550RH-750H

CUMMINS ENGINE
 We appreciate for both your purchasing and utilizing
this portable screw compressor made by
Shenzhen Sullair Asia Industrial Co. Ltd.
Suzhou Sullair Air Equipment Co., Ltd.

The various types of portable screw compressors made by Shenzhen

Sullair Asia Industrial Co. Ltd. and Suzhou Sullair Air Equipment Co.,

Ltd. (hereinafter “Sullair”) are expected to work to your satisfaction.

Before operating and maintaining the portable rotary screw air

compressor of Sullair, please do read this Operating and Maintenance

Manual carefully.

Sullair reserves the right of research and improvement of its products, and

is not responsible for modifications and improvements on its previous

products.

License No:
Compressor Model:
Compressor Serial Number:
Diesel Engine Model:
Diesel Engine Serial Number:

I
II
 PREFACE

This Operating and Maintenance Manual describes in detail the safety precautions,
structural functions of each system, and operation & maintenance method for 550RH,
600XH and 750H portable screw air compressors designed and produced by Sullair,
and driven by Dongfeng CUMMINS diesel engine.

Operators shall carefully read this Operating and Maintenance Manual and the
Operating and Maintenance Manual of Dongfeng CUMMINS C engine and may carry
out machine operation and maintenance only after fully understanding the structural
functions and safety precautions of each system and component. Unless otherwise
specified in this Manual, if the user doesn’t operate and maintain in accordance with
the operation and maintenance regulations of this Manual, or disassembles and
modifies the machine without authorization, or uses the parts not designated by Sullair,
then it will lose the right of claim.

This Manual does not include parts list. If you need to order parts from Sullair, please
see Parts List (88291004-642). It is important to note that your product may differ
from the one described in this Manual because Sullair always puts efforts on research
and improvement of its products. Consult Sullair Service Department before ordering
parts.

If you encounter any problem during operation that is not clearly described in this
Manual, contact local Sullair authorized dealer, or directly Sullair branches or Sullair
Service Department. Solution to your problem can be assured.

——Editor

June 2009

III
IV
 SAFETY PRECAUTIONS
Read carefully before operating the compressor.

▲ WARNING

Compressed air and air compression system are dangerous!

Failure to follow the instructions, procedures and safety precautions in this
Manual may result in accidents and injuries to you or others!
Read this Manual carefully and make sure you fully understand every part of
this Manual before operating and servicing the compressor!
User is responsible for appropriate care of the machine!

For details of safety precautions and potential hazards when operating the compressor, refer to
Safety Precaution section in this Manual. Before shipment, conspicuous warning labels have
been attached on the locations where precautions and hazards should be taken into account.

In this Manual, operations involving safety issue will be in bold font and indicated as Caution,
Warning, or Danger, depending on the degree of damage to the compressor or personal injury.

Caution indicates a potentially hazardous situation, which, if not avoided, may result in general
damage to the machine.
Warning indicates a potentially hazardous situation, which, if not avoided, may result in damage
to the machine or personal injury.
Danger indicates an imminently hazardous situation, which, if not avoided, may result in major
accident, death or injury.

1. You must read this Manual carefully and fully understand this Manual prior to any operation
and maintenance of the compressor.
2. Never operate the compressor when it exceeds the rated discharge pressure, otherwise, the
engine may be damaged due to overload.
3. Each protection and control function has been properly set up at factory. Never modify or
remove control parts of the machine, otherwise it may cause severe damage to machine or
injury.
4. Never remove or loosen any piping components, connectors, plugs, and connections when the
compressor is running. DO NOT operate the relief valve. The thermal substance inside the
machine is pressurized and may cause severe personal injury.
5. Prior to any maintenance, you have to make sure that:
 The compressor is shut down;
 Internal pressure has been released completely.
6. Only use safe solution to clean the compressor and accessories.
7. Any part that is found defective must be changed immediately to avoid irreparable damage.

V
VI
 TABLE OF CONTENTS
PREFACE....................................................................................................................... III
SAFETY PRECAUTIONS ..............................................................................................V

Section 1 SPECIFICATIONS
1.1 Technical Parameters ......................................................................................................................1
1.2 Dimensions(DPQ550RH-750H) .....................................................................................................2
1.3 Dimensions(DLQ550RH-750H).....................................................................................................2
1.4 Compressor Fluid............................................................................................................................3
1.5 Engine Oil .......................................................................................................................................3
1.6 Engine Coolant ...............................................................................................................................4
1.7 Diesel Fuel ......................................................................................................................................5

Section 2 SAFETY
2.1 General............................................................................................................................................6
2.2 Towing and Parking........................................................................................................................6
2.3 Pressure Release .............................................................................................................................8
2.4 Fire and Explosion ..........................................................................................................................8
2.5 Moving Parts...................................................................................................................................9
2.6 Hot surfaces, sharp edges and sharp corners...................................................................................9
2.7 Toxic and Irritative Substances.......................................................................................................9
2.8 Electrical Shock ............................................................................................................................10
2.9 Battery...........................................................................................................................................10
2.10 Lifting .........................................................................................................................................10
2.11 Miscellaneous .............................................................................................................................10

Section 3 DESCRIPTION
3.1 Introduction...................................................................................................................................11
3.2 Machine Layout ............................................................................................................................11
3.3 Compressor unit & Diesel Engine Assembly................................................................................12
3.4 Compressor Inlet System ..............................................................................................................13
3.5 Diesel engine inlet system ............................................................................................................14
3.6 Compressor Discharge System .....................................................................................................15
3.7 Compressor Cooling and Lubrication System ..............................................................................16
3.8 Control System .............................................................................................................................17
3.9 Auto Protection System ................................................................................................................19
VII
3.10 Engine Fuel System ....................................................................................................................19
3.11 Engine Lubrication System.........................................................................................................20
3.12 Engine Cooling System...............................................................................................................20
3.13 Engine Discharge System ...........................................................................................................21
3.14 Instrument Control System .........................................................................................................22
3.15 Electrical System ........................................................................................................................29
3.16 Frame-Moving System................................................................................................................29
3.17 Enclosure Assembly....................................................................................................................29

Section 4 OPERATION
4.1 General..........................................................................................................................................32
4.2 Purpose of Controls and Indicators...............................................................................................32
4.3 Initial Start-up Procedure..............................................................................................................33
4.4 Subsequent Start-up Procedure .....................................................................................................33
4.5 Shutdown Procedure .....................................................................................................................34
4.6 Mode Setting Procedure................................................................................................................34
4.7 Jump Start Procedure ....................................................................................................................34
4.8 Storage ..........................................................................................................................................35

Section 5 MAINTENANCE
5.1 General..........................................................................................................................................36
5.2 Maintenance of Rotary Screw Compressor ..................................................................................36
5.3 Maintenance of Diesel Engine ......................................................................................................38
5.4 Parts Replacement and Adjustment Procedures............................................................................41
5.5 Troubleshooting ............................................................................................................................43

Section 6 NOISE CONTROL

6.1 Noise Emission .............................................................................................................................49
6.2 Prohibited Operation.....................................................................................................................49
6.3 Service Record..............................................................................................................................49

PARTS ORDERING ...................................................................................................... 50

VIII
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

Section 1SPECIFICATIONS
1.1 Technical Parameters
Technical parameters and overall dimensions of the compressor are shown in the table below:

MODEL 550RH 600XH 750H

General
Nominal Delivery m3/min (cfm) 15.5(550) 17.0(600) 21.2(750)

Rated Discharge Pressure –bar (psi) 17(250) 13.8(200) 10(150)

Pressure Range-bar 6.5-17 3.5-13.8 3.5-10

Max Towing Speed-km/h 35 (Only for DPQ550RH-750H)

Noise level @ 7m, ±3dB (A) 79

Gross Weight-kg (DPQ550RH-750H) 3200

Gross Weight-kg (DLQ550RH-750H) 3000

Dimensions: 4560×2150×2050 (to the top of casing)
L×W×H – mm (DPQ550RH-750H) 4560×2150×2170 (total height of machine)
Dimensions: 3480×1680×1680 (to the top of casing)
L×W×H – mm (DLQ550RH-750H) 3480×1680×1806 (total height of machine)
Tire Size 7.5-16-14PR ( only for DPQ550RH-750H)

Tire Pressure - kPa (psi) 690-760 (100-110) (only for DPQ550RH-750H)

Max Altitude - m 3048

Engine

Mamufacturer Dongfeng CUMMINS

MODEL 6CTA8.3-C240 6CTA8.3-C260

Speed, full-load/no-load - rpm 1800/1400 1800/1400

Rated Power - BHP (kW) 240(179) 260(194)

Displacement - L (in3) 8.3(136)

Coolant Tank Capacity - L (U.S.gal) 9.8(2.6)

Engine Oil Capacity - L (U.S.gal) 18(4.8)

Fuel Tank Capacity - L (U.S.gal) 375(99)

Fuel consumption at full-load
38.6(10.2) 37.4(10.0) 40.4(10.7)
L/h (U.S.gal/h)
Electrical System Voltage -V 24

Battery Capacity 210Ah/ea.

Compressor

Service valve spec. One Rp2 and one Rp3/4

Fluid Capacity - L (U.S.gal) 26 (6.8)

1
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

1.2 Dimensions (DPQ550RH-750H)

Air Inlet
Control Panel
Air Inlet
Air Outlet Maintenance Port
of Control Valve

Fluid Sight-glass
Hole

Lifting Orifice
Maintenance door
of Cooler
Maintenance
Port of Fluid/air
Mounting Plate separator
of Silencer

Figure 1-1 Dimensions

1.3 Dimensions (DLQ550RH-750H)

Figure 1-2 Dimensions

2
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

1.4 Compressor Fluid

The fluids as shown in the table below can be used in the portable rotary screw compressor
designed and made by Sullair. These fluids are suitable under conditions where severe oil oxidation
can occur. Suitable ambient temperature, load condition, as well as change interval vary from fluid
to fluid. Two-year warranty service is only available when Sullair ® AWF ® fluid designated
by Sullair is used.

Fluid Type Change Interval, Hours Ambient Temperature, oC Model

Sullair® AWF® 500 -29～49
Mobil 1 Synthetic AFT 800 -29～49
RH Model
Mobil Rarus SHC 1026 800 10～52
Mobil Rarus SHC 1024 1000 -29～38

Fluid Type Change Interval, Hours Ambient Temperature, oC Model

Sullair® AWF® 2500/1800/1200 -29～38/39～44/45～50
D-A Torque Fluid 1000 -12～43
XH and H
SAE 10W SE,SF,SG,CD 300 -18～38
Model
MIL-L-2104E 10W 300 -18～38
DexronⅢ 550 -18～38
Note: Part numbers for Sullair AWF are 250030-757(5gal/19 liter package) and 250030-758(55
gal/208 liter package).
Normally, portable rotary screw air compressor designed and manufactured by Sullair is equipped
with Sullair®AWF® fluid. This fluid is a kind of heavy-duty, multi-viscosity all-weather fluid,
applicable for various climate conditions, being the special portable rotary screw compressor oil
supplied by the manufacturer, having good application performance.
Periodically remove the condensate at the bottom of the fluid/air separator sump. In high ambient
temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a
“milk” color. The fluid should be changed if this condition develops.
DO NOT mix different types of fluid. Mixing different fluids may lead to problems such as
foaming, filter plugging, orifice or line plugging. If serious, it will cause cooler plugging or air-end
locking.
When ambient temperature exceeds specification or if conditions require use of other extended-life
fluid, contact Sullair. Sullair encourages the user to participate in a fluid analysis program. This
could result in a fluid change interval differing from that stated in the manual. Sullair offers a fluid
analysis program for Sullair®AWF®. Contact your local Sullair representative for details.
1.5 Engine Oil
Diesel engine shall use multi-grade oil of API CH-4, API-CG-4 conforming to American Petroleum
Institute (API) categories. Using nonconforming engine oil will seriously affect the service life of
engine and may cause accidents such as scuffing or bush-burning, etc.
Engine oil grade
API CH-4, API CG-4 Ambient temperature
SAE 0W30 Engine oil for ultra low temperature (-40℃~-25℃)
SAE 5W30 Engine oil for low temperature (-30℃~-15℃)
SAE 10W30 Engine oil for low temperature (-20℃~-5℃)
SAE 15W40 Engine oil for normal temperature (-10℃~+38℃)
SAE 20W40 Engine oil for high temperature (above +38℃) or under
severe load condition

Caution: Using low-viscosity engine oil, e.g. 10W-30, will be helpful for engine startup and

3
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

providing sufficient oil volume under low ambient temperature. However, continuous use of
low-viscosity engine oil will reduce engine service life.
70506-J Premium Blue engine oil provided by Sullair (equivalent to CH-4 grade 15W-40 engine oil
of API classification) can ensure normal operation of the diesel engine under normal temperature.
The Sullair part number for premium blue engine oil is: 88290003-329.
1.6 Engine Coolant
Antifreeze & antirust coolant not only prevents the water jacket of cylinder block/head and water
tank from cracking due to freezing in winter, it also prevents the rust and removes the scale.
Moreover, the boiling point of the antifreeze & antirust solution is higher than that of the ordinary
water, which also has certain advantage on the cooling system. Therefore, this engine series
requires antifreeze & antirust coolant throughout the year and never use ordinary cooling
water.
Coolant also acts as fluid in water pump of the engine.
Antifreeze & antirust coolant normally consists of three compositions: water, additive and glycol
(or ethylene glycol), and the three compositions are concocted in certain proportion. The proportion
must be controlled precisely, because different proportions will have different effects.
It is recommended to use distilled water or de-ionized water in engine cooling system. If there is no
distilled water or de-ionized water, please use water that meets the requirements in the following
table:

Minimum requirement of water acceptable to diesel engine

Item Upper limit
-1 40mg/l
Chloride (CL )
-2 100mg/l
Sulfate (SO )
Total hardness 170mg/l
Total solid 340mg/l
Acidity Ph5.5～9.0

Sullair offers DCA60L-J antirust additive to supplement the concentration of antifreeze & antirust
solution, ensuring the service life of diesel engine cooling system. No antirust additive is required
for new machine. Only add when experiment indicates that the SCA (supplementary coolant additive)
concentration is lower than 6%. It is suggested to use 6%-8% SCA in the coolant. Sullair part
number for DCA60L-J antirust is 88290002-597.
Sullair offers the concentrated antifreeze liquid (glycols). Through different mixing ratio with water,
it can make the freezing point and boiling point of the cooling system to various points. Glycol
concentration in Sullair coolant is 50%.
Sullair’s part number of condensed antifreeze antirust liquid is 88290002-598.

Glycol concentration
Concentration Antifreeze protection Boiling protection
50% -32℃ 106℃
60% -50℃ 108℃

▲Warning
If the machine is intended to be stored or operated in cold region, the lowest local
ambient temperature should be available to make sure the antifreeze protection temperature
is lower than lowest ambient temperature so as to avoid damage to diesel engine and cooling
system.

4
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 1 Specifications

1.7 Diesel Fuel

User can choose light diesel fuel of different grades based on the local ambient temperature:
0# light diesel fuel Ambient temperature above 4℃
－10# light diesel fuel Ambient temperature above -5℃
－20# light diesel fuel Ambient temperature -14℃ ~ -5℃
－35# light diesel fuel Ambient temperature -29℃ ~ -14℃

▲Warning
Since diesel will separate out the paraffin crystal first before solidification, blocking the
fuel line and fuel filter, causing the diesel engine unable to start. Therefore, appropriate light
diesel must be used at low temperature. Before the wax is formed from diesel, thoroughly
drain diesel not conforming to environment requirement, including all diesels in engine fuel
line and fuel filter.

5
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

Section 2 SAFETY
2.1 General
Sullair designs and manufactures its rotary screw air compressors so that they can be operated
safely and reliably. However, the responsibility for safe operation rests with those who use and
maintain these products. The following safety precautions, if consciously followed, will minimize
the possibility of accident.
Only those who have been trained and delegated to do so, and who have read and
understood this Manual should operate the air compressor. Failure to follow the instructions,
procedures and safety precautions in this Manual can result in accidents and personal injuries or
even death.
NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the air
compressor with a known unsafe condition. Tag the air compressor and render it inoperative by
disconnecting the power at source so others who may not know of the unsafe condition will not
operate it accidentally until the condition is corrected.
Compressed air is dangerous. Maintain or repair the air compressor unit only when all
compressed air in the whole compressor system has been bled empty.
DO NOT modify internal structure or control mechanism of the compressor except with written
approval from Sullair.
Perform daily maintenance of the air compressor and check for leaks, loose or missing parts,
damaged parts or parts out of adjustment. Correct problem without delay.
Check hoses frequently to see if there is any damage that may affect its performance, e.g., scratch,
wear, crack, hardening, bulge, etc. Replace if any of the conditions is evident. Use time of hose
shall not exceed its nominal service life.
Caution: Use time of hose is 2000 hours. User shall calculate the service life based on actual
conditions.

2.2 Towing and Parking

2.2.1 Preparation

▲Warning
DO NOT tow the compressor should its weight exceed the rated limit of the towing vehicle, as the
vehicle may not brake safely with excess weight. See rated limit in towing vehicle operator’s
manual, and review its instructions and other requirements for safe towing.

1) Prior to hitching the air compressor to the tow vehicle, check all attaching parts for: (1) signs
of excessive wear or corrosion; (2) parts that are cracked, bent, dented or otherwise deformed
or degraded; (3) loose nuts, bolts or other fasteners; (4) Check if the stay bolt (marked in red )
for transport on the fluid/air separator base is in place and secure; (5) check if the stay bolt
(marked in red ) for transport on the diesel engine and air end support is in place and secure.
Should any such condition be present, do not tow until the problem has been corrected.
2) Before coupling, turn the handle of drawbar leg of the machine to adjust the machine to an
appropriate position (lean forward a little).
3) During the coupling, have the tow vehicle slowly backed to a proper position when attaching
the compressor.
4) If the lug of compressor’s drawbar is not at the same height of tow vehicle’s hook, change the
mounting position of direction of lug or adjust the height of the leg to achieve desirable
height.
5) Make sure the tow pin is secured and the connection mechanism is absolutely engaged,
fastened and locked.
6) Make sure the safety chain is securely fastened to tow vehicle to avoid the connection system
goes off by accident.
7) Fold the leg before towing once the machine is connected to the tow vehicle.
▲Warning
Fold the leg of drawbar only after the compressor is connected to tow vehicle. Secure the leg with pin.
6
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

8) Make sure the towing mechanism and adjustment device of towing vehicle and the machine
do not interfere with or disturb each other when moving on any kind of terrain.
9) Make sure the tyres are in good condition. Do not change the size of tyre. Tighten the bolts of
tyre to specified torque.
10) Make sure the lights of towing vehicle are in good condition. The reflective surface of
compressor shall be clean and intact.
11) Make sure the air service hose has been unraveled.
12) Make sure all doors of the machine are closed and secured. Make sure there is nobody inside
the machine before closing doors.
13) Make sure the wheels of the machine are not blocked and the machine can move freely.
14) Test the performance of towing vehicle’s brake before driving at rated speed.
15) DO NOT carry loose or inappropriate tools or equipment on or in the compressor unit.
16) DO NOT load this equipment with accessories or tools that is likely to cause unit unbalance.
Such unbalance may reduce the tow-ability of this equipment and may increase the
possibility of tipping, rolling over, jackknifing, etc.
2.2.2 Towing
Caution: The compressor is a specially designed construction equipment and is not recommended
on road at normal situation. If it is necessary, please do follow the requirements below:
1) DO NOT exceed the Max. Towing speed of 35 km/h under ideal conditions. Reduce running
speed according to posted speed limits, weather, traffic, roads or terrain conditions.
2) 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 similar dangerous maneuvers. Avoid excessive deviation when
back the towing vehicle. Slow down speed when make U-turns.
3) Avoid grades in excess of 15o (27%).
4) Avoid potholes, rocks and other obstructions and soft shoulders or unstable terrain.
5) Maneuver in a manner that will not exceed the freedom of motion of the compressor’s
drawbar and/or coupling device, in or on the towing vehicle’s coupling device and/or
adjacent structure whether towing forward or backing up, regardless of the terrain being
traversed.
6) Make sure all service doors are closed and locked.
7) DO NOT permit personnel to ride in or on the compressor. No personnel are allowed
standing between the towing vehicle and the compressor unit.
8) Make sure no personnel are near the compressor.
9) Make sure that the stay bolt (marked in red) for transport on the fluid/air separator base is in
place and secure.
10) Make sure that the stay bolt (marked in red) for transport on the diesel engine and air end
support is in place and secure.
2.2.3 Parking
1) Park or locate the compressor on a level and firm surface, if possible. Otherwise park or
locate the compressor across grade so the compressor does not tend to roll down hill.
2) When parking, the compressor should be leaning forward a little. Support the rear end if
necessary.
Caution: DO NOT park or located the compressor on grades in excess of 15o (27%).
3) Park or locate the compressor in such a place that the exhausted hot air and radiator heat is
away from the compressor air inlet openings. Avoid the compressor be exposed to excessive
dust environment.
4) Loose the chain on towing vehicle. The chain shall not make contact with ground to avoid
rust.
5) Block both directions of wheel using stone blocks.
6) Disengage connection mechanism. Do not stick your hand.
7) Unfold the leg of drawbar and pin the leg.
7
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

Caution: The leg must rest on solid ground. Never put your feet under the drawbar.
8) Turn the handle of drawbar leg of the machine to adjust the machine to an appropriate
position (lean forward a little).
9) The towing vehicle should be parked in a place that will not disturb the operation of
compressor, preferably away from the compressor.
10) If the compressor is parked at the midst of road or nearby, install signs, barriers as well as
indication lights during night to warn other vehicles.
11) Make sure that the stay bolt for transport on the fluid/air separator base and the stay bolt
(marked in red) for transport on the diesel engine and air end support are loosened prior to
power-on.
2.3 Pressure Release
1) Make sure the working pressures in hoses, pneumatic devices, lines, valves, filters, and other
accessories are not in excess of the rated pressure.
2) Make sure to shut down the compressor and bleed the sump to zero before removing the cap.
3) Make sure to bleed the internal pressures when disconnecting any piping, connector, valve, oil
plug, filter and separator.
4) Keep personnel out of line with and away from any discharge openings, regardless of service
air end, compressor or pneumatic devices.
5) Pressure of air used for dust cleaning purpose should not be in excess of 30psi (2.1bar), and
dust protection equipment should be provided in working.

2.4 Fire and Explosion

1) Allow the compressor to cool before adding fluid. Ground the compressor and fluid/air
separator together before adding fluid and keep sparks, flames and other sources of ignition
away.
2) Clean up spills of fluid immediately should such spills occur. Do not permit fluid on acoustic
material or the surface of other components. Wipe down using a cleaner or steam clean as
required. If necessary, replace contaminated acoustic material. Any acoustic material with a
protective covering that has been torn or punctured should be replaced immediately to prevent
accumulation of fluid within the material.
Caution: DO NOT use flammable solvents for cleaning purpose.

3) Disconnect the ground line (negative) of power supply prior to any repairs or cleaning inside
the enclosure. Tag the disconnected location so others will not unexpectedly reconnect it.
4) Make sure the electrical system is in good condition, i.e. the connection is clean and secure.
Change whenever damage occurs.
5) Keep grounded conductors (e.g. tools) away from exposed live electrical parts (e.g. terminals)
to avoid arcing.
6) Disconnect charger before servicing or wiring the battery.
7) Change damaged fuel tank and pipes immediately.
8) If the fuel system is leaking, it must be corrected before starting the machine. Install warning
signs until the problem has been corrected.
9) If welding is required during the repair, remove any acoustical material and other materials
inflammable or vulnerable to heat.

▲Warning

Do not weld near fuel or lubrication system.

10) Keep sufficient and reliable fire extinguishers available and check regularly.
11) Keep oily rags, trash, leaves, litter or other inflammables out of and away from the
compressor.
12) Open all access doors before starting the compressor for full ventilation.
13) DO NOT operate the compressor under low over hanging leaves or permit such leaves to
contact with hot surfaces of the compressor when working in forested areas.
8
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

2.5 Moving Parts

1) Keep hands, arms and other parts of the body and also clothing away from couplings, fans,
belts and other moving parts.
2) DO NOT attempt to operate the compressor with the fan, coupling or other guards removed.
3) Wear snug-fitting clothes and confine long hair when working around the compressor,
especially when exposed to hot surface or moving parts inside.
4) Keep access doors closed except when making maintenance.
5) Make sure all personnel are out of and clear of the compressor prior to attempting to start the
compressor.
6) Shut down the engine prior to following operations: adding fuel, fluid, coolant, or changing
electrolyte.
7) Disconnect the negative terminal of battery when servicing and render it inoperative so others
who may not know of the condition will not connect wire accidentally.
8) Sometimes it might be necessary to adjust the pressure regulator or engine speed when the
compressor is running. In such a case, do not touch other moving parts or the terminal of
engine starter. Other adjustment operation can only be carried out after the compressor is shut
down.
9) Clean the oil and water contaminant on hand, foot, machine parts and ground near the
machine, to avoid slipping.
2.6 Hot surfaces, sharp edges and sharp corners
1) Avoid body contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.
2) Keep all parts of the body away from all points of air discharge and exhaust port of cooling
fan.
3) Wear personal protective equipment including gloves and head covering when working in, on
or around the compressor.
4) Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infection.
▲Danger
NEVER remove the heat insulation sleeve of engine tail pipe. Replace immediately if damaged.
Otherwise, it may cause serious accidents such as machine fire or burn!

2.7 Toxic and Irritative Substances

1) Do not use air from the compressor for respiration.
▲Danger
Death or serious injury can result from inhaling compressed air without using proper safety
equipment!

2) Operate the compressor only in open or well-ventilated areas. If the compressor is operated
indoors, fully discharge engine exhaust fumes outdoors.
3) Locate the compressor so that personnel or compressor is not likely to ingest or intake exhaust
fumes.
4) Care should be taken to avoid accidental ingestion and/or skin contact with fuel, fluid and
coolant. Wash with soap and water in the event of skin contact. In the event of ingestion, seek
medical treatment promptly.
5) Wear an acid-proof apron and a face mask when servicing the battery. If electrolyte is spilled
on skin or clothes, immediately flush with large quantity of water.
6) If eyes are spilled by coolant or irrigated by volatile gas, flush with water for 15 minutes and
see a doctor, preferably ophthalmologist.
7) Do not store coolant in a closed space.
8) Coolant is toxic. Never swallow, contact with skin or inhale its volatile. If swallowed, drink
large amount of salty water to wash the stomach. After the puke is clear, drink a cup of soda
water and lie down. Call a doctor immediately.

9
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 2 Safety

2.8 Electrical Shock

1) Keep the compressor, towing vehicle and personnel at least 3m away from electric wire.
2) Keep all parts of the body and any hand-held tools or other conductive objects away from
exposed live parts of electrical system. When servicing and adjusting these parts, stand on
insulation surface. Do not wet the feet and do not contact other parts of the compressor.
3) Maintain the compressor at a clean, dry and well-lighted place.
4) Stay away from the compressor during lightning.

2.9 Battery
1) The battery may contain hydrogen. Since hydrogen is highly inflammable and explosive, no
sparks, flames and other sources of ignition shall be present near the compressor.
2) Electrolyte in battery is highly corrosive and toxic. Never contact it with eyes, skin or fabrics.
Otherwise, it may cause injury or loss of property. In case of electrolyte spill, flush with large
amount of water immediately.
3) If the electrolyte is frozen or has ice in it, never start the compressor. Otherwise, the battery
may explode.
4) Avoid contact of leads and wire clamp with other metal parts to prevent the electric arc, which
may cause fire.

2.10 Lifting
1) Before lifting, inspect points of attachment for cracked welds and for cracked, bent, corroded
or otherwise degraded members and for loose bolts or nuts.
2) Make sure the entire lifting, rigging and supporting structure has been inspected, is in good
condition and has a rated capacity of at least the weight of the compressor. If you are unsure of
the weight, then weigh compressor before lifting.
3) Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and
latched on the bail or slings.
4) Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has
been lifted.
5) Do not attempt to lift in high winds.
6) Keep all personnel out from under the compressor whenever it is suspended.
7) Keep lift operation in constant attendance whenever compressor is suspended.
8) Lift compressor no higher than necessary.
9) Do not drive the crane while lifting to avoid damage to compressor.
10) Set the machine down only on a surface capable of supporting the machine.
11) Block both directions of compressor’s wheels before releasing the hook.
12) Use steel cable or wire to secure wheel axle and drawbar before transporting the compressor.

2.11 Miscellaneous
1) If it is necessary to enter the enclosure to perform service adjustment, you must inform other
personnel before doing so, and secure and tag the access door in the open position to avoid the
possibility of others closing the door with personnel inside.
2) Make sure all personnel are out of the machine before closing the door.
3) Air spring used to support doors is a high air pressure product. Never put it over flame or
bump or dismember it.

10
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Section 3 DESCRIPTION
3.1 Introduction

The 550RH, 600XH and 750H diesel engine driven portable screw compressor designed and
manufactured by Sullair will provide you with improved reliability and greatly reduced maintenance.
Your compressor, a diesel engine driven, air-cooled fluid injection screw portable type, is convenient
to travel depending on operation requirement.
The compressor is designed and manufactured by Sullair, offering great power performance, cost
effectiveness and reliability. It can be operated 24x7 at full load.
Driver of the compressor is Dongfeng CUMMINS 6C diesel engine. Its excellent performance
guarantees power supply to the compressor.
The compressor features logical layout, comprehensive functions, ease of use & operation and elegant
appearance. The enclosed silent design minimizes noise of the compressor. Display instruments and
indicators on instrument panel give abundant messages and diagnostic functions.
In reading this Manual, you will know how to use and maintain the compressor. With attention, you
will find out that it is easy to maintain the machine at its top performance.
Read Section 5 Maintenance to keep your portable screw compressor in top operating condition.
Should any problem or questions arise which cannot be answered in this Manual, contact your local
Sullair representative or Sullair Service Department.

3.2 Machine Layout

Engine Discharge Inlet System
System
Cooling and
lubrication system

Discharge system

Diesel engine and

Compressor unit assembly

Frame-moving System

Electrical System

Fig. 3-1 DPQ550RH, 600XH and 750H portable rotary screw compressor

11
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Fig. 3-2 DLQ550RH, 600XH and 750H series screw compressor

See Fig. 3-1 and Fig3-2 for parts and layout of 550RH, 600XH and 750H diesel engine driven
portable screw compressor of Sullair. The machine consists of compressor unit & diesel engine
assembly, compressor inlet system, engine inlet system, compressor discharge system, cooling and
lubrication system, control system, engine discharge system, fuel system, electrical system,
frame-moving system, etc. Sound insulation enclosure of the machine is equipped with acoustic
materials to minimize noise of the compressor on the surrounding environment.

The compressor is driven by the rear side of output shaft of diesel engine through a heavily loaded
spring type coupling mounted on flywheel. Air filtered by inlet filter enters the inlet chamber of
compressor through inlet control valve, and then compressed in screw groove before being discharged
from air end. Then the compressed air enters fluid separator for oil/gas separation. Separated
compressed air with little oil goes through min pressure valve, air service piping and service globe
valve for customer to use. Separated fluid sets to the bottom of sump tank and is cooled by fluid
cooler and returned to the chamber of compressor unit under pressure difference.

The front side of output shaft of diesel engine drives a blow type cooling fan through belt. The cooling
fan is used to cool compressor fluid and engine coolant, removing heat generated during operation.

3.3 Compressor unit & Diesel Engine Assembly

See Fig. 3-3. Compressor unit & diesel engine assembly consists of the air end, diesel engine,
connection component, elastomer coupling, cooling fan, shock absorber, bracket, etc. The system is
the core of the entire machine.

12
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Coupling and Connector

Diesel Engine

Compressor

Compressor Support
Fan

Engine Support

Shock Absorber
Fig. 3-3 Compressor unit & diesel engine assembly

3.3.1 Compressor Unit

The compressor is very important in the compressor unit designed by US Sullair, featuring fluid
injection and lubrication. This unit provides continuous pulse-free compressed air to meet your needs.
Compared to other compressors, the Sullair air end is unique in mechanical reliability and durability
design. With its working parts meeting the “inspection free” process requirement, the air end is free of
maintenance and internal inspection during normal operation.
Inside the casing of the compressor unit, there is a pair of parallel fine-machined rotors (male rotor
and female rotor) with spiral grooves. Inlet and outlet are diagonally placed on rotor case. Screw
groove of female rotor meshes with and is driven by the screw tooth of male rotor. In a working cycle
of inhaling, enclosing, compressing and exhaling, the revolving rotors enclose inhaled air in the closed
screw groove space between rotors and case, and the bulk of screw groove space varies as the rotors
are revolving.
Rotors revolve to suck air. In the meantime, large amount of fluid is injected into the closed screw
groove space between rotors and case through a specially designed injector and mix with air directly.
Fluid serves for three main purposes:
1) As coolant, the injected fluid controls the rise of air temperature by absorbing large amount of
heat normally associated with compression.
2) Seals the leakage gap between the rotors and the stator and also that between the rotors to reduce
internal leak.
3) Acts as a lubricating film between the rotors, allowing the male rotor to directly drive the female
rotor. It also absorbs part of mechanical noise.
3.3.2 Diesel Engine
Diesel engine is another crucial part of the portable rotary screw compressor. The diesel driven
portable rotary screw compressors use Dongfeng CUMMINS 6C diesel engine. 6C is not only
powerful, fuel-economic and durable, but also easy to service and requires little maintenance. See
Operating and Maintenance Manual of Dongfeng CUMMINS B engine.

3.4 Compressor Inlet System

See Fig. 3-4. The compressor inlet system provides clean air to the compressor. It consists of one
compressor air filter, one Inlet control valve and pressure difference indicator for filter element, etc.

13
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Air filter assembly

Anchor hoop

Pressure difference indicator

Air intake hose

Anchor hoop

Support

Fig. 3-4 Compressor Inlet System

Air filter of compressor inlet system adopts cross-flow mode, capable of dealing with very dirty air.
Operator should frequently clean the dust gathered in the dust pocket in the rear cover of air filter. If
the pressure drop alarm of filter turns red, then the flow resistance in air filter is too high. Please
service or replace the main filter element in time. A safety element is equipped in the filter to give
temporary protection in case of main filter element failure. Safety filter element does not need
maintenance normally and should be replaced together with the main element.
Caution: (1) The mesh of safety filter element is larger than that of main element. It only provides temporary
protection in case of main element failure (for 4 to 6 hours). Therefore, the failed main element must be
replaced immediately. Otherwise, rotor wear or bearing damage could occur.

(2) If the pressure drop alarm indicator at the outlet of air filter turns red, please service or replace the main
filter element promptly and then press the reset button on the end of pressure drop indicator to clear the
alarm.

Piping of compressor inlet system is made of high quality rubber hoses, capable of resisting cold or
hot environment and is highly durable. To ensure air tightness and reliability, stainless steel “T”
screw-type hoops are used for connection.

▲Warning
Never use iron wire to strap the rubber hose. Never use rubber hose with crack. If a loose T hoop or hose
damage is found, stop the machine immediately and take measures to ensure air tightness of the piping.

Never attempt to run the machine when air filter element is not present or is damaged, otherwise the
compressor unit may be seriously damaged.

3.5 Diesel engine inlet system

See Fig. 3-5. The engine inlet system provides clean air to the diesel engine. It consists of one air filter,
intake pipeline and pressure difference indicator for filter element, etc.

14
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Air filter support

Air filter assembly Anchor hoop

Pressure difference indicator

Reducing Joint
Intake Stainless Steel Tubing

Air intake hose

Fig. 3-5 Diesel Engine Inlet System

Air filter of engine inlet system is the same with compressor adopts cross-flow mode, capable of
dealing with very dirty air. Operator should frequently clean the dust gathered in the dust pocket in the
rear cover of air filter. If the pressure drop alarm of filter turns red, then the flow resistance in air filter
is too high. Please service or replace the main filter element in time. A safety element is equipped in
the filter to give temporary protection in case of main filter element failure. Safety filter element does
not need maintenance normally and should be replaced together with the main element.
Caution: (1) The mesh of safety filter element is larger than that of main element. It only provides temporary
protection in case of main element failure (for 4 to 6 hours). Therefore, the failed main element must be
replaced immediately. Otherwise, early wear out of diesel engine and even scuffling could occur.

(2) If the pressure drop alarm indicator at the outlet of air filter turns red, please service or replace the main
filter element promptly and then press the reset button on the end of pressure drop indicator to clear the
alarm.

Piping of engine inlet system is made of high quality rubber hoses, capable of resisting cold or hot
environment and is highly durable. To ensure air tightness and reliability, stainless steel “T”
screw-type hoops are used for connection.

▲Warning
Never use iron wire to strap the rubber hose. Never use rubber hose with crack. If a loose T hoop or hose
damage is found, stop the machine immediately and take measures to ensure air tightness of the piping.

Never attempt to run the machine when air filter element is not present or is damaged, otherwise the
compressor unit may be seriously damaged.

3.6 Compressor Discharge System

Compressor discharge system consists of fluid/air separator, min pressure valve, relief valve, service
globe valve, discharge piping, etc. See Fig. 3-6.

15
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Min pressure valve

Air Discharge Pipe Relief valve

Fluid/air separator tank

Relief valve Discharge Pipe

Air service support

Service valve Unit discharge pipe

Drain pipe

Fig. 3-6 Compressor discharge system

In a working compressor, air trapped in the screw grooves is compressed constantly; meanwhile the
fluid continuously injected into screw grooves absorbs the heat created in compression. When the bulk
of screw groove drops to certain value (designed value), screw groove space is connected to a
specifically designed outlet, and oil/air mixture is discharged. Since there are multiple screw grooves
between the rotor pair, and rotors revolve at high speed, compressed air is discharged continuously
without surge.
Oil/air mixture discharged from air end then enters a specifically designed fluid/air separator. Oil/air
mixture flows along the inside of sump tank due to high speed. Most of the fluid is separated from air
due to centrifugal effect and forms larger fluid droplets. Fluid droplets fall to the bottom of the sump.
Baffle boards and isolation boards inside the separator make air and fluid droplets spin and change
direction, to separate more and more fluid from compressed air. After first stage of separation, only
tiny amount of fluid mist is left behind. As the air travels through the element of the separator, fine
fluid droplets are condensed on separator element’s fiber due to collision, dispersion and interception.
Droplets collected on the outer side of fiber then fall to the bottom of sump tank under gravity.
Droplets collected on the inner side of fiber converge at the bottom of separator element. A return line
leads from the bottom of separator element to the low pressure chamber of compressor unit. Fluid
collecting on the bottom of the separator is returned to the low pressure chamber of compressor unit
due to pressure difference. The return line is equipped with an orifice (with filter) to ensure steady
fluid return. A check valve is also provided in return line to prevent fluid backflow from compressor
unit to filter, which may otherwise contaminate discharge air with fluid content next time the machine
is started.
A min pressure valve is equipped between the fluid/air separator and service valve to establish a
minimum tank pressure when the compressor unit is operating, to maintain proper operation of
lubrication system. When the machine is not operating or unloaded, the min pressure valve acts as a
check valve to prevent compressed air from backflow. Triggering pressure of the min pressure valve
has been set before shipment.
After separation, oil content in the compressed air is only a few PPMs. Compressed air is available to
user through the min pressure valve. There are two service valves of different specifications on the
bottom of control panel side, so as to accommodate different needs of the user.
A relief valve is equipped on the separator sump tank. When air pressure inside the tank exceeds
pressure setting of the relief valve, the relief valve opens automatically. Triggering pressure of relief
valve is preset at factory. Please do not change. A temperature probe and a temperature switch are
equipped on the discharge tube of air end. If compressor discharge temperature is above the setting of

16
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

the temperature switch, which will shut down the machine automatically.
The fluid filling screw cap of separator has been specially designed to discharge residual pressure
within the tank when you disassemble the machine. The sight glass on the sump tank is used to
observe fluid level inside the separator. For a machine not in operation, fluid level should fall slightly
below the center of sight glass.
▲Warning
DO NOT remove nuts, oil plug, and other parts when the compressor is running or pressurized. Shut down
and bleed internal pressure of the compressor prior to operation.
NEVER replace with or use the relief valve of other type.

3.7 Compressor Cooling and Lubrication System

The cooling and lubrication system of compressor consists of cooler set (fluid cooler, coolant tank and
intercooler), fluid filter, thermal valve and piping. See Fig. 3-8.
Compressor fluid not only serves as the coolant, absorbing heat generated in compression to control
temperature rise of compressed air, but also the sealant between rotors and case, and fluid of moving
rotors.
The thermal valve has two entrances and two exits. The entrances are called Port A and Port B. Fluid
from fluid/air separator enters through Part A and fluid from cooler enters through Part B. The exits
are called Port C and Port D. Fluid from Port C goes back to air end via
B fluid filter and fluid from Port D enters cooler.
Upon start-up, the fluid temperature is low. So the thermal valve is closed.
Therefore, Port A and D are not connected. Cold fluid flows out from Port
A Cfluid
through thermal valve without passing fluid cooler. Then it goes into
filter before entering the working chamber and lubrication points of
bearings.
C As the compressor continues to run, fluid temperature rises. At a certain
point, the thermal valve begins to open, and Port A is connected with Port
C and D. A portion of fluid is routed from Port D through the fluid cooler.
D Cooled fluid flows into thermal valve through Port B. Since Port B and C
are always connected, cooled fluid goes to the filter via Port C before
Fig. 3-7 Thermal Valve Diagram entering air end. The rest of fluid flows back to air end from Port C
without going through cooler. As fluid temperature continue to rise to the threshold of thermal valve,
the valve full opens and Port A and C are disconnected. Therefore all fluid goes into fluid cooler
through Port D. Cooled fluid flows into thermal valve from Port B. Then it goes into fluid filter before
entering air end.

The fluid filter consists of filter seat, replaceable spin-on element with a built-in bypass valve, which
maintains a proper fluid flow even when the filter element becomes plugged or when the fluid
viscosity is too high. A visual pressure drop indicator is equipped on the top of fluid filter. When it
turns red, the fluid filter element should be replaced.

17
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Cooler Assembly Water supply pipe

Fan Guard

Return line system

Oil outlet pipe

Drain Pipe (Water Cooled)

Fluid filter

Oil inlet pipe Thermal valve

Drain Pipe (Fluid Cooled)

Fig. 3-8 Cooling & lubrication system

The cooler is equipped with the coolant recovery tank, to which all air stored up in the water supply
chamber will be pushed from the top as the coolant is heated and expands during operation. If there is
no air in the water supply chamber, the extra coolant will be pushed into the recovery tank. When the
machine is down, the coolant contracts, due to cooling of the engine system, and is forced back to the
main radiator system with air pressure through vacuum valve on the radiator cover. The coolant
recovered by the recovery tank can be recycled.
3.8 Control System
Control system (see Fig. 3-9) is capable of modulating inlet air volume and engine speed
automatically based on air demand, while maintaining a fixed service pressure. The system consists
of:
Inlet control valve, pressure regulation valve, circulation blow-off valve, Start/Run solenoid valve,
Start/Run/Stop switch, orifice, shut-down blow-off valve, piping and connectors.

Normally the control system needs not to be adjusted. In case adjustment is necessary, written
approval from Sullair shall be obtained. Please refer to Section 4.6 – Mode Setting Procedure.

To modulate the capacity of the compressor is to modulate inlet air volume by varying engine’s RPM
and opening of inlet valve. The compressor has four working modes: A. Starting mode; B. Loaded
operating mode; C. Modulating mode; and D. Shutdown mode.
3.8.1 Starting mode
Before starting the machine, turn the Start/Run/Stop switch to “Start” position. Now the inlet valve is
closed under spring force to ensure minimum load upon starting. Once the machine is started, inlet
valve will be opened by vacuum and system pressure will build up rapidly. During pressure rise,
pressure regulating valve does not work and Start/Run solenoid valve is energized. Control air reduces
the inlet valve via Start/Run solenoid valve. Meanwhile, circle unloading valve and blow-down valve
are activated. When air volume from inlet valve equals to air volume to blow-down valve, the inlet
valve is in balance. In the meantime, control air goes to the speed cylinder of diesel engine to control
the engine at idle speed (1300rpm). With the engine fully warmed up (warm-up time is 60s), Start/Run
solenoid valve is cut off and Start/Run/Stop switch will trip to “Run” position automatically. Now the
compressed air that controls the openness of inlet valve and engine speed is completely vented. Inlet
valve is opened again and engine runs at full speed under spring force.

In cold region, it is difficult to start the diesel engine at low temperature. The engine is equipped with
electric heating module. Press the “Test” button below instrument panel and pressure “Preheat” once
the yellow light is on. Preheating function normally ends in 45s. Turn off the Preheat button after
preheating is over and restart the machine.

18
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

3.8.2 Loaded Operating Mode

When system pressure exceeds the threshold of min pressure valve, the valve will open and the
machine will start to service. Now the inlet valve is fully opened and the machine is running under
load. System pressure soon reaches the rating and machine enters normal operating mode. The diesel
engine keeps running at normal speed during normal operation.
3.8.3 Modulating Mode
If the demand of compressed air is lower than machine’s delivery, line pressure will increase. When
the pressure exceeds the threshold of regulation valve, the regulation valve will open gradually,
sending high pressure control air into the piston chamber of inlet valve and speed regulation cylinder
of engine to narrow the inlet proportionately. Meanwhile, system will reduce engine speed. If line
pressure continues to rise, inlet port will be further reduced and so is engine speed until the engine is
running at idle (idle speed is preset).

If demand of compressed air increases now, the pressure which inside the fluid/air separator will drop.
When the pressure drops to the threshold of regulation valve, the valve will close, causing control air
to fully open the inlet valve. Now the engine will run at full speed and the machine will operate at full
load.
3.8.4 Shutdown Mode
Normally the Shut-down blow-off valve is closed. Turn the Start/Run/Stop switch to “Stop” position.
Now the Start/Run solenoid valve is energized. Control air gradually reduces the inlet valve.
Meanwhile, circle unloading valve and blow-down valve are activated to release compressed air in
fluid/air separator. In the meantime, control air goes to the speed cylinder of diesel engine to control
the engine at idle speed (1300rpm). The engine runs at idle speed for 3 minutes. Once the machine is
cooled down, it will stop automatically.

In case of emergency, press emergency stop button to stop the machine immediately. Note that in such
a case, the cooling & lubrication system of compressor unit and engine will stop working immediately
while the machine is still very hot. Therefore emergency stop can be harmful to the machine. Do not
use the emergency stop button unless there is an emergency.

Circulation blow-o ff valve

Orifice Solenoid valve

Shut-down blow-o ff valve

Air filter clog indicator Pressure difference

indicator for fluid/air
separator element
Air filter
Water trap
Pressure regulate valve
Check
valve Electronic drain valve Min pressure valve
Air filter clog
indicator
Air filter Orifice
Inlet control
valve Check valve Relief
Orifice
valve

Filter
Diesel Engine
Air end
Orifice Sight Glass Check valve
Speed Regulation Cylinder Fluid/air separator
Coupling

Thermal
valve

Legend Fluid Piping Air filter clog indicator

Control Air Piping Blow-off valve
Measurement Air Piping
Compressed Air Piping Cooling fan Fluid Cooler Fluid filter

Fig. 3-9 System schematics

19
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

3.8.5 Energy-saving Module

The module is a patented product from Sullair which helps reduce fuel consumption and overall cost
with improved efficiency

3.9 Auto Protection System

Auto protection system is crucial to the machine. It is used to make sure the machine could not be
started, or would stop automatically or otherwise give alarm message in case of fault conditions, thus
protecting the compressor unit and diesel engine. The system consists of compressor discharge
temperature protection, engine fuel level protection, engine coolant temperature protection, engine oil
pressure protection and starting sump tank pressure protection, etc.

When the machine is running, any of the above protection functions may stop the machine or make it
unable to start. Each protection function is detailed below.

 Compressor discharge temperature protection: A temperature switch is mounted on the discharge

piping of air end. When compressor discharge temperature is above the setting temperature
(129℃/265°F for RH model,115℃/239°F for XH and H model), the discharge temperature
switch will open to stop the machine automatically. Meanwhile, corresponding alarm indicator
will appear on instrument panel.
 Hot protection in the fluid/air separator tank: discharge pipe temperature in the air end normally is
higher than that in fluid/air separator tank, and discharge temperature of the air end is protective;
however, to prevent abnormal conditions, such as fire in the separator tank, a temperature switch
should be placed near the mixed gas inlet of the fluid/air separator which acts when the
temperature is higher than the preset temperature (for RH model: 129℃/265°F, for XH and H:
115℃/239°F) and causes the unit power off automatically, Meanwhile, corresponding alarm
indicator will appear on instrument panel.
 Diesel fuel level protection: when the level is below the setting of the level sensor, SULLAIR
multi-function display will show accordingly.
 Engine coolant temperature protection: Coolant temperature switch of the engine is mounted on
the main coolant pipe of the engine. When coolant temperature of engine reaches 107℃ (225°F),
the engine will stop automatically, At the same time SULLAIR multi-function display will show
accordingly.
 Engine oil pressure protection: Pressure of engine oil is crucial to the operation of engine. Normal
engine pressure range is 240kPa to 480kPa. It is normal that the pressure is lower at idle speed. If
oil pressure is lower than 103 kPa(15psi), the engine will stop automatically, At the same time
SULLAIR multi-function display will show accordingly.
 Starting sump tank pressure protection: If the fluid/air separator sump tank pressure is above 15psi,
system is unable to be started and alarm indication will be shown on instrument panel.
3.10 Engine Fuel System
Fuel system is an important system of diesel engine. It significantly influences the power, cost
effectiveness, reliability and durability of the engine. Fuel system provides clean fuel free of dust,
water and air, to meet the requirements of engine on power, torque, RPM, fuel consumption, noise,
emission, start-up and idle speed. The fuel system consists of fuel tank, filling strainer, fuel prefilter,
suction filter, fuel level sensor and fuel piping. See Fig. 3-10.

The filling cap is equipped with a filling strainer. It is convenient for filling operation and can prevent
impurities from entering the system.

Suction filter is mounted on tank. It is used to further remove impurities inside fuel tank.

The prefilter is installed after suction filter and is equipped with a water separator. It not only removes
water inside fuel, but also effectively reduces the load on fuel filters of the engine.

20
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Fuel prefilter
Fuel level sensor
Fuel Suction Tube
Fuel inlet
Suction filter filter

Return pipe

Fuel tank

Fig. 3-10 Fuel System

Maintain the fuel system according to requirements １, you will find out that it is easy to keep the
electric fuel injection system at its top performance and lowest fault rate.
Fuel tank capacity is 275L, sufficient for the operation of one shift with 8 hours. A blow-off valve
under the bottom of fuel tank is used to remove water and impurities accumulated at the bottom of
tank regularly.
See Section 1.6 – Diesel Fuel for details of fuel.
See the Operating and Maintenance Manual of Dongfeng CUMMINS C Industrial Engine for
details of fuel system of the engine.

3.11 Engine Lubrication System

Engine lubrication system provides pressurized fluid to the moving parts of engine to create fluid
friction (contact-free friction), and to cool those parts unable or difficult to be cooled the by cooling
system. The system also cleans the surface of engine parts.
See Section 1.4 – Engine Oil for details of engine oil.
See the Operating and Maintenance Manual of Dongfeng CUMMINS C Industrial Engine for
details of lubrication system of the engine.

3.12 Engine Cooling System

Cooling system of the engine consists of radiator, coolant pump, thermostat, water jacket and rubber
pipe. See Fig. 3-7. Total and partial circulations of cooling system are realized through thermostat to
maintain favorable temperature for engine, thus achieving better power, cost-effectiveness and
reliability.
A temperature switch is equipped on the main coolant pipe of the engine. When coolant temperature
of engine reaches 107℃, the engine will stop automatically. If engine temperature persists above 99℃,

１
1) Use fuel manufactured by a reputable company. Fuel must be settled for at least 24 hours before using to separate
water and impurities.
2) Clean water in the water separator and fuel tank everyday before start to work.
3) Top up fuel tank with diesel after work everyday to expel air and prevent condensate.
4) Clean and service fuel system and fuel filters as specified regularly.

21
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

the engine oil will deteriorate at an early time and the non-metal flexible parts in engine and cooling
system will harden sooner. Therefore operating time above 99℃ should be avoided as much as
possible. Operation at such a condition shall not exceed 50h during a year.
Radiator is an important component of engine cooling system. It is an enclosed, direct flow, forced
circulation tube-and-fin radiator with pressure cap. The opening threshold of pressure cap is 50kPa,
which guarantees that water will not boil below 108℃ at an altitude of 1500m. Pressure cap not only
enhances cooling performance of the radiator, but also reduces or even eliminates bubble and air-lock
in the coolant circulation, especially the air-lock effect around coolant pump inlet (where the pressure
is the lowest). Pressure cap keeps the inlet of pump at positive pressure, reducing erosion on pump
impeller and case, ensuring stable coolant flow and removing heat from the engine with sufficient
coolant.
Please use long-life antifreeze & antirust coolant for the diesel engine. See Section 1.5 – Engine
Coolant. Antifreeze & antirust coolant does not erode metal or rubber materials, and can ensure that
no scale would form in water jackets of the cooling system to protect engine in extremely cold regions.
Coolant should be changed every 2 years or 3000 hours. A properly sealed system needs not to add
coolant frequently. However, user should check and refill antirust regularly to maintain the
concentration. Please fill the coolant slowly in order to release air remnant and vapor created at high
temperature.
Caution: DO NOT MIX antifreeze & antirust of different brands.

3.13 Engine Discharge System

Engine discharge system operates to reduce exhaust noise, prevent exhaust from leaking and keep
exhaust way clear. The system consists of tail pipe, silencer, rainproof cap, etc.
Silencer

Rainproof cap
Tail pipe

Silencer cover

Fig. 3-11 Engine Discharge System

Turbocharger connects to intake manifold on one end and exhaust manifold on the other. All air/fume
sucked in/exhausted by diesel engine goes through the turbocharger. When the engine is running, fume
from exhaust manifold enters turbocharger and pushes impeller; on the other end, air from air filter
enters the inlet of turbocharger and is compressed by turbocharger impeller before flowing into the
intake manifold of engine.
When engine load increases, more fuel will be injected into cylinder and thus more fume generated,
causing turbocharger impeller revolving faster to suck more air. Since extra air is provided by
turbocharger, more fuel will combust, thus higher output power of the engine.

22
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Top speed of turbocharger is controlled by turbocharger control tube, maximum engine racing speed
setting and field altitude.
To eliminate potential scalding or fire caused by hot exhaust piping, the tail pipe is covered with heat
insulation sleeve to insulate heat and reduce noise.
A section of corrugated metal tube is inserted into tail pipe to accommodate heat expansion and
deformation caused by vibration. The rain cap above the outlet of silencer prevents rain/snow from
entering into the silencer. Do not remove the rain cap or replace with an inappropriate one.

3.14 Instrument Control System

See Fig. 3-12 Instruments and controls on the panel include SULLAIR multi-function display,
discharge pressure gauge, discharge thermometer, Start/Run/Stop switch, Preheat/Test/Non-preheat
Switch and alarm indicators. To ensure normal operation of the machine, operators shall be familiar
with the function and use of each display and control in order to make correct judgment according to
readings.

Discharge
overheat

High starting
Discharge temperature Discharge pressure sump tank
pressure
Preheat Start

Test Run

Non-Preheat Stop

SULLAIR Multi-function Display

Fig. 3-12 Instrument & control system

Discharge pressure gauge – It displays the pressure of compressed air supplied by the machine.
Discharge thermometer – It is used to measure the discharge temperature of compressor unit. Normal
reading for RH model should be 176~265℉ (80~129℃) and 176~239℉ (80~115℃) for H and XH
model.
Start/Run/Stop switch – It is used to engage the electrical system of the machine and the starter of
diesel engine. It is a 3-position switch, i.e. “Start”, “Run” and “Stop” in sequence. Turn the switch to
“Start” to start the machine. In such a case the engine will run at idle speed with no load for 60s. Once
it is fully warmed up, the switch will trip to “Run” automatically. Now the engine will run at full
speed and the compressor will work at rated pressure with load. Turn the switch to “Stop” and the will
engine run at idle speed for 3 minutes. Once the machine is cooled down, it will stop automatically.
Preheat/Detection/Non-preheat Switch: when the diesel engine temperature is too low to start, the
switch is placed at “Detection” position, if the battery power is not sufficient, “Preheat” yellow
indicator lights; the unit is ready for the air inlet preheat setting with heating intervals at 45s. Switch
off when the heating is done and restart the unit.
Alarm indicators – Two indicators, Discharge overheat and High can pressure. Corresponding
indicators will be on when there is a fault condition within the machine.

23
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

3.14.1 SULLAIR multi-function display

SULLAIR display can show:

Parameters: General Fault Indicator Shutdown Indicator

(Amber) (red)
 Engine rotation
speed
 Hours of operation
of the engine Screen
Panel box
 Hours of operation
of the unit
 System voltage
 Coolant temperature
Menu key Enter key
 Engine oil pressure
 Fuel level
Left key (up) Right key (down)

SULLAIR multi-function display uses matured technology of capacitive touch key without any tear
and wear. The key effects can be shown by screen flashes, with the functions as below:
Menu key: to enter/exit the menu

Left key: to select left/up

Right key: to select right/down

Enter key: confirm or conceal/read dynamic Fault information

3.14.1.1 Basic application

a. Press the Menu key to enter the menu.

Enter into four parameters display

Language
History Fault Codes
Engine Configuration
Setting single parameter display

b. Scroll to select with Left/Right key.

Enter into four parameters display

Language
History Fault Codes
Engine Configuration
Setting single parameter display

c. In the case of multiple pages, when the cursor is pointed at top or bottom the screen will
auto-page.

24
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Setting single parameter display

Setting four parameters display
Measurement
Backlight Adjustment
Contrast Adjustment

d. When the cursor is pointed at the selected option and press the Enter Key the relevant content
under the option will appear.

e. The “MORE” as shown at bottom of the screen indicates there are more pages to show by
Left/Right key.

More

3.14.1.2 Operation Guidance

a. When the Sullair multi-function display is powered on, the screen will show as they are if the
engine ECU transmission waits for start-up signal. When there is no such info it is possible to
start the engine.

Preheat, Standby

b. Once the engine is started, the rotation speed can be shown on the screen. Press Left/Right key
to browse other parameters.

RPM Water temperature

3.14.1.3 Screen Display Setup

Each screen may display one engine parameter only (the “single parameter display”) or four
parameters (the “four parameters display”).
a. Single Parameter Display
There are three options:

25
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

“Default Settings”– this option includes a set of preset engine parameters: Hours of engine operation,
engine rotation speed, system voltage, battery voltage, engine coolant temperature and engine oil
pressure.
“Customized Settings”– this option allows a user to set up the type, number and sequence of
parameters for display.
“Auto Scan”– if this browse function is selected, the display will automatically display the selected
parameters one by one repeatedly.
b. Display Setup of Single Parameter Display
1. Press the Menu key, and move the Left/Right key to the “Setting Single Parameter Display”, then
press the Enter Key.
2. If “Default Settings” is to be selected, move the cursor on the option and press the Enter key when
the screen displays the message “Restore to Default Settings at Factory”.
3. If “Customized Settings” is to be selected, move the cursor on the option and press the Enter key
when the screen displays the engine parameters available.
4. Press the Left/Right key to the desired parameter and then the Enter key. The number right to the
selected parameter represents the serial number of the parameter.
5. To cancel display of a selected parameter, move the cursor on the option and press the Enter key
when the number right to the selected parameter disappears indicating the display canceled.
6. Move the cursor to select other parameters as Customized settings. To return to the Customized
Setting any time by pressing the Menu key.
7. If “Auto Scan” function is selected, each parameter will be displayed once on a screen repeatedly.

When the above display settings are done, press the Menu key once to return to the main menu, or
twice to Single Parameter Display page.
c. Four-Parameter Display Settings
Four-Parameter Display screen consists of four blocks, each of which represents a parameter. The
four parameters displayed at factory are: coolant temperature, engine rotation speed, engine oil
pressure, and battery voltage. The operator may also customize the parameters for display.

1. Press the Menu key, move the Left/Right key to select the “Setting four-parameter display”, then
press the Enter key.
2. If “Default Settings” is to be selected, move the cursor on the option and press the Enter key
when the screen displays the message “Restore to Default Settings at Factory”.
3. If “Customized Settings” is to be selected, move the cursor on the option and press the Enter key
when the four-parameter screen displays.
4. Move Left/Right key to the block for edit.
5. Press the Enter key and the parameters optional will display. The parameter where the cursor is
located is the parameter to be selected. The number right to the selected parameter represents the
location of the block on the screen.
1 = upper left, 2 = bottom left, 3 = upper right, 4 = bottom right

Engine rotation speed 3

Hours of operation of the engine
Water temperature RPM Fuel level
Engine Coolant temperature 1
Engine oil temperature 2
Engine oil Engine oil Engine oil pressure 4
temperature pressure

6. Press the Left/Right key to the desired parameter and then the Enter key to confirm.
7. Press the Menu key to return to the Customized Settings page.

26
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

8. The newly selected parameter has replaced the old one in the block for edit.
9. Repeat the steps above for customized settings of the remaining blocks.

3.14.1.4 Main Menu Options

In this section the functions all the options under the main menu of the Sullair Multi-function Display
will be introduced. Press the Menu key any time to display these options on the screen. Select with
the Right/Left key and press the Enter key to enter the option as selected.

“Language”

In this option, you can choose Chinese and English. The selected language is suffixed with an asterisk
mark.

“History Fault Codes” *

In this option, you can check the historical fault information of the engine and transmission system.

“Engine Configuration” *

In this option, you can check the configuration data of the engine and transmission system.

* This function is not supported by the all types of engines.

“Measurement”

You can choose appropriate measurement with this option. British: PSI, oF. Metric: KPA, BAR, and
KPa, Bar and oC.

“Backlight Adjustment”

Use this option to adjust lightness of the backlight on the screen.

“Contrast Adjustment”

Use this option to adjust contrast of the screen.

“Tools”

This option provides troubleshooting and setting functions. (For details read the section “Tools”)

3.14.1.5 Fault and Alarm

Sullair Multi-function display provides two methods to display fault of the engine and alarms: the
visual alarm (See the section “Panel Functions”) and the screen display the fault for alarming.

Visual Alarm
 Amber —general fault

27
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

 Red –shutdown
Fault alarm is displayed on screen

Instrument Fault
General Fault
Shutdown

Instrument Fault

Simulation signals on the instruments will be connected to the display. In the event of fault on the
simulation instruction, the single parameter or four-parameter display page will be replaced with the
fault screen message “no response from the instrument”.

General Fault

When the display receives fault signal form the engine, the single parameter or four-parameter
display page will be replaced with the dynamic fault screen page.

Shutdown

When the display receives the shutdown signal form the engine, the single parameter or
four-parameter display page will be replaced with the dynamic fault screen page.

Hints: Fault alarm disappears only when the causes of the fault have been settled.

Fault Confirmation Information

1. Press the Enter key to confirm and hide the dynamic fault message page. The screen display will
return to the single parameter or four-parameter display page. However, the relevant fault symbol will
remain on the page.

2. Press the Enter key to confirm and hide the dynamic fault message page. The screen display will
return to the dynamic fault message page. Press the Enter key again to return to the single parameter
or four-parameter display page.

3.14.1.6 Tools
Choose the “Tools” in the main menu and the options below will appear:

1. “Option List Data”- This option is used to check the instruction related information when the PVA
or PVM simulation instruction is connected with the display.
2. “Clearing all the Option Lists”- Delete the simulation instruction information stored from the
display memory.
3. “Software Version“- Check the displays software version.
4. “Modbus Settings”- See the section “ Modbus Settings” as below.
5. “Fault Version Conversion”- Check/change J1939 Fault Code Conversion.

28
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

Hints: There are four versions of the J1939 Fault Code Conversion. The display will search the J1939
v. 4 by default, and in case of failure the code can be set up to interpret the three other versions of the
J1939 codes. For most of the engines, the ECU (current fault) uses the J1939 v. 4, therefore, this
option is rarely used.
Once a fault received cannot be interpreted, the user may try other version J1939. If it is impossible to
interpret with the changed version (SPN), this means the ECU is using the J1939 v. 4. If it is
impossible to interpret with the changed fault code, try other J1939 version available and continue to
check the fault code (SPN).

6. “Simulation Signal Input”– Two options are available:

“Backlight Adjuster” may be used to receive signal transmitted by an external backlight adjuster.

“Fuel Level” may be used to receive signal transmitted by a fuel level sensor.

7. “Choose Engine ECU”– monitor all the ECU or a specific engine

3.14.1.7 Modbus Setting

1. Enter the “Tools” menu, choose the“Modbus Setting”.

2. Choose between the two communication modes and press the Enter key to confirm.

“Slave Station Activation”– SCADA or remote Modbus Master Station

“Master Station Activation”– Driving simulation instrument

3. Choose “Serial communication port settings” (valid on in the Slave Station Activation mode),
press the Enter key to complete the following settings.

4. Scroll the cursor to set up each of the options: “Baud Rate”, “Parity”, “Data Bit”, and “Stop Bit”.

3.14.1.8 Troubleshooting
“Preheat, Standby” Message on the Screen
If the connected engine ECU (choose the engine) transmits the signal “Preheat, Standby”, the display
will show accordingly. When this message is not shown, the operator may start the engine. Hints: the
engine vendors suggest not start an engine when this message is shown. Once the prestart process
ends, the screen will not display this message any longer.
“CAN Bus Fault” Message on the Screen
CAN bus has not received CAN bus information for at least 30 seconds.
“ECU No Response” Message on the Screen
The engine ECU does not respond to the history fault code (DM2) sent by the display. This means
that the engine ECU may not support broadcasting the history fault code (DM2) on the J1939 CAN
bus.
“No History Fault Code” Message on the Screen
The engine ECU does not respond to the history fault code (DM2) sent by the display. There is no
history fault code.
“No History Option List Data” Message on the Screen
There is no information about the connected Option List.
“No Data” Message in the Parameter Area
The display has not received any information of the parameter for at least 5 seconds.

29
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 3 Description

“Not Supported” Message in the Parameter Area

The engine ECU sends the message to the display to indicate this parameter is not supported.
“Data Error” Message in the Parameter Area
The engine ECU sends the data is error message to the display or to select fule level in the Simulation
Signal Input of the Tool menu, but the display does not connect to Murphy sensor.
The screen display color is too light or dark to read.
It may be caused by inappropriate contrast settings. Press down the Menu key for more than 5
seconds and the contrast will resume to the default setting at the factory.
Caution:
(1) The unit may be restarted only when the pressure in the fluid/air separator is below 15psi (1.0bar).

(2) Oil pressure low indicator will stay on until the pressure goes back to 20~50psi (1.4~3.5bar).

(3) When the machine is not running, turn the Start/Run/Stop switch to “Stop” position to run the machine at
idle speed for 3~5 minutes.

(4) Remove all fault conditions before restarting the machine.

3.15 Electrical System

See Fig. 3-12. The electrical system is responsible for machine start/stop, parameter display and
automatic protection. The system consists of battery, engine starter, alternator, start/stop relay, electric
cabinet, sensors and switches.

3.16 Frame System

The machine is mounted on a two-wheel moving frame for convenient mobility. Drawbar of the
machine cannot be folded. A leg with adjustable height is used to support the machine. The leg can be
adjusted within a range of ±15°. Height of the drawbar can be adjusted as well (within a range of
480mm) to accommodate all types of tow vehicle.
The lifting chain of the machine is used for protection during lifting operation. Use the chain for
lifting. The grounding chain in the back of the machine is used to ground the machine during lifting.
Do not remove it.

3.17 Enclosure Assembly

The enclosure of the machine is elegant and conducive to ventilation. All components need to be
serviced can be accessed through air spring supported flip-up service doors. Enclosure is properly
sealed to prevent rain. Heat-resisting, flame-retardant and acoustic material is arranged inside the
enclosure, significantly reducing noise of the machine. Reflective label and warning decal provide
instruction to operators on how to operate and maintain the machine properly and safely.

30
 1 1 1

E-stop
KA9 EH1
1
KT2 KA7 KA1 KT1(180S)
46
(60S) Inlet preheater
QF3(10A)
14 1

14 7 7 7 7 6 5 4 1
1
YV1 QF1(10A)
Loading/Unloading Solenoid Valve KA8 8 QF2(40A)
Two-Position Two-Way Normally Closed
KA2 KT3 * KT2 * 60
Start switch 3
8 2
43 41 3 1
43 43 43 KA1 *
0 0 +
11 KA0
KT1 KA5 KA6
KT4 * KV1 KV1 0 (180S) 3
0 40 3 While Starter
KT4 0 KA3
Red
KA6
(45S) 9 YV2
42 12 26 0
40 0
44 Start relay KA0 Fluid cut-off solenoid valve
45 Preheat switch Black 34
KA8 KA4 KA5
KA8 0 N
0 KA9 Fluid Cut-Off
13 Relay
0 Alternator
KA7
MeCAN 0 E R

7 7 7 7 7 7 7 Rotation Measure Terminal (Purple) 0

7 Power + Pole (Red) 34 35
Rotation Calibration Terminal (Grey)35

Fig. 3-12 Wiring Diagram

0 Power - Pole (Black) Rotation Feedback Terminal (Green-yellow) 0

Water Temperature Measure Terminal (While) 33

1
16 CAN high (yellow)
17 CAN low (Green) Oil Pressure Measure Terminal (Orange) 32
1
DC 24V
Unit Temperature
KT3 Engine Oil Switch (Sum Battery
Pressure Tank)
(5S) Switch KA4 5KΩ DC12V
1 KA3 27 POWERVIEW Adjustable
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual

17 CAN low Resistance

(Green) Battery
Starting CAN high Oil Level Rotation DC12V
SU L LAI R R 22 sump tank
7 16 (yellow) Measure 31
pressure Terminal Speed
Unit Temperature Switch 25 7 Power + Pole (Blue) Corrector
0 Switch(Discharge (Red) 31 32 33
Port) Power - Pole
Engine Water 0 (Grey)
G G G
Temperature
Switch
21 23 24
Sullair Patent Fluid level Engine Oil Coolant
Oil-saving module temperature Main Power Switch
sensor Temperature
KA2 KA4 KA5 sensor sensor
0 0 0 0 0 0 0 0 0 0 0
Engine Oil Cooling Water Unit Temperature Unit Overheat
Pressure Test Temperature Test Test
Section 3 Description

31
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 4 Operation

Section 4 OPERATION
4.1 General

While Sullair has built into the 550RH-750H diesel portable fluid injection screw compressors a
comprehensive array of controls and displays/indicators to assure you that it is operating properly,
you will want to recognize and interpret the readings or conditions displayed/indicated to
determine the condition or malfunction of the machine. Before starting the machine, familiarize
yourself with the controls and displays/indicators – their location, purpose and use.

4.2 Purpose of Controls and Indicators

Component Location Purpose and/or use
Turn the switch to “Start” to start the machine. In such a case the engine
will run at idle speed with no load for 60s. Once it is fully warmed up, the
Start/Run/Stop switch
switch will trip to “Run” automatically. Now the engine will run at full
speed and the compressor will work at rated pressure with load.
When the engine cannot be started due to low temperature condition, place
Preheat/Test/Non-preheat the switch at the “Test” position. If the battery power is sufficient, “preheat”
Switch button lights (yellow) and the unit can be set for inlet preheat at interval of
Instrument & 45s. Switch off this button when heating is complete and restart the unit.
control panel
Discharge pressure gauge Service pressure of the machine.
Discharge thermometer Discharge temperature of compressor unit.
SULLAIR Multi-function
Display
Display the running parameters of the engine
Corresponding indicators will be on when there is a fault condition within
Alarm indicator
the machine.
Compressor air filter
plugging indicator When the indicator is in red zone, it means the air filter element is seriously
Air filter
Engine air filter plugging plugged and requires immediate maintenance or replacement.
indicator
Inlet control valve Inlet port of air end Adjust inlet volume based on the demand for compressed air.
Fluid/air separator
Sight glass It is used to check the fluid level and quality inside the separator.
sump tank
It is used to adjust the temperature of compressor fluid. It is closed when
Fluid exit of
Thermal valve fluid temperature is low to bypass the fluid. In such a case the cold fluid
fluid/air separator
will not flow through fluid cooler.
Discharge temperature
Discharge pipe Stop the machine automatically when temperature exceeds the setting value.
switch

Engine oil pressure switch Stop the machine automatically when oil pressure exceeds threshold.
Diesel Engine
Stop the machine automatically when coolant temperature exceeds
Engine coolant switch
threshold.
Diesel fuel level sensor Fuel tank Message will be given if fuel level is above threshold.
Temperature switch of the Fluid/air separator
Stop the machine automatically when temperature exceeds the setting value.
fluid/air separator tank tank
Fluid/air separator
Min pressure valve It keeps the air pressure in separator.
cap
It ensures that the pressure vessel would work at safe operating pressure.
Fluid/air separator
Relief valve When the pressure inside the separator exceeds safety pressure setting, the
sump tank
relief valve will open to vent air.
When line pressure reaches setting, it sends control air to the inlet valve of
Pressure regulator compressor and speed regulation cylinder proportionately to adjust inlet
volume and rotating speed
Send control air to the inlet valve and speed regulation cylinder to adjust
Start/Run solenoid valve inlet volume and rotating speed when the machine is being started and
Control pipeline
stopped.
Filter Filter out water and foreign content in the control air
Blow-off Valve Release the compressed air in separator when the machine is being stopped.
It is used to ensure working cycle of the compressor when preheat
Circulation blow-off valve
and adjustment is initiated.

32
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 4 Operation

4.3 Initial Start-up Procedure

1) Park the machine on a level ground upper-wind of the construction/operation site. Check
coolant level in radiator ２. Add coolant as stated if the level is low.
2) Check fuel tank to see if diesel needs to be filled ３.
3) Drain the water in the water separator of fuel system.
4) Check engine to see if engine oil needs to be added ４.

Caution: See Section 1 of this Manual and the Operating and Maintenance Manual of Dongfeng CUMMINS
C Industrial Engine for details of engine coolant, fuel and engine oil.

5) Check compressor fluid level５. Normally the fluid level should fall slightly under the
center of upper sight glass.
6) Close all service valves.
7) Put Start/Run /Stop switch to “Start”.
8) Check the condition of each instrument.
9) Press the button of “Start”, once the machine is started, let it warm up at 1400rpm for 1
minute, and the machine will enter running mode automatically. Now the engine is running
at rated speed and the compressor reaches rated discharge pressure quickly.
10) Close all service doors to contain machine noise and ensure proper ventilation.
11) Check the readings of instruments on instrument panel. See Section 4.5 – Troubleshooting.
12) After initial start-up, stop the compressor according to procedure. Check radiator to see if
additional coolant is required and if additional fluid is required in fluid/air separator. Check
each point of connection to see if there is any looseness. Check the tension of fan belt.
13) Make sure that the stay bolt for transport on the fluid/air separator base and the stay bolt
(marked in red) for transport on the diesel engine and air end support are loosened prior to
power-on.

▲Warning
Never load the machine when it is cold.
Never let the engine run at idle speed for more than 10 minutes.
Avoid continuous operation when coolant temperature is below 60℃ or above 100℃.

4.4 Subsequent Start-up Procedure

1) Park the machine on a level ground upper-wind of the construction/operation site. Check
coolant level in radiator. Add coolant as stated if the level is low.
2) Check fuel, coolant and engine oil. Add if necessary.
3) Check fluid level in fluid/air separator. Add if necessary.
4) Drain the water in the water separator of fuel system. Drain the water separated from fuel
tank. Drain the condensate in fluid/air separator sump.
5) Proceed with step 3) to 12) of Initial Start-up Procedure.
Caution: Drain the condensate from fluid/air separator sump regularly before starting the machine for the first
time every day.

２
Coolant is 50:50 glycol solution and has been filled at factory.
３
Fuel tank capacity is 275L.
４
Engine oil capacity is 18L and has been filled at factory.
５
Compressor fluid capacity is 26L (6.8gallon) and has been filled at factory.

33
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 4 Operation

4.5 Shutdown Procedure

1) Close all service valves. Press “Stop” button and the engine will run at idle speed for 3
minutes before shutting down.
2) In case of emergency, press emergency stop button to stop the machine immediately. Note
that in such a case, the cooling & lubrication system of compressor unit and engine will stop
to work immediately while the machine is still very hot. Therefore emergency stop can be
harmful to the machine. Do not use the emergency stop button unless there is an emergency.

▲Warning

Never shut down the machine directly during normal operation.

Caution: Each time after work, top up the fuel tank to avoid forming of solid coagulant or condensate in the tank.

4.6 Mode Setting Procedure

Mode Setting Procedure including the setting of no-load speed and rated speed of engine, and
rated pressure and low pressure of the machine. See Section 1 – Specifications for rated pressure
of the compressor.
4.6.1 Setting of Rated Mode

1) Close all service valves.

2) Start the machine according to subsequent start-up procedure.
3) Slowly open the service valve (venting behind) to speed up the engine. Then adjust the
opening of service valve to maintain system pressure (sump tank pressure) at rated operating
pressure (see Section 1 – Specifications).
4) Slowly close the service valve. When system pressure reaches “rated operating pressure + (1
~ 1.4bar)”, the pressure will stop to rise any more. Now the engine runs at idle speed and the
machine stops to supply air. If the rated pressure is not achieved, adjust pressure regulation
valve accordingly.
5) Open/close service valve repeatedly and check the system operating pressure setting. If the
setting is incorrect, find out causes and readjust until the pressure setting is right. Then lock
with adjusting screw.

▲Warning
Service valve should be opened slowly. Opening/closing service valve frequently or opening the service
valve abruptly may introduce oil in compressed air or abnormal opening of relief valve.

4.7 Jump Start Procedure

▲Warning
The battery may contain hydrogen. Since hydrogen is highly inflammable and explosive, no sparks,
flames and other sources of ignition shall be present near the compressor.
Electrolyte in battery is highly corrosive and toxic. Never contact it with eyes, skin or fabrics.
Otherwise, it may cause injury or loss of property. In case of electrolyte spill, flush with large amount of
water immediately.

1) Before jump start, read Section 2 – Safety of this Manual carefully. Jump start is an
emergency procedure in case that the battery capacity is low.
2) Wear an acid-proof apron and a face mask before operation.
3) Remove the vent hole cap of battery (if any). Be cautious not to allow the dust or impurities to
fall into the battery. Check the level of electrolyte and add if necessary. Then use clean wet
cloth to cover the vent hole. “Maintenance free” battery does not need electrolyte level check.

34
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 4 Operation

Caution: If the electrolyte is frozen or has ice in it, never start the compressor. Otherwise, the battery may
explode ６.

4) Park the power source vehicle beside the machine. Note that there should be no metal contact
between the vehicle and compressor.
5) Activate the parking brake of power source vehicle and block wheels using stone blocks or
other objects.
6) Set the power source vehicle to Neutral or Parking gear. Turn off irrelevant electrical
equipment on the vehicle and start engine.
7) Connect one end of the first jumper wire with the positive pole of the source vehicle. If the
source vehicle has two 12V batteries in series, connect the wire onto the positive pole of the
non-grounded battery.
8) Connect the other end of the jumper wire with the positive pole of the battery of compressor
starter. If the source vehicle has two 12V batteries in series, connect the wire onto the positive
pole of the non-grounded battery.
9) Connect one end of the second jumper wire with the negative pole of the source vehicle. If
the source vehicle has two 12V batteries in series, connect the wire onto the negative pole of
the grounded battery.
10) Connect the other end of the second jumper wire onto the diesel engine.
11) Start the machine according to normal starting procedure. Be careful not to ignite
continuously for a long period of time.
12) Let the engine warm up to steady condition at idle speed. Remove the negative terminal from
the machine, and then remove the other end from the negative pole of the source vehicle.
Remove another wire from the positive pole of the machine battery, and finally remove the
positive terminal from the source vehicle.
Caution: ① The jumper wire should be clean, and the rated current of the wire should be greater than the starting
current.
② Avoid accidental contact of the wire lead and wire clip with other metal parts to prevent electric arc,
which may cause fire.
③ Do not connect 24V power supply to a battery of 12V, and do not use a 12V battery to start the
compressor requiring 24V voltage.
④ Only use the source vehicle with a battery system similar to that of the machine for power supply,
and the supply voltage should be the same. Do not use power generator, electric welder or other DC
power as power source, which may cause accident.
⑤ Make sure the wire lead is firmly attached and is away from fuel line, crankcase vent hole and
battery.

4.8 Storage
If the machine is not operated for a few weeks, fluid will run off from lubrication surface of
engine and compressor. Lack of fluid will cause rust on friction pair parts and create direct metal
contact between piston, piston and cylinder sleeve, between the shaft and bearing and between
the crankshaft and connecting rod bearing pad upon next startup. Such direct metal contact,
especially when rusty, will greatly shorten the service life of machine. Therefore, it is required to
do the following after operation each time:
① Carry out maintenance as per maintenance regulations in this Manual, and cover the
rain-protection canvas onto the machine.
② The machine storage place should be clean and dry, free of corrosive gas.
③ Start the machine once a week (at least once a month), and carry out routine regular
inspection. If the machine is not to be used for a long period of time, protect and keep the
machine properly. For the requirements of safekeeping, please contact Sullair Asia Service
Department and CUMMINS Service Department.

６
The machine is installed with low-temperature start battery at factory.

35
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

Section 5 MAINTENANCE
5.1 General
Appropriate maintenance is crucial to the operation and lifespan of the machine. Therefore, the
maintenance procedures of rotary screw compressor must be followed. Service program given
below will keep the machine at top performance. Besides this section, see the Operating and
Maintenance Manual of Dongfeng CUMMINS C Industrial Engine for maintenance of diesel
engine. Before any maintenance work, please read Section 2 – Safety of this Manual.

▲Warning
Maintenance not only affects proper operation of the compressor but also the safety of the operators.
Please drain water in the fuel water separator and fuel tank every day before starting the machine to
ensure proper operation of diesel engine.
Do not remove nuts, oil plugs, and other parts when the compressor is running or pressurized.
Shut down and bleed internal pressure of the compressor prior to operation.

5.2 Maintenance of Rotary Screw Compressor

Rotary Screw Compressor Maintenance Schedule describes the daily service of the compressor.
Please service the machine according to the Operating Hour or Maintenance Interval stated in the
Schedule, whichever comes first.
Check fluid level before starting. If fluid is low, please refill. If the machine needs to be refilled
frequently, you need to check the machine. See Troubleshooting.
Once the machine is started, check instrument readings. After the machine is warmed up, check all
instruments/gauges and check for oil/air leakage. Check for abnormal mechanical sound. If yes,
please stop and release pressure before taking further procedures.
Rotary Screw Compressor Maintenance Schedule:
Operating Maintenance Maintenance
Maintenance description
hours interval position
Clean the dust collection pocket. Service the
Air filter
filter element if there is an alarm.
Fluid/air separator Bleed water entrapped before start up.
10 Daily Fuel/water
Bleed water entrapped before start up.
separator
Refill fuel every day after operation. Bleed
Fuel tank
water entrapped before start up.
Relief valve Check if it is plugged/damaged.
Replace filter element after the first 50
50 Weekly Fluid filter
operation hours.
In 50 hours after initial start-up, clean return
Return line
line orifice and strainer.
Fluid cooler Clean surface.
200 1 month Fan belt Check tension.
Battery Check electrolyte level.
Air filter Service main filter element.
300 2 months
Fluid Change fluid if not AWF® fluid.
Fluid filter Change element if AWF® fluid.
500 4 months Fuel line Check, clean if dirty and plugging.
Hose Check, change if necessary.

36
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Operating Maintenance Maintenance
Maintenance description
hours interval position
500 4 months Fluid Change fluid if AWF® fluid for RH model,
Fluid return line Clean orifice and filter.
1200 8 months Bearing of
Add grease.
moving system
Replace main filter element and safety
Air filter
element.
2000 12 months
Replace the rubber hose in fluid line, control
Rubber hose
line and fuel line.
Change fluid if AWF® fluid for XH and H
2500 12 months Fluid
model,.
Fluid/air separator
Pressure difference indicator points red.
As required element
Battery Clean terminals, apply oil.

5.2.1 Relief valve maintenance

Plugged relief valve will result in failure to open, or close after opening. In the first case, the relief
valve will not provide protection against the pressure system, thus the compressor. In the latter
case, fluid blowing out of the sump tank may lead to property loss. Stop the compressor weekly
and check the relief valve condition.
5.2.2 Fluid filter maintenance
After initial 50 hours operation, change fluid filter element, then after every 500 hours or four
months of operation, change the element. For element change procedure see Section 5.4: PARTS
REPLACEMENT AND ADJUSTMENT PROCEDURES. It is necessary to stop the machine
before changing the element. Carefully wipe away dirty or oily foreign substances and avoid
foreign substance entering the lubrication system.
5.2.3 Fluid maintenance
If AWF® fluid is used, It is necessary to replace lubricant oil for the model RH for every 500 hours
or four months, and for the model XH and H for every 2500 hours or 1 year, whichever is earlier.
Note: Change interval of different types of fluid varies. Refer to detailed information in Section 1:
SPECIFICATIONS.
If the compressor is running in bad environment, change interval will be shortened.
Some fluids are incompatible, if mixed, will lead to formation of indiscernible sediment, which may cause
fluid filter plugged and other severe problems. Therefore, always avoid mixing different types of fluid and
use different type of fluid only after all fluid is drained.
This screw compressor made by Sullair uses Sullair® Fluid AWF®, which is availed at this company and
local branches.

Should fluid level in the sump tank is below the middle position of the sight glass after the compressor is shut
down, add fluid. However, this addition should be made only after the compressor is shut down and is drained.

Note: Formation of indiscernible sediment on the fluid filter element indicates that the compressor fluid is bad for
proper operation, change immediately.

5.2.4 Return line maintenance

The purpose of the return line is to return fluid entrapped in the fluid/air separator element to the
compressor low-pressure chamber, on which orifices keep proper return flow. If the return line is
plugged severely, especially in orifice and strainer, discharged air will contain excessive fluid.
Check return line regularly, clean the orifice and strainer.

37
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

5.2.5 Fluid cooler maintenance

When oil, grease, dust and dirt collect on the cooler surface, the heat exchange effect will be
reduced, ultimately leading to very high discharge temperature. For every one month or 200 hours,
use dust collector, detergent or low-pressure compressed air to clean the cooler surface.
5.2.6 Air filter maintenance
The air filter should be checked daily.
Clean the dust collector daily. Do it more frequently in dusty environment.
When air filter alarm indicator is on, service the filter element. Air filter element should be
replaced every 2000 operating hours or a year, whichever comes first. See Section 5.4 – Parts
Replacement and Adjustment Procedures on how to change filter element.

5.2.7 Fluid/air separator maintenance

Generally, if the air filter and fluid filter are maintained properly, it is not required to change the
fluid/air separator element regularly.
If pressure difference indicator of fluid/air separator points red, or when fluid contained in
discharged air surges, check the fluid/air separator element, or change it as required in Section 5.4:
PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES.
When condensation water mixes with fluid, the fluid will become emulsified and deteriorated.
Prior to routine start, open drain ball valve at the bottom of the sump tank to drain water that was
collected in previous day. If fluid emulsification is severe, simply change fluid.

5.2.8 Battery maintenance

Keep battery leads, connectors, and cord grips clean, and wipe with oilcloth to prevent corrosion.
Maintain proper electrolyte level in the battery.

5.2.9 Wheel/tyre pressure

The compulsory tyre pressure is 690-760kPa, see Section 1: SPECIFICATIONS.
Grease roller bearings of the axle each year. To grease, remove end covers.

5.2.10 Hose maintenance

For every 500 hours or four months of operation, check inlet hose, hoses in lubrication piping and
control line, and change if necessary. For every 2000 hours or one year of operation, whichever
occurs first, change the rubber fitting in the fluid rubber line, control line and fuel line.

5.3 Maintenance of Diesel Engine

Diesel Engine Maintenance Schedule:

Operating Maintenance
Maintenance item Maintenance description
hours interval
Oil sump Check oil lever, refill if necessary.
Radiator Check coolant lever, refill if necessary.
Clean dust collector. Service filter element if
Air filter
10 Daily there is an alarm.
Fuel tank Discharge water and sediments.
Prefilter Drain water.
Diesel engine Check diesel engine for abnormities.
Fuel suction filter Check or clean.
50 Weekly Check status and tension after the first 20 to
Belt
40 hours.

38
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Operating Maintenance
Maintenance item Maintenance description
hours interval
If not using API CH-4 with TBN minimum
Oil sump
value of 11, replace oil and fluid filter.
Engine valve clearance Measure/adjust by professionals.
Alternator Check.
Battery Check electrolyte level.
Belt tension Check. Adjust if necessary.
Cylinder head
Check/clean/fasten.
grounding stud
300 2 months
Crankcase vent hole Clean.
Fuel/water separator Replace.
Primary fuel filter Replace.
Secondary fuel filter Replace.
Cooling system Check/add SCA antirust.
Radiator Clean surface.
Air filter Check for damage and clean.
Inlet system Check for leak and clean.
Engine valve clearance Measure/adjust by professionals.
600 4 months
Engine speed Check and adjust.
Fan hub Check.
1200 8 months
Belt Check tension. Replace if necessary.
Replace main filter element and safety
2000 One year Air filter
element.
3000 Two year Cooling system Change coolant.
Cooling system Drain and wash if coolant is dirty.
As required
Fuel system Refill and vent the fuel system as required.

Diesel Engine Maintenance Schedule describes the daily service work of the diesel engine.
Please service the engine according to the Operating Hour or Maintenance Interval stated in the
table, whichever comes first. Engine may need to be serviced more frequently in harsh
environment. See the Operating and Maintenance Manual of Dongfeng CUMMINS C
Industrial Engine for other maintenance requirements and operation description of the diesel
engine.
5.3.1 Fuel tank
Fuel tank should be refilled with diesel suitable for local ambient temperature daily or every 8
hours. In order to prevent fuel from freezing, it is recommended to refill the tank everyday after
work, and drain the condensate in the tank next day before starting the machine.
5.3.2 Engine oil/fluid filter
Check oil level using dipstick oil ruler everyday. Oil level should be in the range between Max
and Min mark. Discharge oil if oil level exceeds the Max mark and add oil if lower than the Min.
If API CH-4 oil with TBN minimum value of 11 is used, change the oil and fluid filter every 300
operating hours or 2 months, whichever comes first. See Section 5.4 – Parts Replacement and
Adjustment Procedures on how to change.
If oil is diluted, a thorough check must be carried out to find out the cause. Otherwise diesel
engine may be seriously damaged.

39
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

5.3.3 Coolant radiator/intercooler/cooling system

Check coolant level everyday. Add if necessary.
If coolant needs to be added everyday, please check cooling system for leakage.

▲Warning
Coolant is hot and pressurized when the machine is running.
Hot coolant and vapor may cause injury.
Check coolant level only when the diesel engine is not running and the radiator cap is not feeling
hot.
Screw off radiator cap slowly to release pressure.
Antifreeze/antirust contains alkaline, which may cause injury if contacted with skin or eyes.
Never use water as antifreeze/antirust coolant.

The performance of cooler will be impaired if cooler surface is covered by oil, grease, dust or
contaminants. This could lead to coolant ebullition and machine unable to operate, or intake air
overheat even if it is cooled. Please clean the cooler surface with vacuum, detergent or
low-pressure compressed air twice a month.
Check SCA content (see the table below) in coolant every 300 operating hours or 2 months, in
order to protect engine cooling system from being damaged by coolant contamination, weld point
yellowing and general erosion. Add if SCA content in the antifreeze & antirust coolant is low.
SCA content check table
Spec. Color Freezing point ℃ Specific gravity PH
-50 Blue -50 1.070～1.060 7.5～9
-40 Blue -40 1.060～1.055 7.5～9
-35 Blue -35 1.055～1.050 7.5～9
-30 Blue -30 1.050～1.040 7.5～9
-20 Red -20 1.030～1.035 7.5～9
-10 Red -10 1.020～1.025 7.5～9

Caution: Before adding antirust to cooling system, you may need to discharge some coolant from the drain
valve at the bottom of radiator.
Check radiator cap gasket. Replace if damaged.

Coolant should be replaced every 3000 operating hours or two years, whichever comes first. See
Section 5.4 – Parts Replacement and Adjustment Procedures.

5.3.4 Inlet system

Air filter should be checked every day.
Clean dust collector and collector cap everyday. Do it more frequently in dusty environment.
When air filter alarm indicator turns red, service the filter element. Check air filter for damage and
leak in inlet system every 300 operating hours or two months, whichever comes first. Air filter
element should be replaced every 2000 operating hours or a year, whichever comes first. See
Section 5.4 – Parts Replacement and Adjustment Procedures on how to service or change filter
element.

5.3.5 Fuel Filter and Water Separator

Discharge the water in water separator everyday.
Replace fuel filter (including water separator) every 300 operating hours or two months,
whichever comes first.
If air exists in fuel system, it will be hard to start engine or engine will work unsteadily. In such a
case, vent the system manually.

40
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

▲Warning
Do not vent the air while engine is hot. It may cause fire if fuel is spilled on the hot exhaust manifold.

5.3.6 Fuel Suction Filter

Check or clean suction filter weekly to clean dirt collector and sieve mesh.

5.3.7 Belt Tension

Check belt tension after the first 20 to 40 operating hours. Check belt tension as follows every 300
working hours or two months thereafter, whichever comes first.
 Check belt for damage. See if there is wear or crack. Replace worn or damaged belt.
 Check belt tension. Check fan belt tension. Apply a force of 110N in the mid-point
between the belt wheels. Properly adjusted belt shall have an offset of 9 to 15mm. If the
tension is not right, adjust through alternator.

5.3.8 Valve Clearance

Check valve clearance after initial 300 operating hours or two months, or every 600 operating
hours or 4 months, whichever comes first. For a new engine, it is recommended to check valve
clearance at the first time of oil change. Only qualified person may do it.

5.4 Parts Replacement and Adjustment Procedures

5.4.1 Changing Compressor Fluid
Keep the compressor running for 5 to 10 minutes to warm up the fluid. Stop the machine and
release all internal pressure. Open the drain globe valve at the bottom of fluid/air separator to
discharge fluid. Refill fluid and replace filter element. See 4.2 – Changing Fluid Filter and
Section 1 – Specifications.

Caution: Do not contact fluid with skin. Hot oil may cause scald.

5.4.2 Changing Fluid Filter

① Use belt wrench to remove used filter element and gasket.
② Clean gasket mounting surface.
③ Apply a thin layer of oil on the new gasket.
④ Fill the new filter with clean fluid.
⑤ Screw the filter until gasket contacts the base. Then further screw 1/2 to 3/4 circle.
⑥ Restart the machine and check for leakage.

▲Warning
In order to minimize damage to the filter element, use Sullair product only since other products may
not match the machine pressure.

5.4.3 Servicing and Changing Air Filter

Clean dust collector every day. Do it more frequently in dusty environment.
When air filter pressure drop indicator turns red, service the filter element. Check air filter for
damage and leak in inlet system every 300 operating hours or two months, whichever comes first.
Air filter element should be replaced every 2000 operating hours or a year, whichever comes first.
Safety filter element does not need maintenance normally and should be replaced together with the
main element.

41
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

Servicing and replacing procedure of air filter element:

① Remove rear cap and clean the dust collector and rear cap;
② Remove main filter element carefully. Check it in front of a light source for damage. ;
③ Use a clean wet rag to clean the inner side of air filter. Do not use compressed air;
④ Tap the end side of the filer element on a flat board. Use dry compressed air not
exceeding 2.1bar (30psi) to blow off the dust in the fold from inside in a direction 45°
to the longitudinal filter;
⑤ Reinstall the cleaned or new filter element;
⑥ Install dust collector and rear cap with opening of dust collector in correct direction.
Caution: Do not disassemble and replace air filter element when compressor is running.
Never clean filter element with oil, water or compressed air that contains water.
Filter element with damaged filter paper or gasket must be replaced immediately.
Apply small amount of oil on the surface of gasket before installing the filter element to prevent adhesion
between gasket and air filter canister.
Inferiors or unqualified air filter element may cause diesel engine not working at full power, oil needs to
be replaced frequently, early wear out of diesel engine and even scuffling.

5.4.4 Changing fluid/air separator Element

If oil is detected in service air while return line strainer, check valve, orifice and blow-off valve
diaphragm are working properly, the fluid/air separator element should be changed as follows:
① Detach all pipelines from flat cap (return line, service pipe, etc.).
② Remove return line (stainless steel pipe) from flat cap connector.
③ Remove bolts and gasket and pull out flat cap (do not remove the min pressure valve).
④ Pull out separator element.
⑤ Clean the gasket surface between flat cap and canister. Do not let debris or dust fall into
the canister.
⑥ Install the new separator element. Do not remove the staple on gasket.
⑦ Install flat cap. Screw on the bolts with hand. Then fasten the bolts in ④ to ⑤ steps
alternately.
⑧ Reconnect all pipes. The stainless steel fluid return should be 1.5mm from the bottom of
separator element to ensure smooth fluid flow.
⑨ Clean return line strainer, orifice and check valve before restarting the machine.
⑩ Fasten bolts on the flat cap as described in step ⑦ after running for 24 hours.

5.4.5 Changing Fuel Water Separator/Fuel Filter

① Use belt wrench to remove used filter element and gasket.
② Clean gasket mounting surface.
③ Apply a thin layer of oil on the new gasket.
④ Fill the new water separator/fuel filter with clean fuel.
⑤ Screw the filter until gasket contacts the base. Then further screw 1/2 to 3/4 circle.
⑥ Restart the machine and check for leakage.
Caution: Fill up the filter element with fuel. If air exists in fuel system, it will be hard to start the engine or engine
will work unsteadily.

42
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

5.4.6 Changing Coolant

▲Warning
Coolant is hot and pressurized when the machine is running.
Hot coolant and vapor may cause injury.
Check coolant level only when the diesel engine is not running and the radiator cap is not feeling
hot.
Screw off radiator cap slowly to release pressure.
Antifreeze/antirust contains alkaline, which may cause injury if contacted with skin or eyes.
Never use water as antifreeze/antirust coolant.

① After the machine is stopped and coolant is cool, screw off radiator cap slowly to release
pressure.
② Screw off drain valve of radiator to discharge coolant of radiator and engine.
③ Close drain valve.
④ Refill coolant as described in Section 1.5.
⑤ Fasten radiator cap.

5.4.7 Changing Engine Oil

Keep the compressor running for 5 to 10 minutes to warm up the fluid. Stop the machine. Open
the drain valve at the bottom of oil sump to discharge oil. Refill oil and replace filter element. See
Section 5.4.2 – Changing Fluid filter and Section 1 – Specifications.

Caution: Do not contact fluid with skin. Hot oil may cause scald.

5.4.8 Adjusting Regulation System

If the compressor cannot reach rated operating pressure or speed, the regulation system needs to
be adjusted. See Section 4.6 - Mode Setting Procedure for details.

5.5 Troubleshooting

Machine fault could be caused by various reasons. Normally a fault is not caused by just one
component or one reason. Therefore troubleshooting can be difficult.
The troubleshooting table is based on extensive field application and laboratory data of
manufacturer. It illustrates common faults that may happen to the machine and general causes and
resolutions of the faults. It may not explicit all possible faults and resolutions.
Before repair or replace any part, please analyze all possible causes thoroughly. When a problem
is encountered, observe carefully and find out fault and its causes before service to avoid
unnecessary damage to the machine.
Always keep the following in mind:
a. Check loose electric wire;
b. Check damaged piping;
c. Check for part damage caused by overheating or short circuit (normally accompanied by
color change or burnt smell).
If the fault condition may not be resolved according to the recommended method, please contact
local representative of Sullair or Sullair Service Department.

43
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

TROUBLESHOOTING
Symptom Probable cause Remedy
Check to see if the air demand matches compressor
Air demand is excessive
delivery.
Engine speed low Adjust speed or check engine fuel filter.
Check if there is any service indication on
Air filter plugged
instruments. Replace filter element if necessary.
Compressed air leakage Check air service pipe and valve for leakage.
1. Insufficient air
delivery Adjust pressure regulation valve as described in
Pressure regulation valve failure Section 4 - Operation. Check regulation valve
or damaged diaphragm and replace if necessary (spare parts
provided).
Fluid/air separator element
Replace separator element, fluid filter and fluid.
plugged
Compressor rotor wear Contact Sullair technician.
Check to see if the air demand matches compressor
Air demand is excessive
delivery.
Check if the pressure drop indicator turns red.
2. Low service Air filter plugged
Clean/replace filter element if necessary.
pressure
Compressed air leakage Check air service pipe and valve for leakage.
Pressure regulation valve failure
Check/replace (spare parts provided).
or damaged
Fluid level in sump tank low Add fluid. Check for leakage.
Fluid cooler is dirty or clogged. Clean fluid filter fin.
Fan belt loose or damaged Adjust tension wheel or replace belt.
3. Compressor Thermal component of thermal
Replace thermal component.
overheat valve failure
Fluid filter plugged. Replace filter element.
Return line plugged. Clean return line strainer and orifice.
Hot air circumfluence Move the machine or change direction to avoid
circumfluence.
Clogged return line strainer Clean strainer and orifice.
Check all pipes, connections and components.
Leak in lubrication system
Repair or replace if necessary.
4. Excessive fluid Fluid/air separator element
Replace the element.
consumption damaged.
Low system pressure Check min pressure valve and orifice of silencer.
Check fluid level from sight glass. Drain excess
Fluid level too high
fluid.
Pressure setting of pressure
Adjust pressure setting.
regulation valve is high
Control air leakage Check control line.
5. Relief valve Inlet valve will not close (stuck) Service or replace inlet valve.
opened Control system clogged Check control line.
Pressure regulation valve failure
Check/replace (spare parts provided).
or damaged
Relief valve failure Replace.
Out of fuel Check fuel level and fuel system.
Discharge temperature switch Activation of discharge temperature switch may be
activated caused by overheat compressor. See item 3.
6. Compressor Coolant overheat Check coolant level, thermostat and fan.
shuts down with
air demand Low coolant level Check coolant level.
present Low oil pressure Check dipstick and fluid filter
Switch failure Test the switch.
Electric circuit failure Test electric circuit.

44
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Engine speed low Adjust speed and check fuel filter.
Bolts of pulley or shock absorber
Fasten bolts or nuts.
loose
Pulley or shock absorber
Replace with new pulley or shock absorber.
7. Excessive machine imbalance
vibration If the vibration is eliminated by detaching the
Fan lobe imbalance.
belt, replace with a new fan.
Machine frame loose or wear Fasten bolts. Replace parts if necessary.
Engine ignition problem or speed
See item 13 to 15.
unstable
No fuel in tank Add fuel.
Fuel line plugged Check/purge fuel line.
8. Engine can be
cranked but cannot Fuel pump failure Check or replace fuel pump.
be started – no Check and replace fuel filter. Check if the fuel
fume in tail pipe Fuel filter plugged is suitable for local ambient temperature and
change thoroughly if not.
Fuel injector failure Remove, adjust and repair or replace.
Low crank speed Check if battery, starter and cable terminals
are secured.
Cold starter is needed or does not Determine devices needed and check if
work operation is proper.
Inferior fuel Drain fuel completely and flush fuel system.
9. Engine is hart to be
or cannot be started “Cloud point” of fuel is higher Replace fuel and fuel filters.
– with fume in tail than ambient temperature
pipe Air filter plugged Check air filter. Clean or replace.
Air in fuel system Vent the fuel system.
Timing problem of fuel injection Check and adjust injection timing.
Valve clearance problem Readjust valve clearance.
Low idle speed Check idle speed adjusting screw.
Engine is loaded Start machine without load.
10. Engine will stop
after starting Inferior fuel Drain fuel completely and flush fuel system.
Air in fuel system Vent the fuel system.
Wrong speed system setting Check and adjust speed system setting.

Fuel filter plugged Check fuel filter. Replace if necessary.

11. Low engine speed
Air filter plugged Check air filter. Clean or replace.
Pressure regulation valve failure Check, adjust or replace.
Low idle speed Check idle speed adjusting screw.
Air in fuel system Vent the fuel system.
12. Engine vibrates at
Low fuel level Add fuel.
idle speed
Fuel line and filter plugged Purge fuel line and replace filter.
Fuel injector failure Remove, adjust and repair or replace.
Low idle speed Check idle speed adjusting screw.
Air in fuel system Vent the fuel system.
13. Idle speed unstable
Timing problem of fuel injection Check and adjust injection timing.
Fuel injector failure Remove, adjust and repair or replace.
14. Engine ignition Inferior fuel Drain fuel completely and flush fuel system.
problem or speed
unstable Air in fuel system Vent the fuel system.

45
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Check pushrod, spring and adjust valve
Wrong valve clearance
14. Engine ignition clearance.
problem or speed Fuel injector failure Remove, adjust and repair or replace.
unstable
Timing problem of fuel injection Adjust injection timing if necessary.
15. Engine temperature Thermometer failure Adjust or replace.
will not rise Thermostat failure Test or replace.
Poor fuel quality. Discharge fuel, replace with new filter element
and refill with clean fuel.
Air in fuel system Vent the fuel system.
16. Rough combustion
Timing problem of fuel injection Check and adjust injection timing.
Use ET to find out failed injector through
Fuel injector failure
cylinder isolation test.
Engine speed regulator or fuel Check if speed limit screw and speed
pump failure regulation cylinder are in proper location and
17. Engine speed will length.
vary at Speed regulation cylinder failure Check speed limit screw or reset spring.
full-load/no-load
Control line failure Check if the control line connected to
regulation cylinder is clogged or is leaking.
Speed regulator not set properly Check/adjust regulation pushrods.
Poor fuel quality Drain fuel and purge fuel line.
Air filter plugged Check, clean or replace.
Air or fuel line leaking or
Fasten connectors. Replace if necessary.
throttled
Air in fuel system Vent the fuel system.
Fuel line and filter plugged Purge fuel line and replace filter.
High oil level Drain excess oil to normal level.
18. Low engine power Fuel return line clogged. Clean.
Leakage in turbocharger or intake Check intake manifold pressure. Clean, repair
manifold or replace.
Carbon accumulation or damage
Check turbocharger. Clean, repair or replace.
on turbocharger
Timing problem of fuel injection Check injection pump timing.
pump
Valve position error Check pushrod and spring.
Timing problem of fuel injection Remove, test, clean and repair.
Fuel injector failure Remove, test, clean and repair.
Fan belt loose or damaged Adjust tension or replace belt.
Fan pulley installation position
Adjust pulley.
problem
Low coolant level Add coolant.
Radiator fin clogged Clean fin surface.
Low oil level Add oil to normal level.
19. Engine overheat
Coolant pump failure Replace pump.
Radiator pressure cap failure Check pressure cap. Replace if necessary.
Thermostat failure or not working Check or replace thermostat.
Fuel quantity high or bad
Check/replace injection pump.
injection timing
Overloaded Check pressure setting. Adjust if necessary.
Check if air filter is plugged. Check if intake
20. Black smoke or
Insufficient air for combustion manifold pressure and turbocharger are
dense gray smoke
working properly.

46
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Injector timing problem Test all injectors. Replace if necessary.
Timing problem of fuel injection Check and adjust injection timing.
20. Black smoke or
Air in fuel system Vent the fuel system.
dense gray smoke
Fuel quantity high Check/adjust injection pump.
Engine temperature will not rise Check thermostat and cooling system.
Too much oil Drain excess oil.
Engine ignition problem or speed
See item 15.
unstable
21. White smoke or Timing problem of fuel injection Adjust timing.
dense blue smoke Check intake manifold for oil. Repair if
Turbocharger oil seal damage
necessary.
Valve guide wear Check/repair cylinder head.
Piston ring wear Replace piston ring.
22. High fuel Fuel system leakage Check fuel system. Repair or replace parts.
consumption Injection timing problem Adjust injection timing.
Oil insufficient Add oil to normal level. Check for leakage.
Pressure gauge or sensor failure Check/replace.
Oil is diluted (with diesel or Find out causes. Change oil and fluid filter
water) element.
23. Low engine oil Wrong oil viscosity Check and change with right oil.
pressure
Fluid filter or fluid cooler clogged Check/clean. Change fluid filter and oil.
Oil pressure regulation valve Check, repair or replace.
failure
Oil pump, bearing wear or other Contact engine manufacturer to repair or
reasons replace parts.
Dirty oil Change dirty oil and fluid filter.
Intake piping leakage Check all intake piping components. Repair if
there is a leakage.
24. Engine early wear
Air filter or gasket damage Check air filter. Replace filter element.
Fuel in oil Find out causes. Repair/change oil and fluid
filter.
Fluid cooler core damaged Replace with new cooler core.
Cylinder head gasket damaged Replace with new gasket and fasten bolts as
specified.
25. Coolant in oil Cylinder head cracked or defect Replace with new cylinder head.
Cylinder block cracked or Replace with new cylinder block.
defective
Cylinder jacket gasket damaged Replace with new gasket.
Too much oil in air port Contact engine manufacturer to check and
repair.
Valve guide wear Check/repair cylinder head.
26. Oil in fume
Piston ring wear Replace with new piston ring.
Engine runs at idle speed for too Do not let engine run at idle speed for too
long long.
Connecting rod bearing liner Check connecting rod bearing liner and neck
27. Abnormal damaged surface of crankshaft.
mechanical noise in Timing gear damaged Replace with new parts.
engine
Crankshaft damaged Repair or replace crankshaft.
28. Abnormal noise in Air valve spring damaged Replace damaged spring.
air valve or air Camshaft damaged Replace the camshaft and clean the engine
valve driving parts thoroughly.

47
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 5 Maintenance

(continued)
Air valve pushrod damaged Replace camshaft and pushrod, and clean the
28. Abnormal noise in engine thoroughly. Check if air valve moves
air valve or air freely.
valve driving parts Air valve damaged Replace air valve. Adjust if necessary.
Low battery output power Check battery. Charge or replace the battery
accordingly.
Circuit or switch failure Repair. Replace if necessary.
29. Motor starter does
not start Starter's magnetic switch failure Replace with new switch.
Starter failure Repair or replace.
Alternator belt loose Adjust belt to proper tension.
Charging circuit, grounding Check all cables and terminals. Fasten all
30. Alternator does not
circuit or battery terminal failure termination nuts and clean terminals. Replace
charge
failed parts.
Rotor winding failure Replace with new winding.

48
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section 6 Noise Control

Section 6 NOISE CONTROL

6.1 Noise Emission
Sullair warrants to the end user and every potential user that the compressor sold by Sullair to the
primary dealer conforms to the noise emission rules and regulations of the People’s Republic of
China and US EPA in terms of design, manufacture, installation and test.
Such warranty applies to the entire machine, and is not restricted to any special part or partial
system only. If there is any violation to noise emission regulations in the machine sold to the
primary dealer, Sullair will be responsible for the solution, whether it is due to the design,
manufacture, installation or specific system or part.

6.2 Prohibited Operation

Never disassemble or damage any parts in the silencing system (except for maintenance)
before selling or delivering to the dealer or when the machine is in use.
Never operate the machine with a part in the silencing system removed.
Never:
A. Disassemble or damage:
a. Diesel engine silencing system and its parts;
b. Compressor inlet system and its parts;
c. Enclosure and any part.
B. Remove:
a. Silencer;
b. Shock absorber
c. Air spring;
d. Door and partition;
e. Fan guard;
f. Weather strip;
g. Acoustic material;
h. Engine tail pipe heat insulation sleeve.
C. Operate the machine when the door is open (except for adjustment or parts
replacement).

6.3 Service Record

Please operate and maintain the machine properly to avoid damaging the silencing system.
Check at least once a year the silencer and engine discharge system, air filter and air inlet system,
engine vibration reduction system, enclosure, etc. Make sure all parts are installed and tightened,
in good operating condition. Check the acoustic materials, and make sure there is no missing or
deformed parts and all the parts are installed in good condition. In case of damage, do not start the
machine. Order and replace parts according the parts list.
For each service, keep record for the service item and service content. Please refer to the following
table:
Service item
Personnel
Location
Data

Service item
Personnel
Location
Data

49
550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section7 Parts Ordering

Section 7 PARTS ORDERING

Procedure for Ordering Parts
Parts should be ordered from the nearest branch of Sullair or your Sullair Representative. If for
any reason parts cannot be obtained in this manner, contact Sullair Parts Department directly at the
address listed at the back cover of this Manual.
When ordering parts, you should always indicate the model and serial number of the compressor.
Since Sullair constantly improves its products, the content in the manual may differ from the
actual assembly after a period of time. Model and serial number can be obtained from the serial
number plate located on the compressor or Bill of Lading.
When ordering parts, please read carefully the illustration parts list. See Parts List, p/n:
88291004-642.

50
600/655 Diesel Driven Portable Rotary Screw Compressor, Operating and Maintenance Manual Section 7 Parts Ordering

Global Sales & Service

SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only)
Fax: 001-219-874-1273

SULLAIR ASIA Website: http://www.sullair-asia.com Hotline: 800-830-3977

Sullair Singapore: 74 Joo Koon Circle, Jurong Singapore 629093
Telephone:65-68611211 Fax:65-68612967
Sullair Taipei: No. 1, 3rd Floor, 248 Zhongshan Road, Linkou Village, Taipei County
Tel: 02-26013500 Fax: 02-26013032
Shenzhen Factory: Zuo Paotai Road, Chiwan, Shekou, Shenzhen, P. R. China
518068
Tel: 0755-26851686 Fax: 0755-26835157
Suzhou Factory: 266 Changyang Street, Singapore Industrial Park, Suzhou, 215000
Tel: 0512-87162388 Fax: 0512-87162389,87162387
Shanghai Branch: Room 2903, Raffles City Plaza, 266 Xizang Road Central,
Shanghai City 200001
Tel: 021-53852036,53852038 Fax: 021-53852035
Beijing Branch: Room 601, Yulin Building, No.5 Xiangjia2 Xiangjunnanli,
Zhaoyang District , Beijing City 100027
Tel: 010-64629770,64629768 Fax: 010-64629773
Chengdu Branch: Room 1102,T2 Raffles city Plaza, No.3 the Fourth ,People south
Road, Wuhou, Chengdou City, 610041, PRC
Tel: 028-86527506, 86527507 Fax: 028-86527505
Shenyang Branch: Room 906 Tower II, City Plaza Shenyang NO.206 Nanjing North
Street Heping District, Shenyang, PRC
Tel: 024-22818450, 22818550 Fax: 024-23342452
Xi’an Branch: Room I, Floor 13, New time Plaza, 55 Lianhu North Street, Xi’an
City 710001
Tel: 029-87206201, 87206202 Fax: 029-87206204
Wuhan Branch: Room 1805,Wanda Center, No.96, Linjiang avenue, Wuchang
District Wuhan City, 430060, PRC
Tel: 027-87322745 Fax: 027-88167769
Xinjiang Branch: Unit J, 9th Floor, National Development Bank Tower, 339
Zhongshan Road, Urumqi, 830002
Tel: 0991-2308451, 2308452 Fax: 0991-2308450

５１
 550RH-750H Diesel Engine Driven Portable Rotary Screw Air Compressor Operating and Maintenance Manual Section7 Parts Ordering

(P/N):88291004-643
(E/N):02