumes outdoors. portion of the compressor when making adjustments
E. Locate the compressor so that exhaust fumes are not or repairs to exposed live parts of the electrical
apt to be carried towards personnel, air intakes system.
servicing personnel areas or towards the air intake of C. Attempt repairs only in clean, dry and well-lighted and
any portable or stationary compressor. ventilated areas.
F. Fuels, fluids, coolants, lubricants and battery D. Stay clear of the compressor during electrical storms!
electrolyte used in the compressor are typical of the It can attract lightning.
industry. Care should be taken to avoid accidental
ingestions and/or skin contact. In the event of
ingestion, seek medical treatment promptly. DO NOT 1.9 Lifting
induce vomiting if fuel is ingested. Wash with soap A. If the compressor is provided with a lifting bail, then
and water in the event of skin contact. lift by the bail provided. If no bail is provided, then lift
G. Wear an acid-resistant apron and a face shield or by sling. Compressors to be air lifted by helicopter
goggles when servicing the battery. If electrolyte is must not be supported by the lifting bail, but by slings
spilled on skin or clothing, immediately flush with instead. In any event, lift only in full compliance with
large quantities of water. OSHA Standards 29 CFR 1910 subpart N or any
other Local, State, Military and Federal regulations
H. Ethyl ether used in diesel engine ether starting aid that may apply.
systems is toxic, harmful or fatal if swallowed. Avoid
contact with the skin or eyes and avoid breathing the B. Inspect lifting bail and points of attachment for
fumes. If swallowed, DO NOT induce vomiting, but cracked welds and for cracked, bent, corroded or
call a physician immediately. otherwise degraded members and for loose bolts or
nuts prior to lifting.
I. Wear goggles or a full face shield when testing ether
starting aid systems or when adding antifreeze C. Make sure entire lifting, rigging and supporting
compound to air line anti-icer systems. Keep structure has been inspected, is in good condition
openings of valve or atomizer tube of ether starting and has a rated capacity of at least the net weight of
aid system pointed away from yourself and other the compressor plus an additional 10% allowance for
personnel. weight of snow, ice, mud or stored tools and
equipment. If your are unsure of the weight, then
J. If ethyl ether or air line anti-icer system antifreeze weigh compressor before lifting.
compound enters the eyes or if fumes irritate the
eyes, they should be washed with large quantities of D. Make sure lifting hook has a functional safety latch or
clean water for 15 minutes. A physician, preferably equivalent, and is fully engaged and latched on the
any eye specialist, should be contacted immediately. bail.
K. DO NOT store ether cylinders or air line anti-icer E. Use guide ropes or equivalent to prevent twisting or
system antifreeze compound in operator’s cabs or in swinging of the compressor once it has been lifted
other similar confined areas. clear of the ground.
L. The antifreeze compound used in air line anti-icer F. DO NOT attempt to lift in high winds.
systems contains methanol and is toxic, harmful or G. Keep all personnel out from under and away from the
fatal if swallowed. Avoid contact with the skin or eyes compressor whenever it is suspended.
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt in each H. Lift compressor no higher than necessary.
glass of clean warm water until vomit is clear, then
administer two tablespoons of baking soda in a glass I. Keep lift operator in constant attendance whenever
of clean water. Have patient lay down and cover eyes compressor is suspended.
to exclude light. Call a physician immediately. J. Set compressor down only on a level surface capable
of supporting at least its net weight plus an additional
1.8 Electrical Shock 10% allowance for the weight of snow, ice, mud or
stored tools and equipment.
A. Keep the towing vehicle or equipment carrier,
compressor hoses, tools and all personnel at least 10 K. If the compressor is provided with parking brakes,
feet (3 m) from power lines and buried cables. make sure they are set, and in any event, block or
chock both sides of all running wheels before
disengaging the lifting hook.

SECTION 1
1.10 Entrapment M. Avoid accidental contact between jumper cable

terminal clips or clamps and any metallic portion of
A. Make sure all personnel are out of compressor before either the compressor or the starting vehicle to
closing and latching enclosure doors. minimize the possibility of uncontrolled arcing which
might serve as a source of ignition.
B. If the compressor is large enough to hold a man and
if it is necessary to enter it to perform service N. Positive battery terminals are usually identified by a
adjustments, inform other personnel before doing so, plus (+) sign on the terminal and the letters POS
or else secure the access door in the open position to adjacent to the terminal. Negative battery terminals
avoid the possibility of others closing and possibly are usually identified by the letters NEG adjacent to
latching the door with personnel inside. the terminal or a negative (-) sign.
O. Connect one end of a jumper cable to the positive
1.11 Jump Starting (POS) (+) battery terminal in the starting vehicle.
When jump starting 24V compressors and if the
A. Observe all safety precautions mentioned elsewhere starting vehicle is provided with two (2) 12V batteries
in this manual. connected in series, connect the jumper cable to the
B. Batteries may contain hydrogen gas which is positive (POS) (+) terminal of the ungrounded battery.
flammable and explosive. Keep flames, sparks and P. Connect the other end of the same jumper cable to
other sources of ignition away. the positive (POS) (+) terminal of the starter motor
C. Batteries contain acid which is corrosive and battery in the compressor, or when jump starting 24V
poisonous. DO NOT allow battery acid to contact compressor, to the positive (POS) (+) terminal of the
eyes, skin, fabrics or painted surfaces as serious ungrounded battery in the compressor.
personal injury or property damage could result. Q. Connect one end of the other jumper cable to the
Flush any contacted areas thoroughly with water grounded negative (NEG) (-) terminal of the battery in
immediately. Always wear an acid-resistant apron and the starting vehicle. When jump starting 24V
face shield when attempting to jump start the compressors and if the starting vehicle is provided
compressor. with two (2) 12V batteries connected in series,
D. Remove all vent caps (if so equipped) from the connect the jumper cable to the negative (NEG) (-)
battery or batteries in the compressor. DO NOT terminal of the grounded battery.
permit dirt or foreign matter to enter the open cells. R. Check your connections. DO NOT attempt to start a
E. Check fluid level. If low, bring fluid to proper level 24V compressor with one 12V battery in the starting
before attempting to jump start (not applicable to vehicle. DO NOT apply 24V to one 12V battery in the
maintenance-free batteries). compressor.
F. DO NOT attempt to jump start if fluid is frozen or S. Connect the other end of this same jumper cable to a
slushy. Bring batteries up to at least 60 ̊F (16 ̊C) clean portion of the compressor engine block away
before attempting to jump start or it may explode. from fuel lines, the crank case breather opening and
the battery.
G. Cover open cells of all compressor batteries with clean
dampened cloths before attempting to jump start. T. Start the compressor in accordance with normal
procedure. Avoid prolonged cranking.
H. Attempt to jump start only with a vehicle having a
negative ground electrical system with the same U. Allow the compressor to warm up. When the
voltage, and is also equipped with a battery or compressor is warm and operating smoothly at
batteries of comparable size or larger than supplied in normal idle RPM, disconnect the jumper cable from
the compressor. DO NOT attempt to jump start using the engine block in the compressor, then disconnect
motor generator sets, welders or other sources of DC the other end of this same cable from the grounded
power as serious damage may result. negative (NEG) (-) terminal of the battery in the
starting vehicle. Then disconnect the other jumper
I. Bring the starting vehicle alongside the compressor, cable from the positive (POS) (+) terminal of the
but DO NOT permit metal to metal contact between battery in the compressor, or if provided with two (2)
the compressor and the starting vehicle. 12V batteries connected in series, from the
J. Set the parking brakes of both the compressor (if ungrounded battery in the compressor, and finally,
provided) and the starting vehicle or otherwise block disconnect the other end of this same jumper cable
both sides of all wheels. from the positive (POS) (+) terminal of the battery in
the starting vehicle or from the positive (POS) (+)
K. Place the starting vehicle in neutral or park, turn off all terminal of the ungrounded battery in the starting
non-essential accessory electrical loads and start its vehicle, if it is provided with two (2) 12V batteries
engine. connected in series.
L. Use only jumper cables that are clean, in good
condition and are heavy enough to handle the starting
current.

SAFETY
V. Remove and carefully dispose of the dampened c. Block any load or machine part prior to
cloths, as they may now be contaminated with acid, working under it.
then replace all vent caps.
d. Electrical circuits should be checked with
1.12 California Proposition 65 calibrated electrical testing equipment and
stored energy and electrical capacitors
should be safely discharged.
WARNING 6. Lockout and/or Tagout each energy source using
the proper energy isolating devices and tags.
CALIFORNIA PROPOSITION 65 Place lockout hasp and padlock or tag at the
WARNING point of power disconnect where lockout is
required by each person performing work. Each
Diesel engine exhaust and some of its person shall be provided with their own padlock
constituents are known to the State and have possession of the only key. If more
of California to cause cancer, birth than one person is working on a machine each
defects and other reproductive harm. person shall affix personal lock and tag using a
Battery posts, terminals and related multi-lock device.
accessories contain lead and other 7. Tagout devices shall be used only when power
compounds known to the State of sources are not capable of being locked out by
California to cause cancer and birth use of padlocks and lockout hasp devices. Name
defects and other reproductive harm. of person affixing tag to power source must be on
Wash hands after handling. tag along with date tag was placed on power
source.
8. Release stored energy and bring the equipment
1.13 Implementation of to a “zero mechanical state”.
Lockout/Tagout 9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
The energy control procedure defines actions necessary B. General Security
to lockout a power source of any machine to be repaired,
serviced or set-up, where unexpected motion, or an 1. The lock shall be removed by the “Authorized”
electrical or other energy source, would cause personal person who put the lock on the energy-isolating
injury or equipment damage. The power source on any device. No one other than the person/persons
machine shall be locked out by each employee doing the placing padlock ad lockout hasp on power shall
work except when motion is necessary during setup, remove padlock and lockout hasps and restore
adjustment or trouble-shooting. power. However, when the authorized person
who applied the lock is unavailable to remove it
A. The established procedures for the application of his/her Supervisor may remove padlock/padlocks
energy control shall cover the following elements and and lockout hasps and restore power only if it is
actions and shall be initiated only by Authorized first:
Persons and done in the following sequence:
a. verified that no person will be exposed to
1. Review the equipment or machine to be locked danger.
and tagged out.
b. verified that the “Authorized” person who
2. Alert operator and supervisor of which machine is applied the device is not in the facility.
to be worked on, and that power and utilities will
be turned off. c. noted that all reasonable efforts to contact
the “Authorized” person have been made to
3. Check to make certain no one is operating the inform him or her that the lockout or tagout
machine before turning off the power. device has been removed.
4. Turn off the equipment using normal shutdown
d. ensured that the “Authorized” person is
procedure.
notified of lock removal before returning to
5. Disconnect the energy sources: work.
a. Air and hydraulic lines should be bled, 2. Tagout System—Tags are warning devices
drained and cleaned out. There should be no affixed at points of power disconnect and are not
pressure in these lines or in the reservoir to be removed by anyone other that the person
tanks. Lockout or tag lines or valves. placing tag on power lockout. Tags shall never be
by-passed, ignored, or otherwise defeated.
b. Any mechanism under tension or pressure,
such as springs, should be released and
locked out or tagged.

SECTION 1
1.14 Explosive Atmosphere
WARNING
DO NOT attempt to operate the
compressor in any classification of
hazardous environment or potentially
explosive atmosphere unless the
compressor has been specially
designed and manufactured for
that duty.
10

Section 2
DESCRIPTION
2.1 Introduction inlet system, compressor cooling and lubrication
system, compressor discharge system, capacity
The Sullair 300HH, 375, 375H, and 425 CFM Standard control system, instrument panel and electrical
and Aftercooled Portable Air Compressors offer superior system. A low profile canopy offers improved handling and
performance, reliability and require a minimal amount of mobility. Large side service doors provide easy access to
maintenance. Compared to other compressors, Sullair’s all serviceable components. This model meets EPA sound
are unique in terms of reliability and durability. Compressor level regulations of 76dbA at 7 meters (23 feet). Sullair air
internal components require no routine maintenance compressors have the following delivery capacities:
inspections.
Model 300HH, 300CFM@ 200 psig (13.8 bar)
Model 375, 375CFM @ 100 psig (6.9 bar)
2.2 Description Of Components Model 375H, 375CFM @ 150 psig (10.3 bar)
Figure 2-1 shows the main components and Model 425, 425CFM @ 100 psig (6.9 bar)
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
375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List 11

SECTION 2
SU_0000673
1. Radiator/Fluid Cooler Assembly 8. Service Valves

2. Radiator/Fluid Cooler Assembly With Air To Air Aftercooler 9. Serial Number Plate Location
3. Lifting Bail 10. Receiver/Sump Tank
4. Engine Air Filter 11. Minimum Pressure/Check Valve
5. Compressor Air Filter 12. Engine Exhaust Muffler
6. Fuel Tank 13. Moisture Separator
7. Battery Shutoff Switch 14. Optional Discharge Air Filters
Figure 2-1: Sullair Rotary Screw Portable Air Compressor – Caterpillar Standard and Aftercooled Models
The control system can easily be adjusted for pressures Refer to the Engine Operator’s Manual for a more
from 80 to 125 psig (5.6 to 8.6 bar) for standard machines, detailed description of the engine. The engine cooling
from 80 to 150 psig (5.6 to 10.3 bar) for “H” machines and system is comprised of a radiator, charge air cooler, high
from 80 psig to 200 psig (5.6 to 13.8 bar) for “HH” capacity fan, and thermostat. The high capacity fan pushes
machines. The compressor unit is driven by an industrial air through the radiator to maintain the engine’s specified
diesel engine designed to provide enough horsepower to operating temperature. The same fan also cools the fluid in
provide an adequate reserve under rated conditions. the compressor cooling and lubrication system.
12 375 Caterpillar Standard and Aftercooled/Filtered Operator’s Manual and Parts List

DESCRIPTION
The engine radiator, charge air cooler, and the compressor the high pressure region of the sump to a lower pressure
fluid cooler are next to each other allowing the fan air to area in the compressor unit. A minimum pressure device
push through all three simultaneously. As air passes (See Compressor Discharge System, Functional
through the fluid cooler, the heat of compression is Description on page 14) is provided to assure adequate
removed from the fluid. The compressor’s high capacity fluid flow under all conditions. When entering the thermal
fuel tank contains enough fuel for one eight hour shift valve upon start-up, the fluid temperature is cool and thus
under normal operating conditions. it is not necessary to route it through the cooler. The fluid
flows through the fluid filter and on to the compressor unit
2.3 Sullair Compressor Unit, bypassing the cooler. As the compressor continues to
operate, the temperature of the fluid rises and the
Functional Description thermostatic control opens, allowing a portion of the fluid
Sullair compressors are single-stage, positive into the cooler.
displacement, flood lubricated-type compressors that When the temperature reaches 155°F (68°C), the
provide continuous (pulse-free) compression to meet thermostat is fully open allowing all fluid entering the
various demand loads. Sullair compressors require no thermal valve to flow to the cooler.
routine maintenance or inspection of their internal parts or
systems. The compressor works by injecting fluid into the The cooler is a radiator type that works in concert with the
compressor unit where it mixes directly with the air as the engine fan. The fan pushes air through the cooler
rotors turn: the rotor’s rotation compresses the air. The removing the heat from the fluid. From the cooler, the fluid
fluid flow has three main functions: is then routed back through the fluid filter. All fluid flowing
to the compressor unit passes through this filter. The fluid
1. I t acts as a coolant, to control the rise of air leaving the filter flows to the compressor unit where it
temperature which is generated by compression (heat lubricates, seals and cools the compression chamber; and
of compression). lubricates the bearings and gears.
2. Seals the leakage paths between the rotors and the
2 3
stator and also between the rotors themselves.
3. Lubricates the rotors allowing one rotor to directly 1
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 the service line and the fluid is cooled
in preparation for re-injection.
2.4 Compressor Cooling

And Lubrication System,
Functional Description 5 6
Refer to Figure 2-2. The compressor cooling and 4

lubrication system is designed to provide adequate SU_0000664
lubrication as well as maintain the proper operating

temperature of the compressor. In addition to the fluid 1. Fluid Cooler
cooler and interconnecting piping, the system consists also 2. Engine
of three other components: a fluid filter, thermal valve, and 3. Compressor
a fan which perform the following functions: 4. Thermal Valve
5. Fluid Filter
• The fluid filter removes and collects any contaminants 6. Receiver Tank
in the fluid.
• The thermal valve functions as a temperature Figure 2-2: Compressor Cooling and Lubrication
regulator directing fluid either to the cooler or to the System
compressor unit.
• The fan pushes air through the cooler dissipating the
heat resulting from compression of 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: the sump serves as the fluid reservoir.
At start-up, fluid flows from the sump to the fluid thermal
valve. Fluid circulation is achieved by forcing the fluid from

SECTION 2
2.5 Compressor Discharge 2.6 Capacity ContRol SysTem,

System, Functional Functional Description
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
Refer to Figure 2-3. The Sullair compressor unit
and match it to the demand (required output) on the
discharges a compressed air/fluid mixture into the sump.
compressor. The control system consists of a pressure
The sump has three functions:
regulating valve(s), air inlet valve, system blowdown valve,
1. It acts as a primary fluid separator. engine speed control, and tubing connecting the various
components of the compressor and engine. The functional
2. Serves as the compressor fluid reservoir.
descriptions of the control system are described by relating
3. Houses the air/fluid separator. them to four distinct phases of operation. They apply to
any control system with the exception of those with
The compressed air/fluid mixture enters the sump and is specified pressures which are dependent on pressure
directed against the side of the sump. Because of a requirements. The given values apply to a compressor
change of direction and reduction of velocity, large droplets with an operating pressure range of 100 to 110 psig (6.9 to
of fluid separate and fall to the bottom of the sump. The 7.6 bar).
small amount of fluid remaining in the compressed air Start – 0 To 40 psig (0 To 2.8 Bar) Cold Start
collects on the surface of the separator element as the
compressed air flows through the separator. As more fluid When the compressor is started, the sump pressure
collects on the element surface, it then flows to the bottom quickly rises from 0 to 40 psig (0 to 2.8 bar). During this
of the separator. A return line (or scavenge tube) leads period the pressure regulator valve is inactive. At this
from the bottom of the separator element to the inlet region pressure range the idle warm-up control keeps the inlet
of the compressor unit. Fluid collecting on the bottom of valve closed for engine idle operation. Within 30 seconds
the separator element is returned to the compressor by the of starting the compressor (the instrument panel
pressure difference between the area surrounding the annunciator light goes off after 30 seconds) turn the
separator element and the compressor inlet. An orifice handle of the warm-up selector valve (located on the
(protected by a strainer) is included in this return line to instrument panel) from the START to the RUN position.
assure proper and unobstructed flow. The sump is ASME The inlet valve is fully open due to inlet pressure, and the
code rated at 250 psig (17.1 bar) working pressure. A compressor operates at full capacity. When the
minimum pressure device located downstream from the compressor operates at full capacity, the engine runs at full
separator, ensures a minimum receiver pressure of 80 speed.
psig (5.5 bar) during all conditions. Keeping this pressure
level stable is necessary for proper air/fluid separation and
proper fluid 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 fluid filler.
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.

DESCRIPTION
2 3
STANDARD MODEL
4
1
7
6
5 9
14
15
13
11
AFTERCOOLED MODEL 12 10
SU_0000665
1. Engine 9. Service Air Outlet

2. Strainer 10. Receiver Tank (Sump)
3. Minimum Pressure/Check Valve 11. Optional Discharge Air Filters
4. Service Air Outlet 12. Moisture Separator
5. Receiver Tank (Sump) 13. Aftercooler
6. Separator Element 14. Air
7. Minimum Pressure Valve 15. Fluid/Air
8. Non-Aftercooled/Aftercooled Service Air Valve
Figure 2-3: Compressor Discharge System – Standard and Aftercooled Models

SECTION 2
21
7
5
3
4
8
22
16
9
18
19
20
15
10
11
14
12
17
13
SU_0000666 CAT T2
1. Air Pressure Gauge 12. Optional Aftercooler

2. Instrument Panel 13. Aftercooled Machines ONLY
3. Idle Warm-Up Valve 14. Fluid Filter
4. Inlet Valve 15. Thermal Valve
5. Air Filter 16. Compressor Unit
6. Regulator/Blowdown Valve Manifold 17. Fluid Cooler
7. Minimum Pressure Check Valve 18. Air
8. Pressure Relief Valve 19. Fluid/Air
9. Fuid Fill/Fluid Level Sight Glass 20. Fluid
10. Optional Discharge Air Filters 21. Strainer
11. Optional Moisture Separator 22. Engine Speed Control Cylinder
Figure 2-4: Control System with Piping and Instrumentation - 375 and 425 Models

DESCRIPTION
1 2
3
4
11
7 12
5
6
8
10
9
13
26
14
15
23
24
25
21
16
17
20
18
22
19
SU_0000667
1. Air Pressure Gauge 14. Compressor Unit

2. Idle Warm-Up Control Selector Valve 15. Fluid Fill/Fluid Level Sight Glass
3. Low Pressure Regulator Valve 16. Optional Discharge Air Filters
4. High Pressure Regulator/Blowdown Valve Manifold 17. Optional Moisture Separator
5. Instrument Panel 18. Optional Aftercooler
6. High/Low Pressure Selector Switch 19. Aftercooled Machines ONLY
7. Air Filter 20. Fluid Filter
8. Orifice 21. Thermal Valve
9. Silencer 22. Fluid Cooler
10. Inlet Valve 23. Air
11. Strainer 24. Fluid/Air
12. Minimum Pressure/Check Valve 25. Fluid
13. Pressure Relief Valve 26. Engine Speed Control Cylinder
Figure 2-5: Control System with Piping and Instrumentation – 300HH and 375H Models

SECTION 2
High
Low
Run
Warm-up
Start
Out In In Out
High Pressure Low Pressure
Standard Air
Moisture Drain
Aftercooled Air
02250169-746R00-1
Figure 2-6: Piping and Instrumentation Diagram

DESCRIPTION
1. Filter, Air T1 Compressor Discharge Temperature Switch

2. Gauge, Filter Restriction (Optional)
3. Inlet Valve
4. Compressor
5. Gauge, Temperature
6. Switch, Temperature
8. Valve, Relief
9. Receiver, Air/Oil
10. Glass, Sight Oil Level
11. Indicator, Delta-P
12. Valve, Minimum Pressure/Check
13. Valve, Ball
14. Cooler, Air
15. Separator, Moisture
16. Trap, Drain
17. Orifice
18. Valve, Blowdown N.C.
19. Strainer
21. Valve, Thermal Bypass
22. Cooler, Oil
23. Filter, Oil
27. Gauge, Pressure
28. Valve, Pressure Regulator
29. Valve, 3-Way Selector
31. Valve, Check

SECTION 2
2 pressure increases, the inlet valve piston will further close

the inlet valve and the engine speed will decrease until it
1 reaches its preset idle speed. When the demand on the
compressor increases, the sump pressure falls below 110
3 psig (7.6 bar) or 165 psig (11.4 bar) for “H” machines, or
220 psig (15.2 bar) for “HH” ones. The pressure regulating
valve closes, the air inlet valve opens fully, and the engine
speed increases to its preset full load rating.
Between the pressure regulating valve and the inlet valve,
there is a small orifice that vents a small amount of air into
the atmosphere when the pressure regulating valve is
4 open. This allows changes in air output to conform to air
demand. This orifice also discharges any accumulated
5 moisture from the regulator.
Shutdown
SU_0000668
The blowdown valve is normally closed. At shutdown the
1. Engine Air Filter back pressure in the compressor inlet signals the
2. Compressor Air Filter blowdown valve to vent the sump pressure into the
3. Air Inlet Valve atmosphere.
4. Compressor
5. Engine 2.7 Air Inlet System,
Figure 2-8: Air Inlet System – Caterpillar Functional Description
Normal Operation – 80 to 100 psig (5.6 to 6.9 Refer to Figure 2-8. The air inlet system consists of two air
bar) or 80 to 150 psig (5.6 to 10.3 bar) for H filters, a compressor air inlet valve and interconnecting
piping to the engine and the compressor.
machines or 80 to 200 psig (5.6 to 13.8 bar)
for HH machines The air filters are three-stage dry element type filters that
are capable of cleaning extremely dirty air. However, when
When the warm-up control selector valve handle is moved operating in dirty environments, the filters should be
to the RUN position, the sump pressure rises above 80 checked more frequently.
psig (5.6 bar). At this time, the inlet valve remains fully
open for maximum air output. The engine will continue to See Air Filter Maintenance on page 33 for Air Filter
run at full speed during this phase of operation. Maintenance Procedures.
Modulation – 100 to 110 psig (6.9 to 7.5 bar)

or 150 to 165 psig (10.3 to 11.4 bar) for H
machines or 200 to 220 psig (13.8 to 15.2
2.8 Instrument Panel Group,
bar) for HH machines Functional Description
If the demand on the compressor is less than its rated Refer to Figure 2-9. The instrument panel group consists
capacity, the service line pressure will rise above 100 psig of a molded panel containing an: air pressure gauge,
(6.9 bar) - low or single pressure rating: 150 psig (10.3 ignition/start switch, annunciator light, hourmeter, and an
bar) for “H” rating or 200 psig (13.8 bar) for “HH” dual or idle warm-up control. A high-low pressure selector valve is
high pressure rating. The pressure regulating valve located on the panel for “H” and “HH” compressors.
gradually opens, applying pressure to the inlet valve piston
and engine speed control. This causes the inlet valve to
partially close and reduces the engine speed. As the

DESCRIPTION
Figure 2-9: Instrument Panel Group

(Optional Full Gauge Panel Shown)
1. Compressor discharge temperature

2. System air pressure
3. Start stop switch
4. Warm-up control
5. High/low pressure selector
6. Warning indicator
7. Hourmeter
8. Engine voltage
9. Engine oil pressure
10. Engine coolant temperature
11. Cold weather starting. (Glow plugs)
12. Engine RPM (optional)
13. Fuel level (optional)
fig_instrpnl_375h_cat_t2-r00
Refer to Figure 2-9 for the locations of the following 9. The optional Engine Oil Pressure Gauge monitors
indicators and controls: the pressure of the lubricating oil in the engine.
1. The optional Compressor Discharge Temperature 10. The optional Engine Coolant Temperature Gauge
Gauge monitors the temperature of the air/oil mixture monitors the temperature of the engine coolant in the
in the sump. engine.
2. The air pressure gauge continuously monitors the 11. The cold weather starting aid can be used to add
sump pressure under various load conditions. additional glow plug time in cold weather. Press the
button and hold for 10-30 seconds (depending upon
3. The engine switch energizes the system and starts the ambient temperature). Release the button prior to
compressor. The engine switch is pressed to the ON starting.
position to energize the electrical system, and pressed
momentarily to the START position to engage the 12. The optional Tachometer monitors the operating
starter and start the compressor. speed of the engine.
4. The idle warm-up control is turned from START to 13. The optional fuel level gauge indicates the fluid level in
RUN after sufficient warm-up is achieved for full the fuel tank.
compressor operation.
5. The pressure selector valve on “H” compressors
allows the selection of the compressor operating WARNING
pressure range, 80 to 110 psig (5.6 to 7.6 bar) or 80 to
165 psig (5.6 to 11.4 bar) for “H” models, or 80 to 220 DO NOT use aerosol types of starting
psig (5.6 to 15.2 bar) for “HH” models. aids such as ether.
6. The shutdown indicator light indicates engine and
Such use could result in an explosion
compressor safety shutdown status.
and personal injury.
7. The Hourmeter indicates the accumulated hours of
operation. If the engine fails to start within 30
seconds, release the starter switch or
8. The optional Engine Voltage Gauge monitors the button and wait two minutes to allow
voltage level of the engine storage battery.
the starting motor to cool before
attempting to start the engine again.

SECTION 2
2.9 Wiring Diagram
02250144-395-r04

DESCRIPTION
2.10 Electrical System, 2.11 Compressor Shutdown

Functional Description & Warning System,
The electrical system consists of the basic electrical Functional Description
elements required to operate the compressor and also has
The Shutdown System and Annunciator Module (SSAM)
a system feature that automatically shuts down the
continuously monitors the status of the compressor. In the
compressor when a malfunction occurs. The system’s
event of a shutdown condition, the SSAM will shut down
components include: an engine starter, battery, alternator/
the compressor and display (flashing) the appropriate
voltage regulator, and a fuel solenoid. It also has a
code on the instrument panel annunciator light. The
compressor discharge temperature switch that will shut the
display will continue flashing until the ignition switch is
compressor down if the compressor temperature exceeds
turned OFF. The shutdown codes are:
250° F (121° C). It has an engine water temperature
switch set to shut down the compressor when the coolant • One flash: high compressor discharge temperature
temperature reaches 225° F (107° C) and an oil pressure
switch that will shut down the compressor if the engine oil • Two flashes: high engine coolant temperature
pressure goes too low. An underspeed sensor shuts down • Three flashes: low engine oil pressure
the compressor if the engine speed falls below 1500 rpm.
• Four flashes: low engine speed
• Five flashes: low fuel level (optional)
The SSAM also provides startup logic for the compressor.
When the ignition switch is in the ON position, the
annunciator light will illuminate for 30 seconds. During this
30 second period, pressing the ignition switch will engage
the engine starter. The low engine speed switch is inactive
during this startup time interval. By the end of these 30
seconds, the annunciator light goes out and the engine
START cycle is disabled. At this time the system runs all
safety checks including low fuel level (if installed).

SECTION 2
2.12 Aftercooled And Filtered from the first stage filter. The condensate should be
drained and stored in a suitable container. From the
Air System, Functional first stage filter, the air enters the (optional) second stage
Description filter. This filter removes smaller particles and any
additional water. The condensate should be drained
Refer to Figure 2-3. The purpose of the aftercooled system and stored in a suitable container. Upon compressor
is to operate the air compressor in conditions when shutdown, the filters will drain to clear the condensate from
compressed air temperature is required to be within 20° to the system. This will prevent freezing in cold conditions.
25°F (13° to 17°C) of the ambient temperature.
A selector valve is provided on all aftercooled
compressors. Choosing the aftercooled air completely NOTE
forces the airflow from the receiver tank to the aftercooler.
The ambient air which is drawn through the aftercooler by The aftercooler system should
the engine fan, cools the compressed air as it passes not be operated when the ambient
through the aftercooler core. Cooled air enters the temperature is below 32°F (0°C). To
moisture separator where condensation is removed from operate in the non-aftercooled mode
the cooler air and discharged. This condensate does close the aftercooler selector valve
carry some oil and it should be disposed of properly
completely.
in accordance with local regulations.
From the moisture separator the air enters the (optional)
first stage filter. Particles and additional water are removed

Section 3
Specifications
3.1 Specifications – 300HH and 375 Caterpillar
DIMENSIONS
Model Series Length (I) Width Height Weight (wet)
in mm in mm in mm lb kg
300HH, and 375
156.2 3967.5 77.2 1960.9 74.0 1879.6 4420* 2004.9*
2-Wheel
300HH, and 375
98.8 2509.5 59.3 1506.2 63.6 1615.4 4175* 1893.8*
Less Running Gear
(l) Length over drawbar for 2 – wheel version
*Add 115 lbs (52 kg) for Aftercooled Version
COMPRESSOR 300HH 375

Type Rotary Screw Rotary Screw
Maximum Operating Pressure 200 psig (13.8 bar) 125 psig (8.6 bar)
Pressure Delivery 300 Free CFM 375 Free CFM
(142 L/S) (177 L/S)
Rated Pressure 200 psig (13.8 bar) 100 psig (6.9 bar)
Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid
Lubricating Compressor Fluid See Table 1 See Table 1
Sump Capacity 7 US gallons 7 US gallons
(26.5 liters) (26.5 liters)
Track Width 67.5" 67.5"
(1714.5 mm) (1714.5 mm)
Tire Size (Load Range) H78 x 15ST (D) H78 x 15ST (D)
Tire Pressure 65 psig (4.4 bar) 65 psig (4.4 bar)
Wheel Size 15 x 6JJ 15 x 6JJ
Lug Nut Torque 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm)
Operating Tilt (maximum) 15° 15°
Electrical System 12 volt 12 volt
Compressor Discharge Shutdown 250°F (121°C) Shutdown 250°F (121°C)
Temperature
Service Valves (2) ¾" (2) ¾"
Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating 5000 lbs 5000 lbs
(2268 kg) (2268 kg)
Sound Level 76 dBA at 7 m 76 dBA at 7 m

SECTION 3
ENGINE: 300HH 375

Type Diesel Diesel
Make Caterpillar Caterpillar
Model C4.4 C4.4
Displacement 268 cu/in (4.4L) 268 cu/in (4.4L)
Cylinders 4 4
Bore x Stroke 4.13 x 5.00 4.13 x 5.00
(105 mm x 127 mm) (105 mm x 127 mm)
Rated Speed 2200 rpm 2200 rpm
Rated Power 129HP/96kW 107HP/79.5kW
Type of Motor Oil See Engine Operator Manual See Engine Operator Manual
Fuel Tank Capacity 56 gallons 56 gallons
(212 liters) (212 liters)
Radiator Capacity 4 gallons (15 liters) 4 gallons (15 liters)
Engine Water Temperature Shutdown 225°F (107°C) Shutdown 225°F (107°C)
Minimum Idle Speed 1600 rpm (II) 1600 rpm (II)
Alternator Rating 65 amp 65 amp
(II) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/
or coupling damage will occur. The compressor is equipped with a Low Speed Shutdown
System that will shutdown the compressor if engine speed falls below 1500 rpm.
3.2 Specifications – 375H and 425 Caterpillar

DIMENSIONS
Model Series Length (I) Width Height Weight (wet)
in mm in mm in mm lb kg
375H and 425
156.2 3967.5 77.2 1960.9 74.0 1879.6 4420* 2004.9*
2-Wheel
375H and 425
98.8 2509.5 59.3 1506.2 63.6 1615.4 4175* 1893.8*
Less Running Gear
(l) Length over drawbar for 2 – wheel version
*Add 115 lbs (52 kg) for Aftercooled Version
COMPRESSOR 375H 425

Type Rotary Screw Rotary Screw
Maximum Operating Pressure 150 psig (10 bar) 125 psig (8.6 bar)
Delivery 375 Free CFM 425 Free CFM
(177 L/S) (201 L/S)
Rated Pressure 150 psig (10.3 bar) 100 psig (6.9 bar)
Cooling Pressurized Compressor Fluid Pressurized Compressor Fluid
Lubricating Compressor Fluid See Table 1 See Table 1
Sump Capacity 7 US gallons 7 US gallons
(26.5 liters) (26.5 liters)
Track Width 67.5" 67.5"
(1714.5 mm) (1714.5 mm)
Tire Size (Load Range) H78 x 15ST (D) H78 x 15ST (D)
Tire Pressure 65 psig (4.4 bar) 65 psig (4.4 bar)
Wheel Size 15 x 6JJ 15 x 6JJ
Lug Nut Torque 60 ft-lbs (81 Nm) 60 ft-lbs (81 Nm)
Operating Tilt (maximum) 15° 15°

SPECIFICATIONS
Electrical System 12 volt 12 volt

Compressor Discharge Temp Shutdown 250°F (121°C) Shutdown 250°F (121°C)
Service Valves (2) ¾" (2) ¾"
Maximum Towing Speed 55 mph (88 kmph) 55 mph (88 kmph)
Axle Rating 5000 lbs 5000 lbs
(2268 kg) (2268 kg)
Sound Level 76 dBA at 7 m 76 dBA at 7 m
ENGINE: 375H 425

Type Diesel Diesel
Make Caterpillar Caterpillar
Model C4.4 C4.4
Displacement 268 cu/in (4.4L) 268 cu/in (4.4L)
Cylinders 4 4
Bore x Stroke 4.13 x 5.00 4.13 x 5.00
(105 mm x 127 mm) (105 mm x 127 mm)
Rated Speed 2200 rpm 2200 rpm
Rated Power 129HP/96kW 129HP/96kW
Type of Motor Oil See Engine Operator Manual See Engine Operator Manual
Fuel Tank Capacity 56 gallons 56 gallons
(212 liters) (212 liters)
Radiator Capacity 4 gallons (15 liters) 4 gallons (15 liters)
Engine Water Temperature Shutdown 225°F (107°C) Shutdown 225°F (107°C)
Minimum Idle Speed 1600 rpm (II) 1600 rpm (II)
Alternator Rating 65 amp 65 amp
(II) DO NOT allow engine idle rpm to drop below minimum idle speed. Compressor and/
or coupling damage will occur. The compressor is equipped with a Low Speed Shutdown
System that will shutdown the compressor if engine speed falls below 1500 rpm.

SECTION 3
3.3 Lubrication Guide – Compressor

Fluid Type Change Period/Hours Ambient Temperature
Range °F (°C)
Sullair AWF (I) 1500 -20 to 120 (-29 to 49)
SAE 10W SE, SF, SG, CD 250 0 to 100 (-18 to 38)
MIL-L-2104E 10W 250 0 to 100 (-18 to 38)
(I) Sullair part numbers for Sullair AWF are 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon drum/208 liters).
3.4 Application Guide

Sullair air compressors are supplied with Sullair AWF
which is a heavy duty multi-viscosity, all weather fluid
which provides an extended change interval when
compared to other fluids. Detergent motor oils (SAE 10W
Class SE, SF, SG, or CD) can also be used. Any of these
oils are suitable under conditions where severe oil
oxidation can occur.
Water must be drained from the receiver tank periodically.
In high ambient temperature and humidity conditions,
condensed moisture can emulsify with the oil forming a
“milky” color. SAE 10W is especially prone to this
condition. The fluid should be changed if this condition
develops. DO NOT mix different fluids. Combinations of
different fluids can lead to operational problems such as
foaming, plugged filters, blocked orifices or lines.
When ambient conditions exceed the recommended
ranges, or if other conditions warrant the use of other
extended life lubricants, contact your local Sullair
representative for recommendations.
Sullair encourages users to participate in a fluid analysis
program. The analysis might indicate a need for change
intervals different from those recommended in this manual.
Sullair Corporation offers a fluid analysis for Sullair AWF.
Contact Sullair for details.
D-A Lubricant® Company Inc. offers an analysis for users
of Sullair AWF. Contact your Sullair representative for
details.
3.5 Lubrication Guide – Engine SU_0000699
1. Fluid Fill Port

Refer to the Engine Operator’s Manual for oil
2. Sight Glass
specifications.
3. Sump Tank
Figure 3-1
NOTE
Proper Compressor Fluid Level
Visible halfway in fluid sight glass
when checked on a level surface with
the compressor not running.

Section 4
GENERAL
4.1 General Compressor Discharge Temperature Switch
While Sullair has built into this compressor a complete set Opens the electrical circuit to shut down the compressor
of controls and indicators that allow the operator to control when the discharge temperature reaches a specific value
and monitor the compressor’s operation and performance. (See Specifications on page 25 and on page 27).
Operators should learn to recognize indications which
identify a service requirement or conditions that could lead Thermal Valve
to (or show) a (current) malfunction. Before starting the Functions as a temperature regulator by directing the
compressor, read this section thoroughly to gain familiarity compressor fluid either to the cooler or to the compressor unit.
with the controls and indicators – their function and
location.
Minimum Pressure Device
4.2 Purpose Of Controls Maintains the minimum of 80 psig (5.6 bar) in the
compressor sump.
Control or Indicator Purpose
Pressure Relief Valve
Engine Switch
Vents sump pressure to the atmosphere if pressure inside
Press this switch to the ON (ignition) position to energize the sump exceeds 250 psig (17.3 bar).
the electrical system of the compressor. Press the switch
to the START position to momentarily engage the starter Air Inlet Valve
and start the compressor. Press the switch to the OFF
position to shut the compressor down. This switch is Regulates the amount of air allowed to enter the air
located on the instrument panel. compressor inlet. Regulation is determined by a signal
from the pressure regulator(s).
Cold Weather Starting Aid Button
Pressure Regulator(s)
Push this button, prior to compressor start-up, to allow the
engine to pre-heat for easier starting. Allows the pressure signal to reach the engine speed
control and the air inlet valve to control air delivery
Hourmeter according to demand.
Indicates the accumulated hours of operation. Useful for Discharge Air Filter Differential Pressure Gauge
planning and logging service schedules. (Optional Aftercooled and Filtered Models Only)
Air Pressure Gauge Monitors the air filter (first and second stage) condition. A
reading over 10 psig (0.7 bar) in the red zone indicates the
Continuously monitors the pressure inside the receiver air filters require servicing.
sump at various load and unload conditions.
Fluid Sight Level Glass Shutdown System/Annunciator Module (SSAM)

Indicates the fluid level in the sump. Proper level is marked Monitors the compressor safety system for conditions
halfway up the sight glass. Check the level when the requiring shutdown. The annunciator on the instrument
compressor is shutdown and on level ground. control will flash the applicable shutdown code.

SECTION 4
Blowdown Valve Shutdown

Vents sump pressure to the atmosphere at shutdown. 1. Close the service valves and run the compressor for
approximately five minutes to allow the compressor to
Idle Warm-Up Control cool down.
Keeps the compressor inlet valve closed for reduced 2. Place the pressure selector switch in the low position
compressor load at start-up. When the compressor is (H and HH models).
warmed-up, the handle is turned from the START to the 3. Press the ENGINE SWITCH to the OFF position after
RUN position for full operation. five minutes.
Pressure Selector Switch (H and HH Models)

4.4 Restart Procedure
Sets compressor operation in the LOW range from 80 to
110 psig (5.6 to 7.6 bar), or in the HIGH range from 80 to After running and shutting down the compressor for the
165 psig (5.6 to 11.4 bar) on H models, and from 80 to 220 first time, perform the following actions when restarting the
psig (5.6 to 15.2 bar) on HH models. compressor:
4.3 Initial Startup/Shutdown 1. Check engine oil, engine coolant, and fuel levels.
2. Check the compressor fluid level (sight glass) and
Procedure drain any water from the fuel/water separator.
Startup 3. Check the dust collectors and clean if necessary.
Perform the following actions when starting the 4. Crack open the service valve.
compressor for the first time: 5. Place the WARM-UP control in the START position.
1. Ensure that the compressor is on a level surface. (If 6. Place the PRESSURE SELECTOR switch to the LOW
the compressor is on an uneven surface, the fluid position (H and HH models).
sight gauge readings will not be accurate, and it will 7. Press the ENGINE SWITCH to the ON position.
not be possible to determine if fluid levels are too low.) (I)
8. In cold weather, press the cold weather starting aid
2. Check the oil and fluid levels in the engine and button. Hold button for 10 to 30 seconds and then
compressor: add oil and/or fluid if necessary. release.
3. Fill the fuel tank and drain any water from the fuel/ 9. Momentarily press the ENGINE SWITCH to the
water separator. START position to engage the starter: release the
4. Crack open one service line. switch when the engine starts.
5. Place the WARM-UP control in the START position. 10. After 30 seconds (the annunciator light will go off after
6. Place the PRESSURE SELECTOR switch to the LOW 30 seconds) Turn the IDLE WARM-UP SWITCH from
position (H and HH models). START to RUN to put the compressor in full operation.
7. Press the ENGINE SWITCH to the ON position. 11. Close all doors to maintain proper noise level.
8. In cold weather, press the cold weather starting aid 12. To shut down the compressor, see Shutdown procedure
button. Hold button for 10 to 30 seconds and then above.
release.
9. Momentarily press the ENGINE SWITCH to the WARNING
START position to engage the starter: release the
switch when the engine starts. DO NOT use aerosol types of starting
10. After 30 seconds (the annunciator light will go off after aids such as ether.
30 seconds) Turn the IDLE WARM-UP SWITCH from Such use could result in an explosion
START to RUN to put the compressor in full operation. and personal injury.
11. Close all doors to maintain proper noise level. If the engine fails to start within 30
seconds, release the starter switch or
(I) The radiator is filled with a 50/50 mixture of ethylene glycol
and water. All engines receive Supplemental Coolant Additive button and wait two minutes to allow
(SCA) at the factory before shipment. Refer to the Engine the starting motor to cool before
Operator’s Manual for specific requirements. attempting to start the engine again.

Section 5
MAINTENANCE
WARNING NOTE
DO NOT remove caps. Plugs The radiator and engine cooling
and/or other components when system must be drained and flushed
the compressor is running or every 1500 hours. Replace the
pressurized. Shutdown the solution coolant with a 50% ethylene
compressor before removing any glycol and 50% water solution or as
components. required for local climatic conditions.
DO NOT use a leak-sealing type
antifreeze. All engines must have
5.1 General Supplemental Coolant Additive (SCA)
added to the engine coolant system.
Consistent and correctly performed maintenance will Refer to the Engine Operator’s
ensure the compressor’s performance and extend its Manual for specific requirements.
operational life. See Part Replacement and Adjustment
Procedures on page 33 for a detailed description of If fluid must be added too frequently
specific compressor components. Before performing at startup, a problem might have
maintenance actions, read the CIMA Safety Manual, if developed causing an excessive
applicable. For engine maintenance requirements and fluid loss. See Trouble Shooting
procedures, refer to the Engine Operator’s Manual. on page 38 (Excessive Fluid
Consumption) for a probable cause
5.2 Daily Maintenance and remedy. After the compressor
has warmed-up, make a general
See Initial Startup Shutdown/Procedure on page 30 for
general operation. inspection of its components and
instrument panel to ensure that the
compressor is running properly.
NOTE
Dispose of fluids in accordance with

applicable federal, state and local
regulations.

SECTION 5
5.3 Maintenance After Initial 50 5. Change the compressor fluid if it is not Sullair AWF:
Hours Of Operation a. Run the compressor for five to ten minutes to
After the initial 50 hours of operation, the following warm the fluid
maintenance actions are required to eliminate b. Shut the compressor down and relieve all internal
contaminants from the system: pressure
1. Clean the return line orifice and change the strainer. c. Drain the fluid sump by removing the plug, or
2. Change the compressor fluid filter. opening the valve at the bottom of the sump tank
3. Check the Engine Operator’s Manual for service d. Remove any dirt from the fluid filter cap before
requirements. filling the sump
4. Check the fuel filter for water. e. Fill the sump with fluid in accordance with the
specifications in Specifications on page 25 and on
5. Confirm that the sump cover bolts are tightened to 160 page 26.
lb-ft (215N•m).
6. Clean or replace the return line strainer.
7. Change the air filter primary elements.
5.4 Maintenance Every 50 8. Change the compressor fluid filter.
Hours 9. Clean the return line orifice.
1. Inspect air filter elements and replace if necessary. 10. Change the fuel filter. (If the filter tends to clog more
often than what is expected, change the filter more
2. Check the fuel filter for water. frequently.)
11. Change the engine fuel/water separator.
5.5 Maintenance Every 100 12. Check the engine rpm idle speed. The idle speed
should be at the specified minimum idle speed listed in
Hours Specifications on page 26 and on page 27.
After 100 hours of operation:
1. Clean the radiator and cooler exterior surfaces.
2. Check the Engine Operator’s Manual for service WARNING
requirements.
Operating the compressor at below
its minimum specified idle speed will
damage the compressor. Operating
5.6 Maintenance Every 250 the compressor in this condition will
Hours cause coupling and/or compressor
failure.
After 250 hours of operation:
1. Check fan belt tension.
2. Clean the radiator and cooler exterior surfaces. 5.7 Maintenance Every 1500
(Where dust and other atmospheric contaminants are
present, it might be necessary to clean these parts Hours
more frequently.) 1. If the compressor fluid is Sullair AWF, change the fluid
3. Check the Engine Operator’s Manual for service and replace the fluid filter element. (See Compressor
requirements. Fluid Filter Element Replacement on page 33.
4. Change the engine oil and filter. 2. Service the engine cooling system.
3. Lubricate axle bearings on wheel-mounted units.
NOTE
The fluid change period varies by
fluid brand, Refer to the Lubrication
Guide – Compressor on page 28.

MAINTENANCE
5.8 Part Replacement And Air Filter Maintenance

Adjustment Procedures Refer to Figure 5-2. Air filter maintenance should be
performed as often as conditions require. If the filters are
Compressor Fluid Change Procedure equipped with optional maintenance indicators, change the
filters every time the indicators show a change is
1. Run the compressor five to ten minutes to warm the necessary.
fluid.
2. Shut the compressor down and relieve all internal
pressure.
3. Drain the fluid sump by removing the plug, or opening
the valve at the bottom of the sump tank.
4. Change the compressor fluid and replace the fluid
filter element (For element replacement see the filter
servicing procedure in this Section.)
5. Fill the sump with fluid in accordance with the
specifications in Specifications on page 25 and on
page 26.
Compressor Fluid Filter Element

Replacement
Refer to Figure 5-1.
1. Remove the old element with a strap wrench.
2. Clean the gasket seating surface.
3. Apply a light coating of fluid to the new gasket.
4. Hand tighten the new element (P/N 250025-525) until SU_0000678
the new gasket is seated.
5. Continue tightening the element by hand an additional 1. Filter Body
1⁄2 to 3⁄4 turn. 2. Filter Cover
3. Safety (Secondary) Element**
6. Restart the compressor and check for leaks. 4. Primary Element*
1 *Replacement Primary Element

P/N 02250164-532
**Replacement Safety (Secondary) Element

P/N 02250164-533
Figure 5-2
Air Filter Replacement

1. Loosen and remove the air filter and cover.
2. Remove the primary and secondary elements.
2 3. Clean the body, inside and out, with a damp cloth.
4. Reinstall (if clean) or replace the secondary element.
5. Replace the new primary filter element.
6. Reposition the cover and lock it into the position.
7. Reset the filter restriction indicator (if equipped).
SU_0000669
1. Filter Head
2. Fluid Filter
Figure 5-1

SECTION 5
Element Inspection 3. Remove the eight (8) cover bolts and washers and lift
the cover off the sump.
1. Insert a bright light source into the element and look
for any light leaks which indicate the presence of 4. Remove the separator element.
damage (holes, cracks, etc.) 5. Scrape the old gasket material from the cover and the
2. Inspect all gaskets and gasket contact surfaces of the flange on the sump. Do not allow the scrapings to fall
housing and replace any damaged ones. into the tank.
3. Store clean elements for later use in a clean container. 6. Install the new element.
4. After installing the element, inspect and tighten all air 7. Replace the sump cover and bolts. Lightly tighten all
inlet connections before operating the compressor. the bolts and then gradually tighten them alternating
between bolts which are diagonally opposite each
other. Torque the bolts to 160 ft-lbs (215 N•m).
Separator Element Replacement 8. Reconnect all piping. The fluid return line tube should
Refer to Figure 5-3. When compressor fluid carryover is extend to the bottom of the separator element which
evident, after replacing or inspecting the fluid return line will ensure proper return line flow.
strainer and orifice, and the blowdown valve; and all are in 9. Clean the fluid return line strainer and clear the orifice
satisfactory condition, the separator element must be before starting the compressor.
replaced with Kit number 250034-087 (element for air/fluid
separator). 10. After 24 hours of operation, tighten the sump cover
bolts to the value given in step 7.
1
Procedure For Setting Speed And Pressure

2 Controls On Portable Compressors
Equipped With Poppet Valves
Refer to Figure 5-4 and Figure 5-5. Before adjusting the
3 compressor’s control system, the rated full-load pressure
and the high/low rpm settings must be determined. This
information is provided in Specifications on page 25 and
on page 26 or can be obtained by contacting a Sullair
representative.
SU_0000670
1. Capscrew
2. Washer
3. Cover
4. Separator Element with Gaskets
5. Receiver Tank
Figure 5-3: Air/Fluid Separator
1. Disconnect all sump cover piping connections to

permit removal (return line, service line, etc.).
2. Remove the fluid return line from the fitting on the
cover.

MAINTENANCE
5. Open the service valve to 100 psig (6.9 bar) (rated full
load pressure) and recheck top engine speed and
control response. Close the service valve and allow
the compressor to cycle and re-check low engine
speed (idle).
1. Compressor Unit
2. Air Pressure Gauge
3. Warm-Up Control Valve
4. High/Low Pressure Valve
5. Receiver/Sump Tank
6. Pressure Regulator/Blowdown Manifold
7. Oil Return Line
8. Blowdown Line (To Fitting At Filter Hose)
Figure 5-5: Control System Adjustment –

Dual Pressure
1. Compressor Unit fig_5-4std-press-t2-r01
2. Air Pressure Gauge

3. Warm-Up Control Valve
4. Receiver/Sump Tank
5. Pressure Regulator/Blowdown Manifold
6. Oil Return Line
7. Blowdown Line (To Fitting At Filter Hose)
Figure 5-4: Control System Adjustment –

Standard Pressure
The following procedure applies to a compressor with full-

load pressure rating of 100 psig (6.9 bar).
1. Start the compressor and allow the engine to warm-
up to its normal operating temperature with the service
valve closed.
2. With the service valve closed, set the engine low
speed (idle) to its specified setting with the idle stop
screw on the engine injector pump. fig_5-4a-hi-press-t2-r01
WARNING
Operating the compressor at below
its minimum specified idle speed will
damage the compressor. Operating
the compressor in this condition will
cause coupling and/or compressor
failure.
3. Adjust the pressure regulator so that the compressor

maintains 115 psig (8 bar).
4. Gradually open the service valve to atmosphere until
the engine comes up in speed and sump pressure is
held at 100 psig (6.9 bar). At this point, set the engine
high speed to its specified setting by adjusting the high
idle threaded rod located on the engine speed control.
To raise or lower the speed, lengthen or shorten the
rod respectively.

SECTION 5
The following steps apply to “H” and “HH” compressors Bearing Lubrication
equipped with dual pressure controls.
Refer to Figure 5-6. Proper lubrication of the portable
1. Start the compressor and allow the engine to warm up compressor’s bearing axle is critical to its proper function
to its normal operating temperature with the service and reduction of wear on this part. Wheel bearings should
valve closed and the pressure selector valve set to the be lubricated at least every 12 months, or more, to ensure
LOW position. proper performance and minimize wear. Use a wheel
2. Follow the procedure for setting the controls to 100 bearing grease that conforms to MILSPEC MIL-G-10924
psig (6.9 bar) rated full load pressure as describe in or a high temperature one such as lithium complex NLGI
preceding steps 2 through 6. consistency #2.
3. Turn the pressure selector valve to the HIGH position Axles with the E-Z Lube feature can be periodically
with the service valve closed. lubricated without removing the hubs from the axle. This
feature consists of axle spindles that have been fitted with
4. Adjust the high pressure regulator so that the
a grease zerk in their ends. When grease is pumped into
compressor maintains a receiver tank pressure of 165
the zerk, it is channeled to the inner bearing and then
psig (11.4 bar) on “H” models or 220 psig (15.2 bar) on
flows back to the outer bearing, and then back out of the
“HH” models.
grease cap hold (see Figure 5-6).
5. Gradually open the service valve to atmosphere until
the engine speed increases and the receiver tank 1. Remove the rubber cap from the grease cap’s end.
pressure stabilizes at 150 psig (10.3 bar) on “H” 2. Using a full charged grease gun, place the gun onto
models or 200 psig on “HH” models. At this point the the grease zerk located on the end of the spindle.
engine should be operating at its rated speed. If Make sure the nozzle is fully engaged on the fitting.
necessary, to raise or lower speed, lengthen or
3. Pump grease into the zerk. The old grease will be
shorten the rod respectively.
displaced and flow out of the cap around the grease
gun nozzle.
4. When the new grease starts flowing out of the cap,
disengage the gun and wipe off any excess off the
cap; and replace the rubber plug.
6
1
2
7
5
SU_0000671
1. Rubber Plug 5. Metal End Cap

2. Outer Bearing 6. Inner Bearing
3. Grease Flow 7. Spring Loaded Double Lip Seal
4. Grease Fitting
Figure 5-6: Typical E-Z Lube Axle

MAINTENANCE
First and Second Stage Discharge Air Filter

1
Maintenance – Aftercooled & Filtered Models
General
Refer to Figure 5-7. Familiarity with the filtration process
and the unit’s monitoring system (consisting of a compete
set of gauges) will enable the operator to locate and
analyze malfunctions.
The first and second stage filter element should be 1
changed when the pressure drop reaches the red band on
the pressure differential gauge.
Daily Operation
Check the automatic drain trap daily to ensure it is
operating properly.
First and Second Stage Element Replacement
1. Depressurize the filter and remove the filter housing.
2. Remove the element.
3. Clean the inside of the filter housing, if necessary.
4. Install a new element and gaskets
(P/N 02250153-294 FIRST STAGE) 2
(P/N 02250153-305 SECOND STAGE) 3 SU_0000680
5. Reassemble the unit and check for air leaks.

6. Record the initial pressure drop when the compressor 1. O-Ring
is started. 2. Filter Element
3. Filter Housing
Safety
Toxic And Irritating Substances Figure 5-7: First and Second Stage Discharge Air
Filter (Optional)
WARNING
These filters will not remove water vapor, oil vapor, carbon
Death or serious injuries can result monoxide, or other toxic gases.
from inhaling compressed air without The first stage filter efficiently removes contaminants such
using proper safety equipment. (See as ash, dust, water aerosols, lubricant mist, carbon
applicable OSHA Standards) particles, rust and other contaminants (0.3 microns and
larger).
The second stage filter removes particulates and all
DO NOT use air from this filter as a source for respiration lubricant aerosols of 0.01 micron size and larger.
(breathing air) except when in compliance with OSHA
STANDARDS 29 CFR 1910, and all other applicable Design Ratings
Federal, state, or local codes or regulations. Design ratings are 150°F (66°C) maximum air inlet
temperature. All welded filter housings are ASME code
stamped for 250 psig (17.3 bar) maximum working
pressure.

SECTION 5
5.9 Trouble Shooting Always:

1. Check for loose wiring or connections.
The following Trouble Shooting chart is based upon data
obtained from factory tests and information from the field. 2. Check for damaged piping.
It lists symptoms, probable causes and remedies. This 3. Check for heat damage to parts (electrical short
chart does not cover all possible malfunctions or cases of circuits can cause heat damage) which can appear as
abnormal operation. Before undertaking repairs or discolorations or the presence of a burnt odor.
replacement actions, analyze all of the available data.
If the troubleshooting remedy does not work, or the
Performing a detailed visual inspection in all cases can malfunction is not covered in this Trouble Shooting chart,
prevent additional damage or abnormal operation. contact your nearest Sullair representative or Sullair for
technical assistance.
ENGINE DOES NOT CRANK OR CRANKS BUT DOES NOT START

SYMPTOM PROBABLE CAUSE REMEDY
NO SSAM FLASH CODE Low voltage or battery disconnected Check battery cables and tighten if loose
Check ground wire for proper attachment
to frame. Tighten if required.
Recharge or replace battery if required.
Blown fuse in wiring harness Remove and inspect fuse. Replace if
necessary.
Instrument panel connectors loose or Check instrument panel connectors and
disconnected. reattach if required
Check instrument panel wires for broken
connections or corrosion. Clean and/or
replace if damaged.
Faulty SSAM module Replace the module
SSAM FLASH CODE: ONE FLASH Compressor temperature switch is open Check wiring connection to the switch and
tighten if loose
Check switch continuity to ground and
replace if necessary
If the compressor feels hot see
COMPRESSOR OVERHEATING trouble
shooting procedure
SSAM FLASH CODE: TWO FLASHES Engine coolant temperature switch is Check wiring connection to the switch and
open tighten if necessary
Check switch continuity to ground and
Cooling air flow is insufficient Clean cooler and check for proper
ventilation
Loose or broken fan belt Check fan belt and tighten or replace if
necessary
Engine problems might be present Refer to the Engine Operator’s Manual
No engine coolant Fill with proper water/glycol mixture as
required
SSAM FLASH CODE:THREE FLASHES Engine oil pressure switch is open Check wiring conne ction to switch and
tighten if necessary
Install gauge in parallel with the switch.
Replace the switch if the pressure
exceeds 15 psig and stays open. If the
pressure is less than 15 psig, refer to the
Engine Operator’s Manual.

MAINTENANCE
ENGINE DOES NOT CRANK OR CRANKS BUT DOES NOT START

SSAM FLASH CODE:FOUR FLASHES Did not start compressor within the 30 After turning the ignition switch to the ON
seconds from turning the ignition switch to position, press the switch to the START
the ON position position within 30 seconds
Low battery voltage Check the battery cables and tighten if
necessary
Recharge or replace battery if necessary
No fuel Refuel
Water or dirt in the fuel and/or filter Drain water from the fuel/water
separators on the fuel filters. Siphon
water from the fuel tank and clean the
tank if necessary
Plugged air filter Clean and replace if necessary
Plugged fuel filter Replace the fuel filter
Starter solenoid relay does not engage Check wiring and tighten all connectors
Replace relay
No input frequency from alternator Check alternator “W” terminal (7.5 ± 2.50
VAC greater than 300 HZ)
SSAM FLASH CODE: FIVE FLASHES No fuel Check fuel level and fill tank if empty
Defective fuel switch Replace switch
COMPRESSOR SHUTS DOWN

NO FLASH CODE: Blown fuse in wiring harness Remove/inspect fuse and replace if
necessary
Instrument panel connectors loose or Check instrument panel connectors and
disconnected reattach if required
Check instrument panel wires for broken
connections or corrosion. Clean and/or
replace if required
Faulty SSAM module Replace the SSAM module
SSAM FLASH CODE: ONE FLASH Compressor temperature switch is open Check wiring connection to switch and
tighten as required
Check switch continuity when cool and
Cooling air flow is insufficient Clean the cooler and check for proper
ventilation
Low compressor receiver tank fluid level Add fluid as required

Clogged compressor fluid filter Change the filter element
Faulty thermostat Change the thermostat element
Loose or broken fan belt Check the fan belt and tighten or replace
if necessary
Plugged fluid cooler tube (internal) Replace the cooler

SECTION 5
COMPRESSOR SHUTS DOWN

Compressor does not achieve Run/start switch not in run position For compressors with idle warm-up
full discharge pressure controls, switch toggle to RUN for full
operation
Air demand is excessive Check service lines for leaks or open
valves
Dirty air filter Check the filter and change the element if
required
Defective pressure regulator Check the diaphragm and replace with Kit
if necessary
Defective idle warm-up control Replace control
Improper unloading with an Pressure regulating valve is set too high Readjust
excessive pressure build-up Control system leak causing loss of Check control lines
causing the pressure relief pressure signal
valve to open Defective pressure regulating valve.
Repair valve (kit available)
Inlet valve jammed Free or replace valve
Restriction in the control system Check all control lines and components—
ice and/or other contaminants could be
the cause
Defective pressure relief valve opens Replace the pressure relief valve
when pressure is too low
Defective pressure regulator Check the diaphragm and replace with Kit
if necessary
Insufficient air delivery Run/start switch not in run position For compressors with idle warm-up
controls, switch toggle to RUN for full
operation
Plugged air filter Replace
Defective idle warm-up control Replace control
Plugged air/fluid separator Replace separator element and also
change compressor fluid and fluid filter
Defective pressure regulator Adjust or repair
Engine speed too low Readjust engine speed
Excessive compressor fluid Clogged return line Clear orifice and return line strainer
consumption Lubrication system leak Check all pipes, connections and
components
Separator element damaged or Change separator element
malfunctioning

MAINTENANCE
Compressor shuts down

COMPRESSOR OVERHEATING Low receiver tank fluid level Fill receiver tank
Loose or broken fan belt Tighten or replace belt
Dirty fluid cooler core Clean core thoroughly
Plugged compressor fluid filter Change element
Faulty thermostat Change thermostat element
Plugged fluid cooler tube (internal) Replace cooler
ENGINE OVERHEATING Loose or broken fan belt Tighten or replace belt
Dirty radiator core Clean thoroughly
Low fluid level Refill
Faulty water pump Change pump
Plugged radiator Clean and flush thoroughly
Defective engine thermostat Replace

SECTION 5
THIS PAGE INTENTIONALLY LEFT BLANK

Section 6
NOISE CONTROL
6.1 Noise Emissions Warranty 2. The use of the compressor after such device or
element of design has been removed or rendered
Sullair Corporation warrants to the ultimate purchaser and inoperative by any person.
each subsequent purchaser that this air compressor was
designed, built and equipped to conform at the time of sale Among those acts included in the prohibition against
to the first retail purchaser, with all applicable U.S. E.P.A. tampering are the acts listed below:
and/or any Federal, State or Local noise control regulations.
1. Removal or rendering inoperative any of the following:
This warranty is not limited to any particular part, a. Engine exhaust system or parts thereof
component, or system of the air compressor. Defects in the b. Compressor air intake system or part thereof
design, assembly, or in any part, component, or system of
the compressor which, at the time of sale to the first retail c. Enclosure of part thereof
purchaser, caused noise emissions to exceed Federal
2. Removal of any of the following:
standards are covered by this warranty for the life of the air
compressor. a. Vibration isolators
b. Control silencer
6.2 Tampering with the c. Floor panel
Noise Control System is d. Fan shroud
Prohibited e. Acoustical materials including fiberglass foam or
foam tape
Federal Law prohibits the following acts or the causing
thereof: 3. Operation with canopy doors open for any purpose
1. The removal or rendering inoperative by any persons, other than starting, stopping, adjustment, repair,
other than for purposes of maintenance, repair, or replacement of parts or maintenance.
replacement, of any device or element of design
incorporated into any new compressor for the purpose
of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use.

SECTION 6
6.3 Noise Emissions Maintenance and Maintenance Record Log

The following instructions and maintenance record log
book, for the proper maintenance, use and repair of this
compressor, is intended to prevent noise emission
degradation.
Noise Emission Maintenance and Maintenance Record Log

1. ANNUAL MUFFLER AND EXHAUST SYSTEM INSPECTION
At least annually inspect muffler(s) and engine exhaust system to make sure all parts are securely mounted, that all joints and
connections are tight, and that the muffler is in good condition. DO NOT operate compressor with defetive exhaust system. Remove
and replace any defective parts by ordering with part numbers indicated in the Parts List.
Maintenance Performed
By
Location
Date
By
Location
Date
2. ANNUAL AIR FILTER(S) AND AIR INLET SYSTEM INSPECTION

In addition to the instructions in the Maintenance section of the Operator’s Manual, the air filter(s) and entire air inlet system should
be inspected at least annually, to make sure all parts are securely mounted, that all joints and connections are tight, that there are no
other leaks in the system, and that the filter element(s) are intact. DO NOT operate compressor with defective air inlet system.
Remove and replace defective parts by ordering with part numbers indicated in the Parts List.
By
Location
Date
By
Location
Date

NOISE CONTROL
3. ANNUAL ENGINE VIBRATION MOUNT INSPECTION

At least annually inspect engine vibration mounts for security of attachment and to make sure the resilient parts are intact. DO NOT
operate compressor with defective engine mounting system. Remove and replace defective parts by ordering with part numbers
indicated in Parts List.
By
Location
Date
By
Location
Date
4. ANNUAL FRAME, CANOPY, AND PARTS INSPECTION
At least annually inspect frame, canopy and parts, for security of attachment. Make sure there are not any missing or deformed members,
including all hinged doors, covers and their fastening devices. DO NOT operate compressor with defective frame, canopy and parts. Remove
and replace defective parts by ordering with part numbers indicated in Parts List.
By
Location
Date
By
Location
Date
5. ANNUAL ACOUSTICAL MATERIALS INSPECTION

At least annually inspect all acoustical materials, if any, for security of attachment. Make sure that there is not any material missing or
damaged (refer to Parts List). Clean or replace, if necessary. DO NOT operate compressor with defective acoustical material. Remove
and replace defective parts by ordering with part numbers indicated in the Parts List.
By
Location
Date
By
Location
Date

SECTION 6
6. ANNUAL INSPECTIONS FOR PROPER OPERATION OF ALL SYSTEMS.

In addition to other instructions in the Operator’s Manual, at least annually, operate compressor and inspect to make sure all
systems are operating properly and that engine runs at rated speed and pressure. DO NOT operate malfunctioning or improperly
adjusted compressor. Repair or adjust, per instructions in Operator’s Manual, as required.
By
Location
Date
By
Location
Date

Section 7
ILLUSTRATIONS AND
PARTS LIST
7.1 Procedure For Ordering When ordering parts always indicate the Serial Number of
the compressor. This can be obtained from the
Parts compressor’s bill of lading or the Serial Number Plate on
the front of the compressor (see Figure 7-1).
Parts should be ordered from the nearest Sullair
representative or the representative from whom the
compressor was purchased. If parts cannot be obtained
from these sources, contact the factory directly at the
addresses, fax or phone numbers listed on following
page.
SU_0000675
Figure 7-1: Serial Number Plate Location

SECTION 7

ILLUSTRATIONS AND PARTS LIST
7.2 Recommended Spare Parts List

Key Description Part Number Note Quantity
1 element for air filter assy (primary) 02250164-532 2
2 element for air filter assy (secondary) 02250164-533 2
3 element for main compressor fluid filter 250025-521 250025-525 1
4 element for air/fluid separator 250034-087 1
5 element for 1st stage discharge filter (aftercooled) 02250153-293 1
6 element for 2nd stage discharge filter (aftercooled) 02250153-304 1
7 element for engine oil filter 02250083-017 1
8 element for engine fluid/water separator 02250118-495 1
9 element for final fuel filter 02250083-016 1
10 repair kit for thermal valve 02250113–796 044583 1
11 repair kit for flange SAE O-ring 02250099-416 1
12 repair kit for pressure regulator valve 250017-280 250019-453 1
13 repair kit for inlet valve 250026-779 250029-249 1
14 repair kit for return line strainer 241771 241772 1
15 repair kit for minimum pressure/check valve 02250094-294 250019-444 1
16 repair kit for shaft seal 602541-002 1
17 repair coupling assemblies (375) 250031-586 1
18 repair coupling assemblies (300HH, 375H, & 425 ) 250024-470 1
19 Sullair AWF (5 gallons/18.9 liters) 250030-757 1
20 Sullair AWF (55 gallon drum/208 liters) 250030-758 1
21 manual, CIMA safety 250023-146 1
22 manual, Portable Component Service 02250056-343 1
23 repair kit for regulator/blowdown valve manifold 02250147-737 1
NOTE
When ordering parts, indicate the
serial number of the compressor.

SECTION 7
7.3 Engine, Compressor And Parts
02250170-256-r00

7.3 Engine, Compressor And Parts (Continued)

1 valve, drain eng oil 19mm x 1.50 02250051-231 1
2 key,shaft step 375h 02250053-263 1
3 elbow,check valve 1/4t x 1/8p 02250058-275 1
4 spacer, brake lever 250p 02250064-594 1
5 washer, rtnr ctl cyl spring 5/16" 02250078-842 1
6 conn, female pipe 1/8-27 npt 02250097-138 1
7 tee,m run 3/8"tube x 1/4"npt 02250099-615 1
8 fan,blower 25" 300h-425 cat 02250115-570 1
9 spacer, speed cyl mtg 375 jd 02250123-876 1
10 spring, ext 3"lg 4.5lb/in 02250124-918 1
11 washer, snubbing vibration mount 02250125-471 4
12 mount, vibration isolator 375 02250125-473 4
13 support, engine front rh cat 02250125-479 1
14 support, engine front lh cat 02250125-480 1
15 washer, snubbing 375 vibration mount 02250125-604 2
16 clamp, t-bolt ss band 3.50"id 02250129-227 1
17 switch, engine oil pressure n.o. 02250130-668 1
18 support, control cyl mnt 375 cat 02250134-715 1
19 sub assembly,control cylinder cat 02250137-006 1
20 clamp, t-bolt ss band 2 1/4"id 02250137-795 3
21 elbow, silicone cac reducing 2 x 3 02250137-802 1
22 hose,rad upper cat 375 tier ii 02250138-190 1
23 hose,rad lower cat 375 tier ii 02250138-191 1
24 pipe,cac hot/upper cat t2 02250138-194 1
25 switch, engine hi-temp 225f nc 1/2npt 02250138-450 1
26 clamp, 2"id high temp 02250140-362 1
27 elbow, silicone cac 2" id x 45 deg 02250145-483 1
28 coupling, assembly ringfedder ac-t4.1 02250146-634 1
29 tube,cac hot sd 375 cat t3 02250164-546 1
30 strap,cac pipe supt 375 ca t3 02250166-753 1
31 sub assembly,control orifice 375h cat t2 exp 02250169-278 1
32 clamp, hose 1 5/16" to 2 1/4" adj. 040014 1
33 clamp, hose 1 13/16" x 2 3/4" adj. 040083 3
34 clamp, hose 13/16" to 1-1/2" 040513 1
35 gasket, 1/32 x 5 1/4odx4 1/8id 040708 1
36 connector,1/4t x 1/4 npt str 250018-428 1
37 adapter, eng-compr 375 jd 250022-732 1
38 valve, air inlet 4" 375 dpq 250026-779 1
39 bushing,taper-loc 2517 1.93id 407848 1
40 nut,hex f pltd 1/4-20 825304-236 1

SECTION 7
02250170-256-r00


41 nut,hex locking 1/4-20 825504-145 3
42 nut,hex locking 5/8-11 825510-329 2
43 capscrew,hex 8.8 m6 x 16mm 828006-016 1
47 capscrew,hex gr5 3/8-16 x 1 1/4 829106-125 8
48 capscrew,hex gr5 1/2-13 x 1 829108-100 10
49 capscrew,hex gr5 1/2-13 x 1 1/2 829108-150 4
50 capscrew,hex gr5 1/2-13 x 4 829108-400 2
51 capscrew,hex gr5 5/8-11 x 3 1/2 829110-350 2
52 screw, hex ser washer 1/4-20 x 3/4 829704-075 2
53 washer, spr lock reg pltd 1/2 837808-125 6
54 washer, pl-b reg pltd 5/8 838210-112 2
55 washer, spr lock-metric pltd m6 838806-160 1
58 hose,heater 1/2" (ft) 842115-050 1
59 washer, metric-iso7089- 10 865410-210 12
60 nipple,pipe-xs plt 1/8 x cl 866402-000 1
61 tee, pipe 150# plt 1/8 866815-005 1
62 bushing,red pltd 1/4 x 1/8 867100-005 1
63 capscrew, ferry head hd pltd 1/4-20 x 1 1/4 867304-125 1
64 capscrew, ferry head hd pltd 1/4-20 x 1 1/2 867304-150 1
65 washer, nord-lock pl 1/2" 878608-077 4
66 engine, diesel cat mech 108hp 375 t2 Consult Factory 1
67 unit,16 series 375 Consult Factory 1

SECTION 7
7.4 Radiator & Compressor Fluid Cooling System
A1
A2
A3
02250166-333R02-CAT

7.4 Radiator & Compressor Fluid Cooling System (Continued)

1 bucket, radiator fluid recovery 02250083-466 1
2 hose, mp 1" x 48" lg 02250088-283 2
3 elb, 90 sae x orfs 1.25" x 1.00" 02250093-804 1
4 filter, fluid 1 5/8 sae str thrd co 02250096-783 1
5 housing, thermo vlv leak free 375 02250113-796 1
6 support, oil filter thrmo-vlv 375 02250114-008 1
7 plate, access 375 after clr 02250116-321 1
10 support, cooler assy 375 dpq 02250119-030 2
12 hose, mp orfs f-swvl 1" 02250135-593 1
13 support, cooler center brace 02250137-235 1
14 clamp, t-bolt ss band 2 1/4"id 02250137-795 4
15 cooler, oil 375 jd/cat tier ii 02250137-798 1
16 radiator, 300h-425q jd/cat tier ii 02250137-799 1
17 cooler, cac 375 jd/cat tier ii 02250137-800 1
18 adapter, cac pipe 2"id x 6"lg 02250138-196 2
19 baffle, clrs. r.h. 375-425 t3 02250164-454 1
20 baffle, clrs. lh 375-425 t3 02250164-455 1
21 baffle, clrs bottom 375-425 t3 02250164-456 1
22 baffle, clrs top 375-425 t3 02250164-457 1
23 shroud, fan 26" 375-425 jd t3 02250164-458 1
25 plug, finishing 2.5" steel 02250164-475 2
26 guard, fan 28" 375-600t3 02250164-542 1
27 drainlock, 1/4" 040061 1
28 grommet, rubber 1" hole 040162 1
29 element, thrm vlv (155 deg f) 044583 1
30 clamp, hose 3/8" 047235 1
31 grommet, rubber 1-3/4" hole 250020-358 1
32 weatherstrip, 1" thick x 1" wide (ft) - 250041-174 7
33 nut, hex f pltd 1/4-20 825304-236 8
34 nut, hex f pltd 5/16-18 825305-283 19
35 capscrew, hex gr5 5/16-18 x 3/4 829105-075 4
36 capscrew, hex gr5 5/16-18 x 1 829105-100 3
40 screw, hex ser washer 5/16-18 x 1 829705-100 20

SECTION 7
A1
A2
A3
02250166-333R02-CAT


43 hose, fuel line 5/16 (ft) 842315-031 3
44 nut, retainer 5/16-18 .092 861405-092 5
45 reducer, str thrd viton 1 1/4 x 1 870020-016 2
46 connector, straight x jic 1 5/16 x 1 5/16 870116-016 2
47 connector, 45 deg str x jic 1 5/16 x 1 5/16 870516-016 1
48 connector, 90d str x jic 1 5/16 x 1 5/16 870616-016 1
49 union, straight thrd 1 5/16-12 871316-131 1
50 tee, run 37fl str thd 1 5/16-12 871916-131 1
A1 Overflow to bottom of frame.

A2 To unit fluid supply.
A3 Air fluid separator tank assembly (reference).
NOTE: For connection “D” to “D” use clear plastic tubing and clamps supplied with overflow bottle.

SECTION 7
7.5 Air Inlet System & Exhaust System
02250166-339R00

7.5 Air Inlet System & Exhaust System (Continued)

1 elbow, 90m 5/16"tube x 1/8"npt 02250109-423 1
2 gasket, exht ca3054na 185q 02250110-425 1
3 tube,exhaust 375-425 cat 02250115-010 1
4 muffler, exhaust 300h-425 ft mtg 02250115-201 1
5 hose, air inlet eng (part 1) 02250140-336 1
6 tube, aluminum 3.5"od x 4"lg 16ga 02250140-363 1
10 tube,exhst ext 375-600q t3 02250164-526 1
11 elbow,air inl compr 375-600 t3 02250164-530 1
12 filter, air inl 375-600 cfm 02250164-531 2
13 support, air fltrs 375 t3 02250164-534 1
14 hose,eng inl 375 t3 02250164-547 1
15 clamp, t-bolt ss band 5.50"id 042324 1
16 clamp. exhaust 3" 043713 2
17 cap, rain exhaust 3" 047208 1
18 nut,hex f pltd 5/16-18 825305-283 7
19 capscrew,hex gr5 3/8-16 x 1 829106-100 3
21 screw, hex ser washer 5/16-18 x 1 1/4 829705-125 4
24 bulkhead, pipe 1/8" npt 841500-002 2
25 plug, pipe 1/8" 3000# stl plt 866900-005 1

SECTION 7
7.6 Control Parts & Discharge Parts - 375 and 425
02250170-257-r02

7.6 Control Parts & Discharge Parts - 375 and 425 (Continued)
1 valve, relief 1"npt x 1 1/4"fnpt 200psig 02250047-679 1
2 insert, nylon tubing 1/4"od 02250052-841 4
3 tube,nyl .25 od x 040w wht(ft) 02250054-860 4
4 tube,nyl .25 od x .040w blk (ft) 02250054-861 3
5 tube,5/16 od x .040 wall 02250081-220 3
6 plug,sight glass 1-7/8" sae 02250097-611 1
7 insert, nyl tubing 3/8"od 02250099-052 8
8 flange, kit sae splt 2.5" - viton 02250099-416 (I) 2
9 elbow, 90 3/8"tube x 1/4"npt m 02250099-626 1
10 valve, relief 1 x 1-1/4 250 psig 02250111-740 1
11 sub assembly,service valves std 375-425 02250118-603 (II) 1
12 connector, tube oil return 5/16x1/4 02250118-809 1
13 hose, air service std 375 02250119-080 1
14 valve, 1 1/2" npt min press chk 02250121-558 1
15 valve, ball 2-way 1/8"npt 90deg 02250130-629 1
16 switch, temp n.c. 250 sf, single pole 02250133-513 1
17 tbg, nylon 3/8"od red 02250139-950 3
18 tbg, nylon 3/8"od yellow 02250139-951 4
19 tbg, nylon 3/8"od blue 02250139-953 2
20 tbg, nylon 3/8"od orange 02250139-954 3
21 hose,discharge 375-600 dpq 02250164-548 1
22 pnl frm frt 375-600 t3 02250164-704 (III) 1
23 support, reg/bd assy 375-600 t3 02250166-243 1
24 sub assembly,reg/bd assy 375 cat t2 exp 02250169-280 (IV) 1
25 tank, air/oil sep 300hh-600 02250170-513 1
26 plug,o-ring boss sae 1 1/4 040029 1
27 strainer, v-type 300psix1/4 241771 1
28 tube,steel 5/16"od oil siphon 250009-253 1
30 elbow, 90 1/4"tube x 1/8"npt 250018-429 1
31 element,oil sep 8.81 x 11.18 250034-087 1
32 washer, .625 hardened 250040-100 8
33 tee, m run 1/4t plsx 1/8npt 250041-088 1
34 plug,str thd 3/4-16 sae vit 250042-623 1
35 connector,tube-male 5/16 x 1/4 812205-025 1
36 capscrew,hex gr8 1/2-13 x 1 3/4 828208-175 4
37 capscrew,hex gr5 5/8-11 x 1 3/4 829110-175 8
39 washer, pl-b reg unfin 1/2 837208-112 4
40 washer, spr lock 1/2 837508-125 4

SECTION 7
02250170-257-r02

42 elbow, 37fl 90m 1 1/2 x 1 1/2 860224-150 1
43 nipple,pipe-xs plt 1 x cl 866416-000 1
44 nipple,pipe-xs plt 1 1/2 x cl 866424-000 1
45 nipple,pipe-xs plt 1 1/2 x 6 866424-060 1
46 bushing,red pltd 1 1/2 x 1 867106-040 1
47 elbow, pipe 45 deg 300# plt 1 1/2" 869430-060 1
48 connector,90d str x jic 1 5/16 x 1 5/16 870616-016 1
A - SHOWN 3/8" OD TUBING BLUE

B - TO START RUN VALVE (END TEE) 3/8 OD TUBING RED
C - TO UNIT OIL RETURN PORT 1/4" OD TUBING WHITE
D - TO START RUN VALVE (SIDE) PORT 3/8" OD TUBING ORANGE
E - TO TEE AT INLET VALVE 3/8" OD TUBING YELLOW (FROM TEE TO
SPEED CYLINDER)
G - TO INLET VALVE HOSE 5/16" OD WHITE
H - TO UNIT (BELOW INLET VALVE) 1/4 BLACK
(I) Replacement o-ring part number 826502-232

(II) See page 74
(III) For color variations consult factory
(IV) See page 68

SECTION 7
7.7 Control Parts & Discharge Parts - 300HH and 375H
02250170-258-r02

7.7 Control Parts & Discharge Parts - 300HH and 375H (Continued)
1 valve, relief 3/4" x 1 1/4"fnpt 02250047-678 1
2 insert, nylon tubing 1/4"od 02250052-841 4
3 tube,nyl .25 od x 040w wht(ft) 02250054-860 4
4 tube, nylon .25"od x .04w black (ft) 02250054-861 4
5 tube,5/16 od x .040 wall 02250081-220 4
6 plug,sight glass 1-7/8" sae 02250097-611 1
7 insert, nyl tubing 3/8"od 02250099-052 8
8 flange, kit sae splt 2.5" - viton 02250099-416 (I) 2
9 elbow, 90 3/8"tube x 1/4"npt m 02250099-626 1
10 valve, relief 1 x 1-1/4 250 psig 02250111-740 1
11 sub assembly,service valves std 375-425 02250118-603 (II) 1
13 hose, air service std 375 02250119-080 1
14 valve, 1 1/2" npt min press chk 02250121-558 1
15 valve, ball 2-way 1/8"npt 90deg 02250130-629 2
16 switch, temp n.c. 250 sf, single pole 02250133-513 1
17 tbg, nylon 3/8"od red 02250139-950 2
18 tbg, nylon 3/8"od yellow 02250139-951 6
19 tbg ,nylon 3/8"od green 02250139-952 2
20 tbg, nylon 3/8"od blue 02250139-953 2
21 hose,discharge 375-600 dpq 02250164-548 1
22 pnl frm frt 375-600 t3 02250164-704 (III) 1
23 support, reg/bd assy 375-600 t3 02250166-243 1
24 sub assembly,reg/bd vlv 375h cat t2 exp 02250168-639 (IV) 1
25 sub assembly,control orifice 375h cat t2 exp 02250169-278 (V) 1
26 tank, air/oil sep 300hh-600 02250170-513 1
27 plug,o-ring boss sae 1 1/4 040029 1
28 strainer, v-type 300psix1/4 241771 1
29 tube,steel 5/16"od oil siphon 250009-253 1
31 elbow, 90 1/4"tube x 1/8"npt 250018-429 2
32 element,oil sep 8.81 x 11.18 250034-087 1
33 washer, .625 hardened 250040-100 8
34 tee, m run 1/4t plsx 1/8npt 250041-088 2
35 plug,str thd 3/4-16 sae vit 250042-623 1
36 connector,tube-male 5/16 x 1/4 812205-025 1
37 capscrew,hex gr8 1/2-13 x 1 3/4 828208-175 4
38 capscrew,hex gr5 5/8-11 x 1 3/4 829110-175 8
40 washer, pl-b reg unfin 1/2 837208-112 4

SECTION 7
02250170-258-r02

41 washer, spr lock 1/2 837508-125 4
43 elbow, 37fl 90m 1 1/2 x 1 1/2 860224-150 1
44 nipple,pipe-xs plt 1 x cl 866416-000 1
45 nipple,pipe-xs plt 1 1/2 x cl 866424-000 1
46 nipple,pipe-xs plt 1 1/2 x 6 866424-060 1
47 bushing,red pltd 1 x 3/4 867104-030 1
48 bushing,red pltd 1 1/2 x 1 867106-040 1
50 connector,90d str x jic 1 5/16 x 1 5/16 870616-016 1
A - SHOWN REGULATORS TO TANK 3/8" OD TUBING BLUE

B - SHOWN START RUN VALVE (END TEE) TO REG BLOCK 3/8 OD TUBING RED
C - TO UNIT OIL RETURN PORT 1/4" OD TUBING WHITE
D - SHOWN START VLV SIDE PORT TO HI-LOW VLV END PORT TEE 3/8" OD ORANGE
E - SHOWN INLET CONTROL ORFICE TO REG. ASSY 3/8" OD TUBING YELLOW (FROM
TEE TO SPEED CYLINDER)
G - TO INLET VALVE HOSE 5/16" OD WHITE
H - TO UNIT (BELOW INLET VALVE) 1/4 BLACK
J - SHOWN HI-LOW VLV(END PORT TEE) TO REG SA 3/8" OD TUBING GREEN
K - SHOWN HI-LOW VLV(SIDE PORT) TO TO REG SA 3/8" OD TUBING YELLOW
(I) Replacement o-ring part number 826502-232

(II) See page 74
(III) For color variations consult factory
(IV) See page 70
(V) See page 72.

SECTION 7
7.8 Regulator/Blowdown Valve - 375 And 425
02250169-281-r01

7.8 Regulator/Blowdown Valve - 375 And 425 (Continued)

1 connector,5/16" tube x 1/4" npt 02250081-219 1
2 tee,m run 3/8" tube x 1/4" npt 02250099-615 1
4 manifold, regulator blowdown 185 02250146-046 (I) 1
6 elbow, 1/4" tube x 1/4" npt 250018-430 1
(I) For maintenance on regulator blowdown manifold, order repair kit number 02250147-737.

SECTION 7
7.9 Regulator/Blowdown Valve - 300HH and 375H
02250168-640-r01

7.9 Regulator/Blowdown Valve - 300HH and 375H (Continued)

1 connector,5/16"tube x 1/4"npt 02250081-219 1
3 elbow, 90 3/8"tube x 1/4"npt m 02250099-626 2
4 connector,3/8 tube x 1/4npt 02250148-188 1
5 manifold, press reg/bd 150psi 185h 02250151-201 (I) 1
6 valve, pressure regulator 250017-280 (II) 1
7 elbow, 1/4" tube x 1/4" npt 250018-430 1
8 tee, pipe 150# plt 1/4 866815-010 1
10 nipple,pipe-hx pltd 1/4 x 1/4 868504-025 2
(I) For maintenance on regulator blowdown manifold, order repair kit number 02250147-737
(II) For maintenance on pressure regulator valve, order repair kit number 250019-453.

SECTION 7
7.10 Control Parts Orifice - 300HH and 375H
02250169-279-r00

7.10 Control Parts Orifice - 300HH and 375H (Continued)

1 orifice,ctl .078 1/8 fnpt x 1/8 mnpt 02250069-264 1
3 silencer, air ejection 1/8"npt-male thread 248755 1
4 tee, pipe 150# plt 1/4 866815-010 1
6 nipple,pipe-hx pltd 1/4 x 1/4 868504-025 1

SECTION 7
7.11 Service Valves
02250118-602R02

7.11 Service Valves (Continued)

1 valve, double ball 3/4" x 1" 250019-916 1
2 coupling, 3/4" female npt 040383 2

SECTION 7
7.12 Optional AfterCooler/Filter And Parts
A1
A2
A4 A3
02250166-353R02

7.12 Optional AfterCooler/Filter And Parts (Continued)

1 valve, blowdown 1/4 npt hi prs 02250049-634 1
2 hose, medium pressure 250psi 1.5" x 38" fjic 02250051-446 1
3 tube, nyl .25 od x .040w blk (ft) 02250054-861 39
4 tube, nylon .375" od x .050w black (ft) 02250099-630 6
5 valve, ball 3-wat 1-1/2 fnpt 02250118-872 1
6 hose, aftr clr to sep 375 48" 02250119-082 2
7 hose, air 3-way to manifold 375 02250119-083 1
8 support, after cooler filters 02250142-733 1
9 cooler, air to air 300h-375 02250142-958 1
10 hose, mpress 1-1/2 x 25" 02250119-083 1
11 connector, 3/8 tube x 1/4npt 02250148-188 1
12 filter, scf-465n 1 1/4" npt w/auto drains 02250153-038 1
13 filter, sch-465n 1 1/4" npt w/auto drains 02250153-062 1
14 kit, auto drain sc filters 02250153-280 1
15 kit, sc head clmp 340-700 02250153-286 2
16 kit, sc mounting bracket 340-700 02250154-587 2
17 separator, water scws-740n 1 1/2" l/ad 02250166-741 1
18 support, manf ac drains 375 t3 02250167-724 1
19 manifold, tubing push-in 1/4 & 3/8 02250167-725 1
20 plug, 1/4" push-in plastic 02250167-726 4
21 orifice, ctl .031 1/8 fnpt x 1/8 mnpt 025690 2
22 orifice, ctl .094 1/8 fnpt x 1/8 mnpt 250014-060 1
23 conn, 1/4" tube x 1/8" npt 250018-427 1
24 elbow, 90 1/4" tube x 1/8" npt 250018-429 2
25 elbow, 90 1/4t pls x 1/4 npt m 250018-430 1
26 connector, straight 1/4t plsx 1/4npt f 250041-084 2
27 clamp, hose 1 3/8" i.d. 408300-008 1
28 nut, hex f pltd 5/16-18 825305-283 5
29 nut, hex locking #10-24 825502-083 2
30 capscrew, hex gr5 5/16-18 x 3/4 829105-075 1
31 capscrew, hex gr5 5/16-18 x 1 829105-100 1
36 elbow, 37fl 45m 1 1/2 x 1 1/2 860024-150 3
37 connector, 37 fl/mpt pltd 1 1/2 x 1 1/2 860124-150 2
38 elbow, 37fl 90m 1 1/2 x 1 1/2 860224-150 4
39 nipple, pipe-xs plt 1/4 x cl 866404-000 1
40 nipple, pipe-xs plt 1 1/2 x cl 866424-000 2
41 nipple, pipe-xs plt 1 1/2 x 3 1/2 866424-035 1
42 nipple, pipe-xs plt 1 1/2 x 8 866424-080 2

SECTION 7
A1
A2
A4 A3
02250166-353R02


44 bushing, red pltd 1/4 x 1/8 867100-005 1
45 bushing, red pltd 1 1/2 x 1/4 867106-010 1
46 coupling, pipe 1/4 300# plt 867430-010 1
47 tee, pipe pltd 1 1/2 868430-060 2
49 screw, rnd phillips 10-24 x 1 1/4" 876002-125 2
A1 To min. pressure valve

A2 Mounted on frame near receiver
A3 Used with aftercooler less filters option
A4 From tee fitting below inlet valve

SECTION 7
7.13 Electrical Parts
02250170-262-r00

7.13 Electrical Parts (Continued)

1 channel, extruded rubber “u” .25"w (ft) 02250086-448 2
2 washer, external serrated m10 02250092-169 2
3 cable, ground 4-gauge strap 02250101-258 1
4 battery, grp 31 hi cap taper post 02250114-276 1
5 lamp,license plate std 02250119-658 1
6 harness, 6-wire lites 375 02250119-673 1
7 bracket, license plate lamp 02250119-678 1
8 relay, 12-volt 40-amp 1no/1nc 02250141-092 2
9 relay, 12-volt 50-amp 1no/1nc 02250144-353 1
10 cable,battery red 54" 1ga 02250144-784 1
11 frame, assy 375-600 q t3 02250164-386 1
12 bail,lifting 375 t3 02250164-550 1
13 chnl, batt hold dwn 375-600t3 02250164-692 1
14 panel,batt cvr/baff 375-600t3 02250164-693 1
15 pnl frm rear 375-600 t3 02250164-958 (I) 1
16 grommet,rubber 1" hole 040162 1
17 nut,plastic square license plate 250006-076 4
18 cable,battery 50"lg black 250019-551 1
19 lamp,tail/turn/stop (shock mtg) 250028-415 2
20 clamp, hose 9/16"id 408300-001 1
21 nut,hex f pltd 1/4-20 825304-236 3
22 nut,hex f pltd 5/16-18 825305-283 4
23 nut,hex locking #10-24 825502-083 2
27 screw, mach-rd hd #10-24 x 3/4 831602-075 2
28 wrap,tie nylon tf4-8 843200-025 4
29 rod,threaded 5/16 x 10" lg 843505-100 2
(I) For color variations consult factory.

SECTION 7
7.14 Instrument Panel & Parts
02250170-259-r01

7.14 Instrument Panel & Parts (Continued)

1 hinge, instrument panel door 185q-8f 02250103-623 1
2 screw,phil pan hd #6-32 x3/8 02250112-009 4
3 catch,locking instrument panel 02250125-511 1
4 door,instrument panel 185 60hp 02250138-181 1
5 inst pnl, cat 375-425 std ga t2 02250154-330* 1
6 can pnl frt lh 375 t3 02250164-807 (I) 1
7 weatherstrip, 3/16 x 3/8 ft 250022-436 3
8 screw, mach phill #10-24 x 1/2 250025-692 8
9 bumper,rubber 1/2 dia 250035-095 2
10 plug, hole n4 1" cond 409918-004 1
11 nut,hex locking #6-32 825500-102 4
12 nut,hex locking #8-32 825501-070 1
13 nut,acorn pltd #8-32 825615-002 2
14 washer, pl-b reg pltd #6 838200-045 4
15 screw,flt phillips 8-32 x 3/4" 875901-075 1
16 screw,rnd phillips 8-32 x 3/8" 876001-038 2
OPTIONAL PANELS (ITEM5)

02250154-330 PANEL, INSTRUMENT 375-425CA STD T2 EXP
02250154-331 PANEL, INSTRUMENT 375H CA STD T2 EXP
02250154-332 PANEL, INSTRUMENT 375 CA FULL T2 EXP
02250154-333 PANEL, INSTRUMENT 375H CA FULL T2 EXP
* P/N 02250154-331 for 300HH and 375H


SECTION 7
02250154-333-r02


1 gauge, pressure air 0-300 2" 02250044-361 1
2 gauge, volt-meter 12 volt 2" 02250044-366 1
3 gauge, temp mech 72" 140-300 sf 02250050-514 1
4 gauge, pressure mech 0-100psi 2" 02250050-516 1
5 hour-meter, 12-24vdc 10000hr 2" 02250050-517 1
7 elbow, 90 3/8"tube x 1/4"npt m 02250099-626 2
8 tube,nylon .375"od x .050w black (ft) 02250099-630 2
9 gauge, temp mech 48" 140-300 sf 02250102-619 1
10 controller, 185/375 shutdown module (ssam) 02250126-682 1
11 lense, cliplite led 02250129-189 1
12 panel, instrument plastic ssam 02250129-190 1
13 decal,dual pressure 185-375 ssam 02250130-630 (I) 1
14 decal,starting aid 185-375 cat 02250130-631 1
15 harness, voltmeter 125-425 jd/cat 02250130-635 1
16 decal,group full gauge (ssam) 02250131-486 1
17 switch, engine ignition 12-volt 02250132-883 1
18 valve, ball 2-way 1/4"npt 02250136-999 2
19 elbow, 90 f 3/8"tube x 1/4"npt 02250137-033 1
20 cover, access ssam molded abs 02250137-265 1
21 harness, wire 375-425 cat tier ii 02250154-329 (II) 1
22 switch, starter push-button 040038 1
23 screw, tc-f rd hd #6-32 x 1/2 835700-050 2
(I) 300HH and 375HH models only

(II) Use P/N 02250144-353 for replacement of glow plug relay, P/N 02250153-875 for replacement of starter relay and P/N
02250155-383 for replacement of shutdown relay.

SECTION 7
7.15 Fuel Tank & Connections
02250170-261-r00

7.15 Fuel Tank & Connections (Continued)

1 adapter,1/2str oring x 1/4 fnpt 02250075-714 2
2 tube,fuel return 1/4" jd 185q 02250102-573 1
3 connector, tube oil return 1/4 x 1/4 02250108-700 1
4 filter, ass’y fuel/water sep 02250118-494 1
5 plug,fuel/water sep 1/2-20 unf 02250118-524 2
7 tube, fuel pick-up 185dpq 60hp 02250139-885 1
8 support, fuel filter cat 375 t2 02250146-051 1
9 adapter, fuel pickup 185 60hp 02250152-163 1
10 plate, fuel outlet cover 02250154-661 1
11 ventilator,fuel tank 02250162-229 1
12 cap, fuel fill buttress thread 02250162-230 1
13 tank, fuel plstc 56 gal 375 02250164-384 1
14 strap, fuel tank mtg 375-600 t3 02250165-197 2
15 connector, hose 5/16"hose x 1/4"npt 043258 1
16 clamp, hose 3/8" 047235 7
17 gasket, fuel gauge neoprene 250004-752 2
18 elbow, 5/16"hose x 1/4"npt 406615 2
19 clamp, hose 7/8"i.d. 408300-004 2
20 nut,hex f pltd 5/16-18 825305-283 7
21 nut,hex locking 5/16-18 825505-166 4
25 washer, spr lock reg pltd #10 837802-047 10
27 hose,fuel line 1/4 (ft) 842315-025 7
28 hose,fuel line 5/16 (ft) 842315-031 5

SECTION 7
7.16 Frame, Axle & Parts And Axle Assembly
02250166-334R02

7.16 Frame, Axle & Parts And Axle Assembly (Continued)

1 reflector, red 3" truck-lite 02250052-701 2
2 reflector, yellow 3" truck-lite 02250052-702 2
3 nut, shackle (dexter 6-7) 02250058-263 2
4 bolt, shackle (dexter 7-17) 02250058-267 2
5 washer, flat hardened 1/2" 02250064-266 8
6 tire, assembly h78-15 st d 02250100-518 2
7 plug, 4" round black plastic 02250106-068 2
8 axle, assembly 300h-425 dpq std 02250116-323 1
9 jack, hd w/pad 185-425 std 02250116-794 1
10 panel, acoustic toolbox 375dpq 02250132-877 1
11 drawbar, std pivot 185dpq 02250133-864 1
12 support, shipping 185 pivot drbar 02250133-984 1
13 support, dr-bar swivel 185q 02250141-183 1
14 fender, 15" wheel 185h-260dpq 02250146-111 2
15 striker, latch frt-bk-sides 185h-260 02250149-684 3
16 frame, assy 375-600 q t3 02250164-386 1
17 bail, lifting 375 t3 02250164-550 1
18 panel, frm rh 375-600 t3 02250164-695 (I) 1
19 panel, frm lh 375-600 t3 02250164-698 (I) 1
20 panel, frm rear 375-600 t3 02250164-701 (I) 1
21 panel, bumper 375-600 t3 02250164-707 (I) 1
22 panel, frm frt 375-600 t3 02250164-704 (I) 1
23 panel, acoustic frm frt 375 t3 02250165-531 1
24 panel, acoustic frm r&l rear 375 t3 02250165-532 2
25 panel, acoustic frm rear 375 t3 02250165-533 1
26 panel, toolbox 375-600 t3 02250165-538 1
27 bolt, keeper (dexter 07-007-00) 040116 2
28 nut, keeper (dexter 06-011-00) 040117 2
29 hanger, front mount 375dpq 045194 2
30 hanger, rear slipper dexter #030-028-03 045195 2
31 eye, 3" lunette demountable - 250002-221 1
32 chain, 3/8" x 71" w/2 hks pltd 250018-492 1
33 nut, hex f pltd 5/16-18 825305-283 18
34 nut, hex locking #8-32 825501-070 4
35 nut, hex locking #10-24 825502-083 6
36 nut, hex locking 1/2-13 825508-262 2
37 nut, hex locking 5/8-11 825510-329 3
38 capscrew, hex gr5 1/2-13 x 1 1/4 829108-125 3
39 capscrew, hex gr5 1/2-13 x 1 1/2 829108-150 14
40 capscrew, hex gr5 5/8-11 x 4 3/4 829110-475 3

SECTION 7
02250166-334R02


46 nut, retainer 5/16-18 .092 861405-092 15
47 capscrew, hex gr5 1/2-13 x 1 1/4 plt 875608-125 8
48 screw, flt phillips 8-32 x 3/4" 875901-075 4
49 screw, rnd phillips 10-24 x 3/4" 876002-075 6

SECTION 7
7.17 Axle Assembly
02250116-323R01

7.17 Axle Assembly (Continued)

1 hinge, instrument panel door 185q-8f 02250103-623 1
2 screw,phil pan hd #6-32 x3/8 02250112-009 4
3 catch,locking instrument panel 02250125-511 1
4 door,instrument panel 185 60hp 02250138-181 1
5 inst pnl, cat 375-425 std ga t2 02250154-330* 1
6 can pnl frt lh 375 t3 02250164-807 (I) 1
7 weatherstrip, 3/16 x 3/8 ft 250022-436 3
9 bumper,rubber 1/2 dia 250035-095 2
10 plug, hole n4 1" cond 409918-004 1
11 nut,hex locking #6-32 825500-102 4
12 nut,hex locking #8-32 825501-070 1
13 nut,acorn pltd #8-32 825615-002 2
15 screw,flt phillips 8-32 x 3/4" 875901-075 1
OPTIONAL PANELS (ITEM5)

02250154-330 PANEL, INSTRUMENT 375-425CA STD T2 EXP
02250154-331 PANEL, INSTRUMENT 375H CA STD T2 EXP
02250154-332 PANEL, INSTRUMENT 375 CA FULL T2 EXP
02250154-333 PANEL, INSTRUMENT 375H CA FULL T2 EXP

* P/N 02250154-331 for 300HH and 375H

SECTION 7
7.18 Canopy, Acoustical Panels & Parts
02250166-351R01

7.18 Canopy, Acoustical Panels & Parts (Continued)

1 catch, pivot slam pad lck blk - 02250107-837 3
2 insulation, clr baff fill 185h 02250147-126 2
3 panel, can frt rh 375 t3 02250164-802 (I) 1
4 panel, can frt lh 375 t3 02250164-807 (I) 1
5 panel, can rear rh 375t3 02250164-812 (I) 1
6 panel, can rr lh 375 t3 02250164-817 (I) 1
7 panel, door can frt 375 t3 02250164-836 (I) 1
8 panel, canopy rear 375 t3 02250164-859 (I) 1
9 panel, roof 375-600 t3 02250164-864 (I) 1
10 hinge, canopy door frt 375 t3 02250164-878 1
11 hinge, can door sides 375 t3 02250164-879 2
12 grille, canopy roof inl 375 t3 02250164-880 1
13 baffle, can roof 375 t3 02250164-881 1
14 louver, air exhaust 375-600 t3 02250164-882 1
15 panel, acoustic can rr rh 375 t3 02250165-522 1
16 panel, acoustic can rr lh 375 t3 02250165-523 1
17 panel, acoustic can rr side rh 375 t3 02250165-524 1
18 panel, acoustic can rr side lh 375 t3 02250165-525 1
19 panel, acoustic rear acc 375 t3 02250165-526 1
20 panel, acoustic can door frt 375 t3 02250165-529 1
21 panel, acoustic can frt 375 t3 02250165-530 1
22 panel, acoustic roof baff 375 t3 02250165-534 1
23 panel, acoustic roof rear 375 t3 02250165-535 1
24 panel, acoustic roof frt rh 375 t3 02250165-536 1
25 panel, acoustic roof frt lh 375 t3 02250165-537 1
26 tabulation, door canopy l&r 375-425 t3 02250167-515 2
27 panel, acoustic can dr r&l 375-425 t3 02250167-545 2
29 hook, door latch male ss 250033-828 3
30 catch, door latch female ss 250033-829 3
31 insert, 1/4-20 blind 250034-538 24
32 nut, hex f pltd 5/16-18 825305-283 6
33 nut, hex locking #10-24 825502-083 36
34 nut, hex locking 1/4-20 825504-145 15
35 capscrew, hex gr5 1/4-20 x 1/2 829104-050 33
36 capscrew, hex gr5 1/4-20 x 3/4 829104-075 6
39 nut, retainer 5/16-18 .092 861405-092 19

SECTION 7
7.19 Decals
2
02250140-925
3
SU_0000681 CAT T2

7.19 Decals (Continued)

1 DECAL, OPER. INTRUCTIONS - CAT 02250133-511 1
2 decal, "need an air tool" sml 02250140-925 1
3 decal, drwbr instl 185q pe std 02250142-050 (I) 1
4 decal, diesel fuel 040248 1
(I) OSHA guidelines are superseded by any federal, state or local regulations whenever applicable.

SECTION 7
7 8
9 10
SU_0000682


7 decal, warning tongue heavy 100-375 02250077-929 (I) 1
8 decal, warning side door T-latch 02250136-670 3
9 decal, lead warning proposition 65 02250118-638 1
10 sign, warning hot surfaces 407408 3

(I) OSHA guidelines are superseded by any Federal, State or Local regulations whenever applicable.

SECTION 7
SU_0000683


14 decal, caution do not overfill 02250142-530 1
15 decal, noise emission control 049463 1
18 decal, 5 year warranty 02250097-455 1
19 decal, rated 2200 idle 1600 rpm 02250146-383 1
22 reflector, red 040103 2
23 reflector, amber 250034-319 2

SECTION 7
SU_0000684


24 decal, “300HH Sullair” frnt blk 02250139-154 1
25 decal, “375 Sullair” frnt blk 02250117-349 1
27 decal, “375H Sullair” frnt blk 02250117-352 1
28 decal, “425 Sullair” frnt blk 02250118-606 1
30 decal, “300HH” 3" tall blk 02250165-929 1
31 decal, “375” 3" tall blk 02250165-927 1
33 decal, “375H” 3" tall blk 02250165-928 1
34 decal, “425” 3" tall blk 02250165-930 1
36 decal, Sullair 3 x 24 blk 02250059-056 1
37 decal, ISO 9001 02250057-624 1

SECTION 7
39
02250168-596R00


39 decal,maint 300hh-425 ca t2 ex 02250168-596 1

SECTION 7
40
02250144-396R04
02250075-505-r00
41
42
02250119-385-r01


40 decal,wd 375 cat tier ii 02250144-396 1
41 decal, aftercooled/filtered air 02250075-506 1
42 decal, aftercooler by-pass valve 02250119-385 1

SECTION 7
7.20 Decal Locations

7.20 Decal Locations (Continued)

1 decal, iso 9001 blk 3.44x5.75 02250057-624 1
2 decal, “Sullair” 3.0 x 24.0 02250059-056 3
3 decal, warning tongue heavy 100-375 02250077-929 (I) 1
4 decal, 5 year warranty 02250097-455 1
5 nameplate, Sullair serial no. 185q-8f 02250108-078 1
6 decal, “375 Sullair” frt blk 02250117-349 1
7 decal, “375H Sullair” frt blk 02250117-352 1
8 decal, “425 Sullair” frt 02250118-606 1
9 decal, lead warning proposition 65 02250118-638 1
10 decal, operator procedure start stop 375 cat 02250133-511 1
11 decal, warning side door t-latch 02250136-670 3
12 decal, “300HH Sullair” frt blk 02250139-154 1
13 decal, “need an air tool?” sml 02250140-925 1
14 decal, drwbr instl 185q pe std 02250142-050 (I) 1
15 decal, caution- do not overfill 02250142-530 1
17 decal, rated 2200 idle 1600 02250146-383 1
19 decal, wiring diagram 375-425 cat 02250144-396 1
20 decal, “375” 3" tall blk 02250165-927 2
21 decal, “375H” 3" tall blk 02250165-928 2
22 decal, “300HH” 3" tall 02250165-929 2
23 decal, “425” 3" tall blk 02250165-930 2
24 decal, maintenance 375-425 cat 02250168-596 1
28 decal, “375HH” 3" tall blk 02250168-422 2
33 reflector, red 1.68 x 4.25 040103 4
34 decal diesel fuel 040248 1
35 decal, noise emission control 049463 1
36 reflector, amber 1.68 x 4.25 250034-319 2
37 sign, warning-hot surfaces 407408 3
38 rivet, pop 1/8 x 3/8 843102-038 1

SECTION 7
7.20 Decal Locations

7.20 Decal Locations (Continued)

A decal, water drain 040345 2
B decal, warning cluster breath 250028-258 1
C sign, warning compr oil fill cap 049685 1
D decal, sullair awf instruction 250032-902 1
E sign, warning sever fan port 049965 2
F sign, warning sever belt drive 049964 1
G sign, caution towing 55 mph 250005-578 (I) 1
H sign, warning hot surfaces 407408 2
I sign, warning crush/sever 408919 (I) 1
J decal, caution doors closed 250038-030 4
K axle lube instructions 250042-543 (I) 2
L decal, warning pressurized clg sys 02250051-826 1
Location
A one on engine near drain, one on rear baffle near radiator drain
B shown -over service valves
C on receiver near fluid fill cap
D on receiver near fluid fill cap
E one on each side of fan shroud
F on alternator
G shown -on top of drawbar
H one on each side of lifting bail
I shown -on top of drawbar
J shown -one on back of each door latch
K shown-one at upper rear of fenders
L shown-on baffle over radiator fill
(I) This decal not used on less running gear machines.

SECTION 7
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WARNING
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects and other
repoductive harm.
Battery posts, terminals and
related accessories contain lead
and other compounds known to
the State of California to cause
cancer and birth defects and
other reproductive harm. Wash
hands after handling.
02250118-633

Worldwide Sales and Service
Printed in the U.S.A

Specifications subject to change

300hh (CAT)

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OPERATOR’S MANUAL AND PARTS LIST

Portable Air Compressor

Caterpillar Standard and Aftercooled and Filtered

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For detailed course outlines, schedule and cost information contact:

Sullair Customer Care Training Department

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Aftercooled And Filtered Air System, Functional Description......................... 24

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1.10 Entrapment M. Avoid accidental contact between jumper cable

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1.14 Explosive Atmosphere

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1. Radiator/Fluid Cooler Assembly 8. Service Valves

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After the air fluid mixture is discharged from the

2.4 Compressor Cooling

Refer to Figure 2-2. The compressor cooling and 4

lubrication as well as maintain the proper operating

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2.5 Compressor Discharge 2.6 Capacity ContRol SysTem,

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1. Engine 9. Service Air Outlet

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1. Air Pressure Gauge 12. Optional Aftercooler

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1. Air Pressure Gauge 14. Compressor Unit

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High Pressure Low Pressure

Figure 2-6: Piping and Instrumentation Diagram

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1. Filter, Air T1 Compressor Discharge Temperature Switch

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2 pressure increases, the inlet valve piston will further close

Modulation – 100 to 110 psig (6.9 to 7.5 bar)

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Figure 2-9: Instrument Panel Group

1. Compressor discharge temperature

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2.9 Wiring Diagram

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2.10 Electrical System, 2.11 Compressor Shutdown

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COMPRESSOR 300HH 375

Figure 5-4: Control System Adjustment –